Downhole Test Simulator Feasibility Study Project Overview Team P17301 LORD Corporation designs and manufactures vibration isolators and shock dampers for use in the downhole drilling industry. Currently, their products are only tested once they are already downhole. To have better control of their testing process and to gain a competitive advantage in the field, LORD intends to build a on-site testing facility for their products. The objective of the project is to determine if LORD can feasibly build a testing apparatus for their products that simulates the downhole environment. Team: Matt Biron (ME), Hyungsuk Kang (ME), Sam Zimmerman (ME), Abby Tremont (ISE), Dan Bowers (EE), Jason Whyte (ME), Nick Fewell (EE) Guide: Gary Werth Engineering Requirements Engineering Requirement Units Ideal Value Actual Value Adjustable component temperature °F 0-350 0-440 Adjustable pressure applied to isolator ksi 0-20 0-22 Drilling mud flow rate for smaller diameters GPM 350 150-350 Drilling mud flow rate for larger diameters 600-800 100-800 Heated drilling mud temperature 125-250 90-275 Apply static axial load lbf 4-1000 Apply static lateral load 4-1250 Apply static torsional load kip-ft 0-50 0-60 Apply dynamic vibration load g 0-70 Apply dynamic shock load G 200-1000 0-140 Product Cost Subsystems Total Cost Loads & Vibrations $ 3,098,396.70 Mud Flow $ 9,185,575.00 Structural $ 2,226,209.02 Controls $ 35,950.08 Acquisition Cost $1,454,413.08 Grand Total $ 16,000,743.88 Hours/Year 4380 2190 Operational Cost $700,800.00 $169,600.00 Electrical $1,063,026.00 $257,262.00 Water $397.50 Diesel Fuel $4,941,165.60 $1,195,807.20 Grand Total $6,705,389.10 $1,623,066.70 System Overview Subsystems: Mud Flow, Axial & Lateral Forces, Torsional Force, Structural, HVAC, and Control Systems Subsystem Integration Pressure Vessel – Top View Testing & Validation Subsystem testing was divided between several analyses, simulations, and prototypes. Axial/Lateral Prototype Test Torsional Prototype Test Mud Flow Simulation Test LORD Corporation, Kate Gleason College of Engineering, Dr. Amitabha Ghosh, Dr. Marca Lam, Dr. Stephen Boedo, Mr. John Wellin, Dr. Ali Ogut Acknowledgements