ENGI 8926: Mechanical Design Project II Downhole Turbine for Drilling Research and Conceptual Design Supervisor: Dr. J. Yang G5Downhole: Bret Kenny Lida Liu Piek Suan Saw Chintan Sharma February 6, 2014 Bret

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

Drilling Overview Drill Pipe Mud Motor Downhole Tools Bit Bret

Mud Motors vs. Turbines Rotor Stator Criteria Mud Motor Turbine High RPM   High Torque Tripping Downtime Market Availability Sold individually Sold with services Bret *We are designing a downhole turbine assy because they allow the passage of fluid in the event of a stall and

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 Lida

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 Lida

Research & Conceptual Design Preliminary Design Design Optimization Phase 1 - Objectives Reviewed - Existing Applications - Scientific Literature - Patents Contacted - Industry Professionals - Potential Suppliers - Faculty Members Concept Selection Lida Mention reversed pumps and turbines

Alternative 1: Pumps Centrifugal Pumps Turbine Pumps Axial Flow Pumps Enclosed impellers are not optimum Low Efficiencies (~5%) Unsuitable Blade design High P or Q needed Propellers can be reversed to generate power Chintan

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 Chintan Pelton Wheel Kaplan Turbine

Concept Selection Criteria Weight(%) Size Compatibility 30 Modular Flexibility 20 Flow Direction Compatibility 15 Efficiency per stage 10 Industrial Application Operational Conditions 5 Maintenance & Reliability Fluid Rheology Chintan

Reversed Centrifugal Pump Conclusion Concept Score Kaplan 4.3 Reversed Axial Pump 3.9 Reversed Centrifugal Pump 3.1 Compressor 2.9 Turgo Turbine 2.7 Francis 1.7 Pelton 1.6 Chintan

SolidWorks Model Chintan

Current Project Status Project Phase Objectives Status Finish Date Phase 1 Background Research Completed Concept Scoring Concept Selection SolidWorks Model - Draft 1 Phase 2 Component Selection End of Week 6 Component Design End of Week 7 System Analysis End of Week 8 SolidWorks Model - Draft 2 Phase 3 System Optimization End of Week 11 SolidWorks Model - Final San Completed In-progress To be completed

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 San

Thank You! Questions? http://g5downhole.weebly.com San