ENGI 8926 Mechanical Design Project II Downhole Turbine

ENGI 8926: Mechanical Design Project II Downhole Turbine for Drilling Preliminary Design Supervisor: Dr. J. Yang G 5 Downhole: Bret Kenny Lida Liu Piek Suan Saw Chintan Sharma March 4, 2014

Agenda Project Overview Design Methodology � Theoretical � Computational � Experimental Results Comparison Conclusion Forward Plan

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

Phase 1 Recap Research & Conceptual Design Reviewed - Existing Applications - Scientific Literature - Patents Preliminary Design Optimization Contacted - Industry Professionals - Potential Suppliers - Faculty Members Concept Selection

Phase 2 Overview Research & Conceptual Design Theoretical Analysis • Rotor and stator sizing: • Blade length • Blade angle • Turbine length • Stage requirement Preliminary Design CFD Analysis • Turbine power curves • Power and stage relationship • Pressure and stages relationship Design Optimization Experimental Analysis • Turbine power curves • 3 stage turbine

Theoretical Analysis: Blade Length Purpose: Maximize output power with OD = 4. 0” Power vs. Flow Rate 14 12 Power (k. W) 10 D =0. 5" D=1. 0" 8 D=1. 5" 6 D=2. 0" D=2. 5" 4 Rotor Cross-Section D=3. 0" 2 D=3. 5" 0 0 500 Flow Rate (GPM) * ω=600 rpm, α=45°, β=135° 1000

Theoretical Analysis: Blade Angle Purpose: Maximize output power with 25°<α<45°, 100°<β<135° Power vs. Alpha 5 4 Stator 4 α β Power (k. W) 3 3 2 B = 100 2 B = 135 1 B = 150 1 Rotor 0 -1 20 40 60 80 Alpha (degrees) * ω=600 rpm, Di = 3. 0”, Q =500 gpm 100

Theoretical Analysis: Conclusion Variable Design Constraint Outer Diameter Inner Diameter Value 4. 0” Max. 4. 0” Tool Diameter Blade Length 3. 0” 0. 5” α 25°<α<45° β 100°<β<135° ΔP ΔP ≤ 300 psi # of Stages (3”/Stage) Turbine Length * ω=600 rpm, Q=200 gpm 24 Max. 6’ 6’

CFD: Power-Stage Relationship Turbine Power Curve - Computational Analysis 10, 0 9, 0 50 Stages 8, 0 Power (k. W) 7, 0 10 Stages 6, 0 5 5, 0 Stages 4, 0 No Weak Dependency of Power on Stages 3, 0 2, 0 Strong Dependency of Power on 3 Stages 1 Stage 1, 0 0 50 100 150 200 250 Flow Rate (GPM) 300 350 400

Experimental Analysis RPM Encoder 0. 5” Output shaft Perforated Cap 3 Stage Turbine 4” ID ABS Pipe 2”X 4” Crossove 2” Male Connection Flow sourc e 2” 90° elbow 2” ID ABS Pipe

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

Result Comparison Power Comparison Curve 83 21, 5139748627854 20 18 16 Computational Result Power (W) 14 Theoretical Result 12 10 8 6 Experimental Result 4 2 0 0 10 20 30 40 50 60 Flow Rate (GPM) 70 80 90 100

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

Current Project Status Project Phase 1 Phase 2 Phase 3 Objectives Status Finish Date Background Research Completed Concept Scoring Completed Concept Selection Completed Solid. Works Model - Draft 1 Completed Turbine Sizing Completed Computational Analysis Completed Power Curve Development Completed Preliminary Experimentation Completed System Optimization End of Week 12 Solid. Works Model - Final End of Week 12 Advanced Experimentation End of Week 12 Completed completed In-progress To be

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

Thank You! Questions? Acknowledgements Dr. M. Hinchey H. Wang/T. Pike Dr. N. Khan D. Tyler/C. Koenig B. Gillis http: //g 5 downhole. weebly. com

Theoretical Analysis: Blade Length Power vs. Flow Rate Curves

Theoretical Analysis: Blade Length ΔP vs. Flow Rate Curves

Result Turbine Curve - Pressure Drop 500 50 Stages 450 Pressure Drop (Psi) 400 350 300 250 200 10 Stages 150 100 5 Stages 50 3 Stages 1 Stage 0 0 100 200 300 400 500 Flow Rate (GPM) 600 700 800 900