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ENGI 8926: Mechanical Design Project II
Downhole Turbine for Drilling
Supervisor: Dr. J. Yang
G5Downhole:
Bret Kenny
Lida Liu
Piek Suan Saw
Chintan Sharma
April 3, 2014
Agenda
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


Introduction
Conceptual Design
Detailed Design
 Fluid Analysis
 Structural Analysis
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
Experimentation/Testing
Conclusion
Project Overview
3


Client: Advanced Drilling Group
Purpose: Design a drilling turbine assembly to power a
variety of downhole drilling tools


Preliminary design work
Advanced testing required for commercial application
Drill Pipe
Bit
Turbine
Downhole Tools
Project Justification
4
Rotor
Stator
Criteria
Mud Motor
Turbo-Drill
High RPM


High Torque


Tripping Downtime


Market Availability
Sold individually
Sold with services
Low O&M
High O&M
Cost
Design Constraints
5
Constraints
Size
Output
Input
Description
Diameter = 5.0”
600-800 RPM
Flow rate: 200 gal/min
∆P < 500psi
Mud Rheology
Water-based drilling mud: ρ ≈ 1000 kg/m3 with fine
particles
Modular Design
Couple multiple turbine assemblies
Cost
Health, Safety &
Environment
Minimize
Pressure build-up mitigation device, compliance tool
Conceptual Design
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
Purpose


Select best turbine type for drilling application
Scope

Conduct literature review of:



Existing applications, patents, scientific theory
Consult industry professionals and faculty members
Desired Outcome:

Develop preliminary concept model
Concept Selection - Result
7
Criteria
Weight(%)
Concept
Score
Size Compatibility
30
Kaplan
4.3
Modular Flexibility
20
Reversed Axial
Pump
3.9
Reversed
Centrifugal Pump
3.1
Compressor
2.9
Turgo Turbine
2.7
5
Francis
1.7
5
Pelton
1.6
Flow Direction
Compatibility
15
Efficiency per stage
10
Industrial Application
10
Operational
Conditions
Maintenance &
Reliability
Fluid Rheology
5
Conceptual Turbine Model
8
Inlet
Bearing
Rotor
Stator
Stages
Output
to Drilling
Tool
Output Shaft
Turbomachinery Analysis
9

Purpose:
Select kaplan turbine blade lengths and angles (rotor and
stator)
 Maximize power output
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
Result:
Stator Angle: 45°
 Rotor Angle: 135°
 Blade Length: 0.5”
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CFD Analysis
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Purpose:
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

Develop relationship between the number of turbine stages and output
power/pressure drop
Compare with Turbomachinery results
Select number of turbine stages
Finite Element Analysis
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Component
Loading
Minimum Safety Factor
Rotor and Stator
Differential Pressure
36
Torque
Housing
11
Axial
Torque
Shaft
4
Bending
Material: AISI 316 Stainless Steel
Stator Diff. Pressure Loading
Stator Stress Distribution
Detailed Design to Experiment
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Rotor and Stator
Shaft
Housing
Rapid Prototyping
0.5” Aluminum
4.0” ABS
Experimental Testing
•
•
•
•
Total Cost: $465
Test Flow Rate: 40-90 GPM
Output Speed: 200-600 RPM
Tested Max. Load: 2 kg
Pressure
Sensor
Result Comparison
Three-Stage Power Comparison Curve
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18
16
Computational Result
Power (W)
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12
10
Turbomachinery Result
8
6
Experimental Result
4
2
0
0
20
40
60
Flow Rate (GPM)
80
100
Conclusion

Experimental results scaled up for 50 stages and
higher flow rates
Tool Specifications
Diameter
5.0”
Length
10.6’
Top and Bottom Connection
Tool Joint NC50
Tool Weight
496 lb
# of Stages
50
Operational Data
Rotational Speed
600-800 RPM
Pressure Drop Range
40-180 psi
Max. Power Output
3 kW
Conclusion and Recommendations
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Recommendations:
 Advanced Flow Testing
 Test at higher flow rates
 Estimate friction and torque for accurate results
Conclusion
Thank You!
Questions?
Acknowledgements
Dr. M. Hinchey
H. Wang/T. Pike
Dr. N. Khan
D. Taylor/C. Koenig
B. Gillis
http://g5downhole.weebly.com
Connections
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Connection Method
Rotor to Shaft
Press Fit
Shaft to Bearings
Press Fit
Housing Ends
NC50 Standard Drill Pipe
Output Shaft
Clamping Hub-Coupling
NC50 Standard DP
Connection
Rotor to Shaft Connection
FEA: Housing & Shaft
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