P17301: LORD Downhole Test Simulator
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Systems Design

Table of Contents

Team Vision for System-Level Design Phase

During the Systems Design phase, the team planned to determine what the final scope of the LORD downhole drilling vibration isolator testing feasibility study would be. The team planned to visit the LORD facility in Erie, PA to gain a better understanding of what the project entailed. Following the final scope definition, the team set goals to define the current sub-systems of the vibration isolator testing vessel and to benchmark feasible sub-system concepts.

Throughout this process, the team was able to visit the LORD facility where they were able to define a final project scope and gain useful insight on the project. Proceeding the visit, the team benchmarked several sub-system options as well as created several feasible concepts for the test vessel.

Meeting Objective

1) Gather technical feedback on generated concepts and design objectives.

2) Inform Lord of plan and schedule leading to next design review.

3) Determine if part needs separate temperature controls from mud temperature.

Updates since Phase I: Problem Definition

Customer Requirements

Updated Customer Requirements

Updated Customer Requirements

Engineering Requirements

Updated Engineering Requirements

Updated Engineering Requirements

Constraints

Updated Constraints

Updated Constraints

Updated PRP

Link to updated PRP:PRP (9/27/16)

Meeting Notes

Date Attendees Role Meeting Notes
Sept 16, 2016 Keith Ptak, Cortland Chapman, Zach Fuhrer Primary Customer, LORD Test Engineer, Project Manager Meeting Notes
Sep 22, 2016 Keith Ptak Primary Customer Meeting Notes

Functional Decomposition

Functional Decomposition

Functional Decomposition

Mapping Engineering Requirements

Mapping Engineering Requirements

Benchmarking

Benchmarking

Benchmarking

Link to full Benchmark Table:Benchmarking Table

Morphological Chart and Concept Selection

Morph Charts

Morph Charts

Selection Criteria

Listed in order of priority:
  1. Safety
  2. Meets all ER's
  3. Scalability
  4. Upkeep costs
  5. Power/energy cost
  6. Construction cost
  7. Subsystems integrate easily
  8. Footprint
  9. Easy to operate/set-up
  10. Complexity

Concept Development

Pugh Chart

Pugh Chart


Link to full Pugh Chart:Pugh Chart


Pugh Chart Scenario Selection

Pugh Chart Scenario Selection


Selection Summary
Scenario 1 was chosen because it had the highest score and its subsystems would be easiest to integrate.


Systems Architecture

Concept Sketch

Concept Sketch

System Overview Block Diagram

System Overview Block Diagram

Mud Intake Valve Concept

Mud Intake Valve Concept

Feasibility: Prototyping, Analysis, Simulation

The most feasible design (Scenario 1) consists of:

Phase II Feasibility Chart

Phase II Feasibility Chart

Test Plan

We plan on testing the following subsystems over the next few phases in the methods described in the below table.

System Method Linked Subsystems Engineer Responsible Priority
Dynamic Load (Axial, Lateral) Analysis/Prototype Mud Intake Valve

Static Load (Axial, Lateral)

Sam 1
Dynamic Load (Torsional) Analysis/Prototype Mud Intake Valve

Static Load (Torsional)

Sam 1
Static Load (Axial, Lateral) Analysis Dynamic Load (Axial, Lateral)

Mud Intake Valve

Hyungsuk 2
Static Load (Torsional) Analysis Dynamic Load (Torsional)

Mud Intake Valve

Hyungsuk 2
Mud Pump Analysis Heat Mud

Piping

Jason 2
Heat Mud Simulation Mud Pump

Piping

Jason 2
Mud Maintenance Analysis Piping Jason 3
Mud Intake Valve Prototype Static Loads

Dynamic Loads

Piping

Sam 1
Heat Component Analysis/Prototype Piping

Pressure Vessel

Matt 2
Piping Analysis All Mud Components

Mud Intake Valve

Pressure Vessel

Matt 3
Pressure Vessel Framework Analysis/Simulation Piping

Heat Component

Matt 3
Pressure Vessel Seals Analysis/Prototypes Piping

Heat Component

Matt 1

All tests will be documented as per the following template:

Test Plan Template

Test Plan Template

Risk Assessment

Phase II Risks

Phase II Risks

Project Plan for Phase II: Systems Design

Phase II Gantt Chart

Phase II Gantt Chart

LORD Facility Visit Action Items:

LORD Visit Action Items

LORD Visit Action Items

Open action items:

  1. Heating &Cooling System Definition & Requirements

Plans for Phase III: Preliminary Detailed Design

Phase III Individual Plans

Phase III Individual Plans

Link to Phase III Gantt Chart:Phase III Gantt Chart

Lessons Learned

  1. Group Peer Evaluations are helpful for the project health
  2. Open communication within team and with customer
  3. Respect everyone's opinions during group meetings
  4. Visit to LORD Facility in person was very beneficial

Phase II Review Action Items


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Build & Test Prep | Subsystem Build & Test | Integrated System Build & Test | Integrated System Build & Test with Customer Demo | Customer Handoff & Final Project Documentation