1. 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
Drilling mud flow rate for larger diameters
Heated drilling mud temperature
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
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