P17301: LORD Downhole Test Simulator
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Preliminary 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.

Concept Sketch

Team Vision for Preliminary Detailed Design Phase

During the Preliminary Detailed Design Phase, the team planned to create test plans in order of highest priority for the customer and related risks. As a result of the created test plans, the team intended to create several drawings and schematics to confirm their test plans. A preliminary bill of materials should be created by the end of this phase as well.

Throughout this process, the team was able to communicate with LORD regarding their testing priorities to ensure the most critical test plans were completed first. A subsystem architecture was created to aid in visualizing how the subsystems will integrate together. Preliminary schematics and drawings were created for the test plans as well. Finally, an updated risk assessment was completed to account for the new risks associated with the developed test plans.

Meeting Objective

  1. Ensure test plans & concepts align with customer's ideas
  2. Obtain clarification on questions at the end of the review

Updates Since Phase II

Date Attendees Role Meeting Notes
Oct 20, 2016 Cortland Chapman, Zach Fuhrer LORD Test Engineer, Project Manager Meeting Notes

Subsystem Architecture

Overall System Architecture

Overall System Architecture

System Priority List

Priority List

Priority List

Lateral/Axial Loading Subsystem

Lateral/Axial Loading Block Diagram

Lateral/Axial Loading Block Diagram

Lateral/Axial Loading Controls Block Diagram

Lateral/Axial Loading Controls Block Diagram

Shaker Controls Block Diagram

Shaker Controls Block Diagram

Load Transmission

Load Transmission

Test Index Test Name Associated Risks Link to Test 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
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
Axial/Lateral Loading BOM

Axial/Lateral Loading BOM

Torsional Loading Subsystem

Torsional Loading Block Diagram

Torsional Loading Block Diagram

Torsional Loading Controls Block Diagram

Torsional Loading Controls Block Diagram

Hydraulic Clamp Controls Block Diagram

Hydraulic Clamp Controls Block Diagram

Torsional Loading - Double Actuator

Torsional Loading - Double Actuator

Torsional Loading - Double Actuator - CAM

Torsional Loading - Double Actuator - CAM

Hydraulic Clamp

Hydraulic Clamp

Test Index Test Name Associated Risks Link to Test Plan
A5 Torsional Vibration Analysis
  1. Exceed rotational limit
  2. Reach the maximum stroke of actuator
A5 Test Plan
S3 Torsional Load Simulation
  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
Torsional Loading BOM

Torsional Loading BOM

Mud Subsystem

Mud Subsystem

Mud Subsystem

Mud Heat Controls

Mud Heat Controls

Mud Pump Controls

Mud Pump Controls

Test Index Test Name Associated Risks Link to Test Plan
C1 Intake Valve Stress Analysis
  1. Seals Break due to excess load
  2. Seals break due to actuation
SCRAPPED
C2 Intake Valve Physical Prototype
  1. Seals break due to abrasion
  2. Seals break due to excess load
  3. Seals break due to actuation
  4. Leakage from seals
SCRAPPED
A3 Mud Flow Analysis
  1. Head Loss from flow moving through system is too great
  2. Pumps fail due to pressure overload
A7 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
BOM

BOM

Structural Subsystem

Pressure Vessel Subsystem

Pressure Vessel Subsystem

Temperature Controls

Temperature Controls

Air Pressure Controls

Air Pressure Controls

Hyperlinks to images used: Here

FKM/Viton Material Datasheet, PolyMod Tech, polymod.com/

FKM/Viton Material Datasheet, PolyMod Tech, polymod.com/

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

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

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/

Typical Mechanical Face Seal, Trelleborg, tss.trelleborg.com/

Typical Mechanical Face Seal, Trelleborg, tss.trelleborg.com/

Submarine Mechanical Seal (BOM #s 11 + 12), Thordon Bearings Inc, thordonbearings.com/

Submarine Mechanical Seal (BOM #s 11 + 12), Thordon Bearings Inc, thordonbearings.com/

Test Index Test Name Associated Risks Link to Test Plan
S4 Piping Simulation
  1. Control wires/sensors disconnect or break
  2. Pipe breakdown due to abrasion
S4 Test Plan
S5 Pressure Vessel Stress 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
Piping Wall Thickness Analysis, Thin Walled Pressure Vessel Formula

Piping Wall Thickness Analysis, Thin Walled Pressure Vessel Formula

BOM

BOM

Validation

Validation Chart

Validation Chart

Link spreadsheet: Validation Chart

Risk Assessment

Risk Mitigation Chart

Risk Mitigation Chart

Link to Risk Excel Spreadsheet: Risks

Phase III Action Items

Action Item Owner Completed? By When?
Decision on point load v. load to be applied along the entire part LORD Yes 10/27
Fluid properties of the mud composition LORD Yes 10/27
Potential reduction of the lateral load from 1000lb LORD No 11/3
Controls Selections Dan & Nick No 11/11
Test Plan Drawings & Schematics RIT Team No 11/20
Test Plan BOMs RIT Team No 11/20

Plans for Phase IV: Detailed Design Review

Phase IV Individual Plans

Phase IV Individual Plans

Phase III Lessons Learned

  1. Improving upon equal division of talking during meetings
  2. Important to have an agenda and all materials prepped before meetings with the customer
  3. Address questions and issues as soon as they arise
  4. Donuts and coffee are the key to a successful meeting!

Questions

  1. Controls
    1. Do we need to get specifications on the control design or is it something we can black box and label as minimal risk?
    2. What output data would LORD like to see?
    3. If we are blackboxing the controllers, what is the power consumption of their current controllers as a similar model?
    4. Does Lord want periodic records of the sensors information?
  2. Does Lord need any other documentation for a successful/unsuccessful test or analysis?
  3. Unit under test
    1. Material Properties
    2. Inner diameter dimension (given drawing does not have a hole)
    3. Do they require any wiring leading out of the pipe?
  4. If there is minimal pressure gradient between air and mud, is heavy duty seal required?
  5. Is there a procedure Lord would like for evaluating failure conditions? (How much vibration is too much vibration, etc.)
  6. Follow up for the DDR (Trip to RIT)

Follow Up Action Items


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