Final Presentation

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1
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
2



Introduction
Conceptual Design
Detailed Design
 Fluid Analysis
 Structural Analysis


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
6

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


Result:
Stator Angle: 45°
 Rotor Angle: 135°
 Blade Length: 0.5”

CFD Analysis
10

Purpose:



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
11
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
12
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
20
18
16
Computational Result
Power (W)
14
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
16
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
19
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
20
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