P17301: LORD Downhole Test Simulator
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Detailed Design

Table of Contents

Background

LORD currently manufactures downhole drilling vibration isolators to prevent the wear on downhole drills caused by the environment created beneath the Earth's surface. To gain a competitive edge in the downhole drilling business and better control over testing their product, LORD has intentions to create a testing facility to simulate the environment that their product would endure while downhole.

The RIT Senior Design Team has been tasked to create a feasibility study to show how the vibration isolator testing vessel could operate. Specifically, the team will be using mathematical analyses, simulations, and scaled prototyping to prove the concept.

End Deliverables for LORD:

End Deliverables for RIT MSD:

Meeting Objective

  1. Review overall concept drawing & 3D Model
  2. Discuss Product & Project costs
  3. Control Schematic Overview
  4. Review high priority analyses, simulations, & prototypes for each subsystem
  5. Explanation behind lack of Torsional Loading Simulation feasibility
  6. Discuss sealing test options
  7. Confirm detailed design is complete to move onto MSDII

Phase 4 Deliverables

Phase 4 Deliverables

Phase 4 Deliverables

Updates/Action Items from Phase III

Date Attendees Role Meeting Notes
Nov 3, 2016 Cortland Chapman, Keith Ptak LORD Test Engineer, Primary Customer Meeting Notes
Nov 17, 2016 Cortland Chapman, Keith Ptak LORD Test Engineer, Primary Customer Meeting Notes
Nov 29, 2016 Cortland Chapman, Keith Ptak LORD Test Engineer, Primary Customer Sealing Meeting
Action Item Owner Completed?
Prototype BOM RIT Team Yes
Project Costs RIT Team Yes
Sealing Material Selction RIT Team Yes
Isolator Specifications LORD Yes
Currently Used Testing Thresholds LORD Yes

Product Cost & Bill of Materials

BOM Overview With Pump Estimate

BOM Overview With Pump Estimate

Yearly Running Cost Estimate

Yearly Running Cost Estimate

Project Cost & Prototype Bill of Materials

Customer/Engineering Requirements

Requirements Flow-down

Requirements Flow-down

Requirements Validation

Requirements Validation

Requirements Validation

Subsystem Integration

Subsystem Integration Isometric

Subsystem Integration Isometric

Subsystem Integration Isometric

Subsystem Integration Isometric

Full System 3D PDF

Subsystem Architecture

Overall System Architecture

Overall System Architecture

Controls Schematic

Key for Following Diagrams

Key for Following Diagrams

Axial/Lateral Subsystem Electrical Setup

Axial/Lateral Subsystem Electrical Setup

Torsional Subsystem Electrical Setup

Torsional Subsystem Electrical Setup

Mud Subsystem Electrical Setup

Mud Subsystem Electrical Setup

Pressure Vessel and Component Temperature Subsystem Electrical Setup

Pressure Vessel and Component Temperature Subsystem Electrical Setup

Sensors and Corresponding Outputs

Sensors and Corresponding Outputs

Lateral/Axial Loading Subsystem

Load Transmission Design

Load Transmission Design

Subsystem Customer Requirement Engineering Requirement Test Plan(s) Validated?
Lateral/Axial Apply Static Loads to Axial Isolator Apply Static Axial Load A2B1, A3B2 No
Lateral/Axial Apply Static Loads to Axial Isolator Apply Static Lateral Load A2B1, A3B2 No
Lateral/Axial Apply Dynamic Loads to Axial Isolator Apply Dyanmic Vibration Load A1, A2B1 A1-Yes, A2B1-No
Lateral/Axial Apply Dynamic Loads to Axial Isolator Apply Dyanmic Vibration Frequency A1, A2B1 A1-Yes, A2B1-No
Lateral/Axial Apply Dynamic Loads to Axial Isolator Apply Dynamic Shock Load A1, A2B1 A1-Yes, A2B1-No
Lateral/Axial Apply Dynamic Loads to Axial Isolator Apply Dynamic Shock Frequency A1, A2B1 A1-Yes, A2B1-No
Analysis Index Analysis Name Associated Risks Link to Plan
A1 Axial Vibration Analysis
  1. Load actuation disconnected from attachment due to fatigue
  2. Bearings can't handle actuation
  3. Transmission of vibration to second actuator
A1 Test Plan
A2 Shaker Analysis
  1. Shakers cannot provide appropriate shock and vibration
A2 Test Plan
Available acceleration from shakers

Available acceleration from shakers

Acceleration transmission through axial-lateral connector

Acceleration transmission through axial-lateral connector

Loads and Vibration Control Scheme

Loads and Vibration Control Scheme

Prototype Design

Prototype Design

Test Index Test Name Associated Risks Link to Test Plan
S1 Axial/Lateral Simulation
  1. Load actuation disconnected from attachment due to fatigue
  2. Static Failure of system
  3. Bearings can't handle actuation
  4. Transmission of vibration to second actuator
S1 Test Plan
T1 Axial/Lateral Prototype
  1. Transmission of vibration to second actuator
  2. Sealing breaks down due to excess load
  3. Sealing breaks down due to actuation
T1 Test Plan

Link to Subsystem Product BOM: Product BOM

Link to Prototype drawing package: Prototype Drawing Package

Link to Prototype Project BOM: Prototype BOM

Torsional Loading Subsystem

Torsional Load Application Design

Torsional Load Application Design

Torsional Vibration Application Design

Torsional Vibration Application Design

Subsystem Customer Requirement Engineering Requirement Test Plans Validated?
Torsional Apply Static Loads to Axial Isolator Apply Static Torsional Load E2F1, E3F2 No
Torsional Apply Dynamic Loads to Axial Isolator Apply Dynamic Vibration Load E1 No
Torsional Apply Dynamic Loads to Axial Isolator Apply Dynamic Vibration Frequency E1 No
Torsional Apply Dynamic Loads to Axial Isolator Apply Dynamic Shock Load E1 No
Torsional Apply Dynamic Loads to Axial Isolator Apply Dynamic Shock Duration E1 No
Torsional Vibraton Model

Torsional Vibraton Model

Torsional Rotation

Torsional Rotation

Loads and Vibration Control Scheme

Loads and Vibration Control Scheme

Prototype Design

Prototype Design

Prototype without Load

Prototype without Load

Prototype with Load

Prototype with Load

Analysis Index Analysis Name Associated Risks Link to Plan
A5 Torsional Vibration Analysis
  1. Exceed rotational limit
  2. Reach the maximum stroke of actuator
A5 Test Plan
S3 Torsional Load Simulation *Not feasible for our team
  1. Fatigue failure of system
  2. Static failure of system
  3. Bearings can't handle actuation
  4. Transmission of vibration to actuator
  5. Slip between clamp and pipe
  6. Exceed rotational limit
  7. Reach the maximum stroke of actuator
  8. Failure of seal
S3 Test Plan
T2 Torsional Load Prototype
  1. Fatigue failure of system
  2. Static failure of system
  3. Bearings can't handle actuation
  4. Transmission of vibration to actuator
  5. Slip between clamp and pipe
  6. Bad alignment of shaker
  7. Exceed rotational limit
  8. Reach the maximum stroke of actuator
  9. Failure of actuator synchronization
  10. Bad alignment of actuator
  11. Failure of seal
T2 Test Plan
Link to Subsystem Product BOM: Product BOM

Link to Prototype Project BOM: Prototype BOM

Mud Subsystem

Mud Subsystem Design

Mud Subsystem Design

Subsystem Customer Requirement Engineering Requirement Test Plans Validated?
Mud Heated Mud Flowing through System at Testing Requirements Drilling Mud Flow Rate for Smaller Diameters C1, C2 C1 - Yes, C2 - No
Mud Heated Mud Flowing through System at Testing Requirements Drilling Mud Flow Rate for Larger Diameters C1, C2 C1 - Yes, C2 - No
Mud Heated Mud Flowing through System at Testing Requirements Heated Drilling Mud Temperature I1 I1 - Yes
Mud Heating Control Scheme

Mud Heating Control Scheme

Mud Flow Control Scheme

Mud Flow Control Scheme

Analysis Index Analysis Name Associated Risks Link to Plan
A3 Mud Flow Analysis
  1. Head Loss from flow moving through system is too great
  2. Pumps fail due to pressure overload
A3 Test Plan
A7 Heating Mud Analysis
  1. Mud is too hot and begins to boil
  2. Time to heat mud is too long
A7 Test Plan
Test Index Test Name Associated Risks Link to Test Plan
S2 Mud Flow Simulation
  1. Seals break due to abrasion
  2. Seals break due to excess load
  3. Seals break due to actuation
  4. Leakage from seals
S2 Test Plan

Link to Subsystem Product BOM: Product BOM

Structural Subsystem

Subsystem Customer Requirement Engineering Requirement Test Plans Validated?
Structural Must be Adaptable to Fit Future Parts Project Constraint K1L1, L2 No
Structural Apply Adjustable Pressure to Axial Isolator Adjustable Pressure Applied to Isolator K1L1, L2 No

Heavy Wall Steel Pipe

American Piping Website Link
4100 Alloy Steel Material Properties

4100 Alloy Steel Material Properties

American Piping Quote

American Piping Quote

Thin Wall Formula For Pipe Factor of Safety

Thin Wall Formula For Pipe Factor of Safety

Sealing Solution (20,000 psi mud to 0 psi air)

Reciprocating Rod Seal

Typical High Pressure Rod Seal, AHP Seals, ahpseals.com/

Typical High Pressure Rod Seal, AHP Seals, ahpseals.com/

Rotary Seal

Typical High Pressure Rotary Seal, AHP Seals, ahpseals.com/

Typical High Pressure Rotary Seal, AHP Seals, ahpseals.com/

Typical Rotary Seal For Dust, Trelleborg, tss.trelleborg.com/

Typical Rotary Seal For Dust, Trelleborg, tss.trelleborg.com/

Pressure Vessel

Approximate Pressure Vessel Quote (250-350¢®¨¡F is fine)

Approximate Pressure Vessel Quote (250-350¢®¨¡F is fine)

Pressure Vessel ISO View

Pressure Vessel ISO View

Pressure Vessel Top View

Pressure Vessel Top View

Pressure Vessel Schematic

Pressurization Control Scheme

Pressurization Control Scheme

Seal Quote

Quote received from AHP Seals:

Reciprocating Wiper Seal

Reciprocating Rod Seal

Reciprocating Buffer Seal

Reciprocating Wear Ring

Rotary Seal

Test Plans & Risks

Sealing Test Plan: Will need to outsource testing

This application is highly unusual. Empirical testing will be needed to determine:

Seals must be completely covered in lubrication to seal

Analysis Index Analysis Name Associated Risks Link to Plan
S4 Piping Simulation
  1. Control wires/sensors disconnect or break
  2. Pipe breakdown due to abrasion
S4 Test Plan
S5 Pressure Vessel Simulation
  1. Pressure Vessel walks crack/break
S5 Test Plan
A4 Pressure Vessel Sealing Analysis
  1. Seals break due to abrasion
  2. Seals break due to excess load
  3. Seals break due to actuation
  4. Leakage from seals
A4 Test Plan

Link to Subsystem Product BOM: Product BOM

Heating/Cooling Subsystem

Subsystem Customer Requirement Engineering Requirement Test Plans Validated?
Heating/Cooling Apply Adjustable Temperature to Axial Isolator Adjustable Component Temperature G1 Yes
Component Temperature Control Scheme

Component Temperature Control Scheme

Analysis Index Analysis Name Associated Risks Link to Plan
A6 Heat Component Analysis
  1. Heating or cooling stress on rubber components
A6 Test Plan

Safety Analysis

Safety Analysis

Safety Analysis

Problem Management

Problem Management

Problem Management

Risk Assessment

High Priority Risks

High Priority Risks

Risk Reduction Chart

Risk Reduction Chart

Feasibility Study Outline

Feasibility Study Outline

Feasibility Study Outline

Plans for MSD II

MSD II

MSD II

MSD II Individual Plans

MSD II Individual Plans

Critical Path

Critical Path

Link to MSD II Project Plan: MSD II Plan

Peer Feedback Lessons Learned

  1. Important to keep all team members informed on decisions & communications with the customer
  2. Continuous improvement upon equal division of talking & contribution during meetings
  3. Don't be afraid to speak up during meetings
  4. Make sure all team members are involved in communication with the customer

MSD Feedback

Weekly Assignments Table

Weekly Assignments Table

Lessons Learned from MSD Process

  1. Address questions and issues as soon as they arise to keep the project on track.
  2. Important to have an agenda and all materials prepped before meetings with the customer to improve meeting efficiency.
  3. The group peer evaluation feedback process that our group followed was very beneficial. We were able to sit down as a group to discuss each other's feedback and keep each other accountable. Also, reviewing peer feedback with our guide helped us create a better relationship with him. Without sitting down to review the peer feedback, our team would not benefit from it as much.
  4. Visit to LORD Facility in person was very beneficial in better understanding our project and connecting with our customer.
  5. It is important to have a clear understanding of the guide's expectation through constant communication to ensure all deliverables are met for reviews.

Future Project Suggestions

  1. Creation of a electrical generator instead a mechanical turbine that reduces pressure.
  2. Break up subsystems into their own projects to further analyze the system
  3. Create graphical user interface for controls
  4. Testing & Developing Seals
  5. Torsional Loading Simulation

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