Project Readiness Package
Rev 7/2/13
ADMINISTRATIVE INFORMATION:

Project Name (tentative):

Project Number, if known:

Preferred Start/End Semester in Senior Design:
Fall/Spring
Spring/Fall

Faculty Champion: (technical mentor: supports proposal development, anticipated technical mentor during project
Reciprocating Compressor: Bearing Dynamic Similarity Test
Machine – Dynamic Loading Upgrade
P15453
execution; may also be Sponsor)
Name
Jason Kolodziej
Dept.
ME
Email
jrkeme@rit.edu
Phone
585-475-4313
For assistance identifying a Champion: B. Debartolo (ME), G. Slack (EE), J. Kaemmerlen (ISE), A. Becker-Gomez (CE)

Other Support, if known: (faculty or others willing to provide expertise in areas outside the domain of the Faculty
Champion)
Name
Stephen Boedo
Bill Nowak

Dept.
ME
MSD
Email
sxbeme@rit.edu
wjnddm@rit.edu
Phone
585-475-5214
585-259-2210
Project “Guide” if known: (project mentor: guides team through Senior Design process and grades students; may
also be Faculty Champion)
o Bill Nowak – Principal Engineer

Primary Customer, if known (name, phone, email): (actual or representative user of project output; articulates
needs/requirements)
o Jason Kolodziej & Steve Boedo

Sponsor(s): (provider(s) of financial support)
Name/Organization
Dresser-Rand (OLN)
Dresser-Rand (PPT)
Contact Info.
James Sorokes,
JSorokes@Dresser-Rand.com
Scott Delmotte
SDelmotte@Dresser-Rand.com
Type & Amount of Support
Committed
$5,000
PROJECT OVERVIEW: 2-3 paragraphs that provide a general description of the project – background, motivation,
customers, problem you’re trying to solve, project objectives.
Last year (2013-14) an MSD team of five engineers designed and fabricated the journal bearing test rig shown in Error!
Reference source not found.. To continue main crank journal bearing research it was determined it would be
advantageous to not require complete compressor disassembly. This test rig allows for
very rapid replacement (<1hr) of the bearing for condition monitoring and tribology
research. (See http://edge.rit.edu/edge/P14453/public/Home)
Building on last year’s Teams success, the objective of this project is focused on the
load actuation system on the test rig. While the successes for the design of the test rig
were numerous, dynamic loading was removed from the original project scope due to high
Page 1 of 4
Figure 1 - Statically Loaded Journal
Bearing Approach Presently
Installed.
Project Readiness Package
Rev 7/2/13
cost and significant complexity and replaced with the static loading method shown in 1. The static loading provided an
excellent proof of concept but does not reflect the actual loading of the ESH-1 compressor. The proposed project will focus
entirely on the load actuation system. Several technologies were considered to achieve the necessary loading: hydraulic,
pneumatic, and electro-mechanical for instance. While these methods will be revisited again to verify the analysis each one was
determined to fail to meet the requirements. The expected solution is likely to be piezoelectric. Preliminary cost estimates for
this type of solution exceed $20,000. After a thorough analysis of possible actuation solutions is repeated by the new design
team it is believed that the engineers will design and implement their own two-axis piezoelectric loading method within the
cost constraints of the proposed budget. The solution must represent the periodic time histories of main bearing loads (1,900lb
@ 360RPM) which are representative of the Dresser-Rand ESH-1 compressor at RIT. Considered an important component of
this project is to continue to build upon the preliminary sensing presently installed on the rig, such a capacitive gap sensors,
ultrasonic probes, accelerometers, load cells, and optical encoders. From a fault detection and condition monitoring perspective
this test rig will also allow for a much faster turnaround time for investigating the journal bearing due to ease of component
installation and removal.
DETAILED PROJECT DESCRIPTION:
The goal of this section is provide enough detail for faculty to assess whether the proposed project scope and required skills
are appropriate for 5th year engineering students working over two semesters. The sequence of the steps listed below may
depend on your project, and the process is usually iterative, so feel free to customize. Emphasis is on the “whats” (qualitative
and quantitative), not the “hows” (solutions), except for the section on “potential concepts,” which is necessary to assess the
appropriateness of required skills and project scope. Not all of the information in this section may be shared with students.
(Attach extra documentation as needed).

Customer Needs and Objectives: Comprehensive list of what the customer/user wants or needs to be able to do in
the “voice of the customer,” not in terms of how it might be done; desired attributes of the solution.
o Brainstorm several design modifications for the “static load actuation system” in the current journal
bearing test rig shown in Figure 1 to create a “dynamic load actuation system.”
o With the aid of Pugh Concept Selection, present the Customer with 1 or 2 design options which will
o
o
o
o

meet his needs.
All other functionality of the current test rig design (P14453) must remain including speed and oil
temperature measurement, accommodation of standard journal bearings, speed controlled to
2,000RPM, bearings loads up to 4,000N (900lbf)
Additional sensors could include but may not be limited to capacitive gap sensors, ultrasonic probes,
accelerometers, and LVDT or optical encoders to measure ring translational and rotational motion
within the clearance space depending on Customer needs and project budget constraints.
No degradation in “ease” or “time” of bearing installation from the static load test system is expected
however any improvement would be welcome.
Safety during operation is critical.
Constraints: External factors that, in some way, limit the selection of solution alternatives. They are usually imposed on
the design and are not directly related to the functional objectives of the system but apply across the system (eg. cost and
schedule constraints). Constraints are often included in the specifications list but they often violate the abstractness
property by specifying “how”.
o

Project Deliverables: Expected output, what will be “delivered” – be as specific and thorough as possible.
o
o
o

It is not completely clear whether Dynamic Loading will be possible for this upgrade to the Bearing
Similarity Test System both from a technical and/or budgetary standpoint.
The characterization and demonstration that all engineering specifications have been met on the
dynamic journal bearing similarity test rig.
This includes the design, modeling results, and measurement data illustrating the targets have been
met.
A final report and poster detailing the results of the investigations with drawings / schematics of the
proposed methods is expected.
Budget Estimate: Major cost items anticipated.
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Project Readiness Package
o
o
o
o
o

Rev 7/2/13
$8,000
Dynamic Load Actuation system
Instrumentation
Re-work of current Static Load system.
Material costs
Intellectual Property (IP) considerations: Describe any IP concerns or limitations associated with the project. Is
there patent potential? Will confidentiality of any data or information be required?
o

Other Information: Describe potential benefits and liabilities, known project risks, etc.
o

None
None
Continuation Project Information, if appropriate: Include prior project(s) information, and how prior project(s)
relate to the proposed project.
o
P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Tester –
 Due to cost constraints this project successfully developed a Bearing Similarity Test System
with “Static Loading”. The purpose of P15453 is to update this system with Dynamic Load
Actuation.
STUDENT STAFFING:

Skills Checklist: Complete the “PRP_Checklist” document and include with your submission.

Anticipated Staffing Levels by Discipline:
How
Many?
Discipline
1
EE
5 (or 4)
ME
Anticipated Skills Needed (concise descriptions)
This test rig is likely controlled by a motor and controller that will require design
and installation. The load actuation system will likely be accomplished by an
electrically controlled device that requires high power.
There are numerous mechanical engineering tasks to complete with this project.
Skill with CAD and the machine shop is critical. Skill with instrumentation is a
plus. Knowledge of journal bearings and tribology would be beneficial.
CE
ISE
Other
OTHER RESOURCES ANTICIPATED:
Describe resources needed to support successful development, implementation, and utilization of the project. This could
include specific faculty expertise, laboratory space and equipment, outside services, customer facilities, etc. Indicate if
resources are available, to your knowledge.
Category
Description
Page 3 of 4
Resource
Available?
Project Readiness Package
Faculty
Rev 7/2/13
Dr. Jason Kolodziej for project guidance / interface with Dresser Rand
David Hathaway-ME Dept Machine Shop Manager; support to make the design
installation and facilities modifications go smoothly.
Environment
ME machine shop & D-R compressor lab (in ME machine shop)
Equipment
The DAQ system currently installed in the test cell on the compressor can be used to
collect measurement data.
Kolodziej also has a portable USB DAQ that can be used
Materials
All materials will either be supplied by D-R or purchased as part of the sponsored
funding.
Other
Prepared by:
Date:
Bill Nowak
Page 4 of 4
August 2, 2014