ENGI 8926: Mechanical Design Project IIDownhole Turbine for Drilling

Research and Conceptual Design

Supervisor: Dr. J. Yang

G5Downhole:Bret KennyLida LiuPiek Suan SawChintan Sharma

February 6, 2014

Agenda

Drilling 101 Project Overview Design Constraints Solution Alternatives Concept Selection Conclusion Forward Plan

Drilling Overview

Drill Pipe

Mud Motor

Downhole Tools

Bit

Mud Motors vs. Turbines

Criteria Mud Motor Turbine

High RPM

High Torque

Tripping Downtime

Market Availability Sold individually Sold with services

Rotor

Stator

Project Overview

Client: Advanced Drilling Group Purpose: Design a downhole turbine-operated assembly to

power a variety of downhole drilling tools Scope:

Turbine Selection Component Design Modular Design Safety/Compliance Tools

Desired Outcome: Final design will incorporate the selection and optimization of existing components

Design Constraints

Constraints Description

Size Diameter = 6.0”Length = 6.0’

Output 600-800 RPM

Input Flow rate:150-300 gal/min∆P < 500psi

Strength Tool strength designed to API drill pipe specs

Operational Conditions

Water-based drilling mud

Modular Design Couple multiple turbine assemblies

Market Availability Existing applications

Cost Minimize

Health, Safety & Environment

Pressure build-up mitigation device, compliance tool

Phase 1 - ObjectivesResearch &

Conceptual

Design

Preliminary

Design

Design Optimization

Reviewed

- Existing Applications

- Scientific Literature

- Patents

Contacted

- Industry Professionals

- Potential Suppliers

- Faculty Members

Concept Selection

Alternative 1: Pumps

Centrifugal Pumps Turbine Pumps Axial Flow Pumps

Enclosed impellers are not optimum

Low Efficiencies (~5%) Unsuitable Blade designHigh P or Q needed

Propellers can bereversed to generatepower

Alternative 2: Turbines

Impulse Reaction

Operating Principal • Momentum change of high-velocity jet on turbine runner

• Momentum change and lift development on turbine blades

Examples • Pelton wheel• Turgo

• Francis• Kaplan• Compressor

Pelton Wheel Kaplan Turbine

Concept Selection

Criteria Weight(%)

Size Compatibility 30

Modular Flexibility 20

Flow Direction Compatibility 15

Efficiency per stage 10

Industrial Application 10

Operational Conditions 5

Maintenance & Reliability 5

Fluid Rheology 5

Conclusion

Concept Score

Kaplan 4.3Reversed Axial Pump 3.9

Reversed Centrifugal Pump 3.1Compressor 2.9

Turgo Turbine 2.7Francis 1.7Pelton 1.6

SolidWorks Model

Completed In-progress To be completed

Current Project Status

Project Phase Objectives Status Finish Date

Phase 1

Background Research Completed

Concept Scoring Completed

Concept Selection Completed

SolidWorks Model - Draft 1 Completed

Phase 2

Component Selection End of Week 6

Component Design End of Week 7

System Analysis End of Week 8

SolidWorks Model - Draft 2 End of Week 8

Phase 3 System Optimization End of Week 11

SolidWorks Model - Final End of Week 11

Forward Plans

Phase 2: Preliminary Design Load Estimation (axial, torsional and lateral)

Bearing selection Drive Shaft Design

Additional Component Selection Transmission Pressure Relief Valve Seals

Generate turbine performance curves Development of rpm and torque vs. length relationship

Flow testing

Thank You!Questions?

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