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 Lida

Agenda Introduction Conceptual Design Detailed Design Fluid Analysis Structural Analysis Experimentation/Testing Conclusion Lida

Project Overview Client: Advanced Drilling Group Drill Pipe Turbine Downhole Tools Bit 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 Lida Highlight that design of drilling turbine will take many years. Our objective was to develop an initial concept to allow further laboratory testing

Project Justification Rotor Stator Criteria Mud Motor Turbo-Drill High RPM   High Torque Tripping Downtime Market Availability Sold individually Sold with services Cost Low O&M High O&M Lida Both mud motors and turbodrills are currently used in industry to power downhole tools Mud motors mainly used for high torque, low rpm applications, and are prone to stalling which results in excessive downtime Turbodrills mainly used for low torque, high rpm applications, provides good solution to powering downhole tools but they can only be purchased with services (from service company). In addition, they are only available in specific regions of the world (middle east and usa), making them difficult to acquire and very expensive Therefore, there is a hole in the marketplace for the development of a drilling turbine that can provide a solution for companies and research groups looking to power their downhole tools

Health, Safety & Environment Design Constraints Constraints Description Size Diameter = 5.0” Output 600-800 RPM Input 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 Minimize Health, Safety & Environment Pressure build-up mitigation device, compliance tool Lida

Conceptual Design Purpose Scope Desired Outcome: 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 San

Concept Selection - Result 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 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 San

Conceptual Turbine Model Inlet Output to Drilling Tool Rotor Stator Stages Bearing Output Shaft San Highlight that this is a simple kaplan turbine without a stator

Turbomachinery Analysis 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 Purpose: Develop relationship between the number of turbine stages and output power/pressure drop Compare with Turbomachinery results Select number of turbine stages Bret

Finite Element Analysis Component Loading Minimum Safety Factor Rotor and Stator Differential Pressure 36 Housing Torque 11 Axial Shaft 4 Bending Material: AISI 316 Stainless Steel Stator Diff. Pressure Loading Stator Stress Distribution

Detailed Design to Experiment Rotor and Stator Shaft Housing Rapid Prototyping 0.5” Aluminum 4.0” ABS Bret

Experimental Testing Total Cost: $465 Test Flow Rate: 40-90 GPM Chintan Total Cost: $465 Test Flow Rate: 40-90 GPM Output Speed: 200-600 RPM Tested Max. Load: 2 kg Pressure Sensor

Result Comparison Chintan

Top and Bottom Connection 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 Chintan

Conclusion and Recommendations Advanced Flow Testing Test at higher flow rates Estimate friction and torque for accurate results

Conclusion Chintan

Thank You. Questions. Acknowledgements Dr. M. Hinchey H. Wang/T Thank You! Questions? Acknowledgements Dr. M. Hinchey H. Wang/T. Pike Dr. N. Khan D. Taylor/C. Koenig B. Gillis http://g5downhole.weebly.com Chintan

Connections Connection Method Rotor to Shaft Shaft to Bearings Press Fit Shaft to Bearings Housing Ends NC50 Standard Drill Pipe Output Shaft Clamping Hub-Coupling Bret NC50 Standard DP Connection Rotor to Shaft Connection

FEA: Housing & Shaft