1. 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

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

3. 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

4. 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

5. Health, Safety & Environment
Design Constraints
Constraints
Description
Size
Diameter = 5.0”
Output
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

6. 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

7. 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

8. 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

9. 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”

10. 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

11. 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

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

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

14. Result Comparison
Chintan

15. 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
RPM
Pressure Drop Range
psi
Max. Power Output
3 kW
Chintan

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

17. Conclusion
Chintan

18. 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
Chintan

19. 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

20. FEA: Housing & Shaft