RE DESIGN OF INDEPENDENT ROTARY DRIVE UNIT BATCH

RE DESIGN OF INDEPENDENT ROTARY DRIVE UNIT BATCH MEMBERS: P. GURUCHANDRANATHAN (07 ME 14) G. KUMANAN (07 ME 21) S. RAJESHKUMAR (07 ME 35) J. SATHISHKUMAR (07 ME 42) PROJECT GUIDE: S. S. NIVAS. M. E, ASST PROF PROJECT VENUE: ONGC

ABSTRACT • The present IRD unit is using gear coupling and chain coupling which seems to be ineffective & have short life time. • So we are proposing to use clutch mechanism instead of gear coupling in order to increase its efficiency & life span.

INTRODUCTION • The independent rotary drive system is used to dig the earth surface and collect the oil & gas which is avail in nature. • It consists of a drive to the rotary table by an independent motor through two speed transmission. • By installing the system, the drive to the rotary table from the draw works is eliminated. • An emergency sprocket is available in this system which gives a provision to use draw works drive in case of emergencies for a temporary failure or a redesign work.

COMPONENTS OF IRD UNIT MOTOR GEAR COUPLING CLUTCH BRAKE GEAR CHAIN COUPLING ROTARY TABLE

PROBLEM DESCRIPTION • At very high speeds (1000 rpm), the conventionally used gear coupling in IRD unit gets damaged very often. • In order to overcome this, we are going to redesign the coupling unit.

GEAR COUPLING USING IRD

SPECIFICATION INPUT SPEED : 1240 rpm OUTPUT SPEED : 566 -1240 rpm INPUT HORSE POWER : 600 -1000 ihp INPUT SHAFT DIAMETER : 3. 940 Inches OUTPUT SHAFT DIAMETER : 3. 940 Inches GEAR RATIO : 1: 1. 128

METHODOLOGY • We can modify the gear coupling unit in two methods 1. Flange coupling. 2. Planetary gear mechanism. • By adopting these two methods the life of the coupling unit is increased compared to the existing gear coupling methods. • Of the two methods, the planetary gear mechanism is noisy in operation. • So we preferred implement of flange coupling

PLANNING • Study about planetary gear mechanism and flange coupling methodology. • Analysing the two methods. • Selection of the best among those two methods. • Implementation and Adoptation in the industrial applications.

DESIGN PROCEDURE FOR FLANGE COUPLING

INPUT SPECIFICATION: N=1240 rpm P=1000 HP 1 HP=736 W 1 W=1 NM/sec P=736 x 103 W P=736 KW DESIGN CALCULATION: P=(2πNT)/60 736=(2×π× 1240×T)/60 T =5667969. 586 Nmm

DESIGN OF SHAFT: After analysing the various material, we are concluded the material for shaft as c 45 from psg data book page no 1. 9 τ=65 N/mm 2 σ=150 N/mm 2 we know that τ=π/16 xτxd 3 where, τ is the allowable shear strength for shaft material, we can calculate the shaft diameter 5667. 96 x 103 =π/16 x 65 xd 3 d=76. 29 = 80 mm(approximately) Based on the observation made in the unit, it is cleared, we have to select more than 100 mm diameter.

Because, the existing shaft dia is equal to 100 mm. By referring Indian standard (IS 3688 -1977) we will select d=122 mm DESIGN OF VARIOUS PARAMETERS: τf =0. 5 d where, τf =thickness of flange d=shaft dia τf =61 mm L=1. 5 d L=length of hub L=183 mm D=2 d

D=outer dia of hub D=2 X 122 D=244 mm D 1 =3 d D 1 =Pitch Circle dia D 1 =366 mm D 2 =4 d D 2 =outside dia of flange D 2 =488 mm Number of bolts, n=4 for “d” up to 100 mm

DESIGN OF HUB: we selected the hub material is plain carbon steel Ʈ = 40 N/MM 2 σ = 80 N/MM 2 T = 5667969. 586 NMM T = π/16 X Ʈ h X [ D 4 - d 4/ D] D = outside diameter of hub d = shaft diameter of hub Ʈ h = 2. 119 N/MM 2 Induced shear stress of hub is less than 40 N/MM 2 The design for the hub is safe

DESIGN OF KEY : From PSG data book page no 5. 16 b = 22 mm h = 14 mm b = width of the key h = thickness of the key L = length of key = 120 mm (a) Check for shearing: T = l X b X Ʈ k X d/2 5667969. 586 = Ʈ k X 120 X 22 X 80/2 Ʈ k = 23. 07 N/MM 2 Induced shear stress of key is higher than the permissible stresses. The design for key is not safe

(b) CHECK FOR CRUSHING: T = σc X l X h/2 X d/2 h = thickness of key d = shaft diameter of key l = length of key 5667969. 586 = σc X 120 X 14/2 X 80/2 σc = 72. 535 N/MM 2 Induced crushing stress of key is higher than the permissible stresses. The design for key is not safe.

To select the material c 45 for the key because, it has the shear value greater than the calculated one that is τ=65 n/mm 2 b=25 mm h=14 mm Check for shearing: T = l x b x τ x d/2 5667969. 586 = 183 x 25 x τ x 122/2 τ = 20. 3 N/MM 2 Check for crushing: T = σc x l x h/2 x d/2 5667969. 586 = σc x 183 x 14/2 x 122/2 σc = 72. 535 N/MM 2 b=28 mm h=16 mm

Check for shearing: τ = 18. 13 N/MM 2 Check for crushing: σc = 63. 46 N/MM 2 b=32 mm h=18 mm Check for shearing: τ = 15. 86 N/mm 2 Induced shear stress of key is less than the permissible stresses. The design for key is safe Check for crushing: σc = 56. 41 N/mm 2 Induced crushing stress of key is less than the permissible stresses. The design for key is safe.

DESIGN OF FLANGE: T=τхtfxπD 2 /2 tf = Thickness of flange D=Outer diameter τ=1. 515 N/mm 2 Induced shear stress of flange is less than the permissible stresses. The design for the flange is safe.

DESIGN OF BOLT: To select the bolt material is c 45 τ=65 N/mm 2 σ=150 N/mm 2 T=τXnxdb 2 xπ/4 x. D 1 /2 where, db =dia of bolt n=num of bolt D 1=pitch circle dia of bolts n=4 and db =13 mm increase the bolt, so n=8 and db =9 mm n=10 and db =8 mm n=12 and db =7 mm

Check for crushing: τ=σxnxdbxtf XD 1 /2 Where, db =dia of bolt tf =thickness of flange Where, n=4 and d=12 σ=10. 57 N/mm 2 n=8 and d=9 σ=7. 05 N/ mm 2 n=10 and d=8 σ=6. 34 N/ mm 2 n=12 and d=7 σ=6. 044 N/ mm 2 Induced crushing stress is less than permissible stress The design of the bolt is safe.