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ENGI 8926: Mechanical Design Project II Downhole Turbine for Drilling Supervisor: Dr. J. Yang

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

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ENGI 8926: Mechanical Design Project II Downhole Turbine for Drilling Supervisor: Dr. J. Yang

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  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

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

  3. Project Overview • 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 Drill Pipe Turbine Downhole Tools Bit

  4. Project Justification Rotor Stator

  5. Design Constraints

  6. Conceptual Design • Purpose • 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

  7. Concept Selection - Result

  8. Conceptual Turbine Model Inlet Bearing Rotor Stator Stages Output to Drilling Tool Output Shaft

  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

  11. Finite Element Analysis Stator Diff. Pressure Loading Stator Stress Distribution

  12. Detailed Design to Experiment

  13. Experimental Testing • Total Cost: $465 • Test Flow Rate: 40-90 GPM • Output Speed: 200-600 RPM • Tested Max. Load: 2 kg Pressure Sensor

  14. Result Comparison

  15. Conclusion • Experimental results scaled up for 50 stages and higher flow rates

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

  17. Conclusion

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

  19. Connections Rotor to Shaft Connection NC50 Standard DP Connection

  20. FEA: Housing& Shaft

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