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ENGI 8926: Mechanical Design Project II Downhole Turbine for Drilling Preliminary Design

ENGI 8926: Mechanical Design Project II Downhole Turbine for Drilling Preliminary Design Supervisor: Dr. J. Yang G5Downhole: Bret Kenny Lida Liu Piek Suan Saw Chintan Sharma March 4, 2014. Agenda. Project Overview Design Methodology Theoretical Computational Experimental

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ENGI 8926: Mechanical Design Project II Downhole Turbine for Drilling Preliminary Design

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  1. ENGI 8926: Mechanical Design Project II Downhole Turbine for Drilling Preliminary Design Supervisor: Dr. J. Yang G5Downhole: Bret Kenny Lida Liu Piek Suan Saw Chintan Sharma March 4, 2014

  2. Agenda • Project Overview • Design Methodology • Theoretical • Computational • Experimental • Results Comparison • Conclusion • Forward Plan

  3. Project Overview • Client: Advanced Drilling Group • Purpose: Design a downhole turbine-operated assembly to power a variety of downhole drilling tools Inlet Bearing Rotor Stator Stages Output to Drilling Tool Gear Box Output Shaft

  4. Phase 1 Recap

  5. Phase 2 Overview • CFD Analysis • Turbine power curves • Power and stage relationship • Pressure and stages relationship • Experimental Analysis • Turbine power curves • 3 stage turbine • Theoretical Analysis • Rotor and stator sizing: • Blade length • Blade angle • Turbine length • Stage requirement

  6. Theoretical Analysis: Blade Length Purpose: Maximize output power with OD = 4.0” Rotor Cross-Section * ω=600rpm, α=45°, β=135°

  7. Theoretical Analysis: Blade Angle • Purpose: Maximize output power with 25°<α<45°, 100°<β<135° Stator α β Rotor * ω=600rpm, Di = 3.0”, Q =500gpm

  8. Theoretical Analysis: Conclusion * ω=600rpm, Q=200gpm

  9. CFD: Power-Stage Relationship Strong Dependency of Power on Stages No Power Weak Dependency of Power on Stages

  10. Experimental Analysis RPM Encoder 0.5” Output shaft Perforated Cap 3 Stage Turbine 4” ID ABS Pipe 2”X4” Crossover 2” Male Connection Flow source 2” 90° elbow 2” ID ABS Pipe

  11. Experimental Result • Total Cost: $465 • Test Flow Rate: 40-90 GPM • Output Speed: 200-600 RPM • Tested Max. Load: 1 kg

  12. Result Comparison

  13. Conclusion • Completed Turbine Sizing • 4” OD/3” ID Rotor/Stator • # of Stages: Max. 24 • Developed Relationship • Power and # of Stages • ΔP and # of Stages • Conducted Preliminary Experiment • Acquired Data for Flow, Torque, and RPM • Revised Solidworks Model

  14. Current Project Status Completed In-progress To be completed

  15. Forward Plans • Phase 3: Design Optimization • Load Estimation (axial, torsional and lateral) • Bearing Selection • Drive Shaft Design • Advanced Flow Testing • Generate Efficiency and Flow Relationships • Generate Power and Turbine Stage Relationship • System Optimization • Finite Element Analysis • Finalize Overall Tool Specification

  16. Thank You!Questions?AcknowledgementsDr. M. HincheyH. Wang/T. PikeDr. N. KhanD. Tyler/C. KoenigB. Gillishttp://g5downhole.weebly.com

  17. Theoretical Analysis: Blade Length Power vs. Flow Rate Curves

  18. Theoretical Analysis: Blade Length ΔP vs. Flow Rate Curves

  19. Result

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