2012/2013

FINAL YEAR PROJECT

Submitted in fulfillment of the requirements for the

ENGINEERING DEGREE FROM THE LEBANESE UNIVERSITY

FACULTY OF ENGINEERING- BRANCH III
Major : Mechanical Engineering

By:

Mohammad BUSSY
Mohamad KACHOUH
________________________________________________

Sliding Mode Control Techniques: Application

on a Quad-rotor
Supervised by:
Dr. Majed MORKOS

Defended on July 10th 2013 in front of the jury:

Dr. Bassam RIACHI

President
Dr. Majed MORKOS Supervisor Dr.
Mohamad HAMMOUD
Member Dr.
Abbass MOUSSAILEB
Member

ABSTRACT

The purpose of the project:

A: Improving blade design for hydraulic optimization:

The Study will release different profiles of new designed Blades from the rotor and stator for
the ability to undertake different Challenges concerning:
1) Decreasing Number of Stages in the Power Section where delivering an
increased total power output at a same total pressure drop and flow rate.
OR Decreasing Number of Stages and delivering same total power output at a
decreased total pressure drop and flow rate.
2) Decreasing the Thrust Load at same pressure drop, power released and flow
rate.
3) Providing an adapted power section for high flows.
By using the ANSYS Simulation Software with coordination of fully explained manual
calculation.

B: Fully explained and designed of Double bent system (used for Directional Drilling).

Table of Content
1.2. General View of turbo-Drill .............................................................................................. 2
1.2.1.Tool Description .............................................................................................................. 2
1.2.2.Turbine performance ....................................................................................................... 3
1.2.3.Turbo-Drill advantages .................................................................................................... 3
1.2.4.Turbo-Drill disadvantages ............................................................................................... 3
1.2.5.Basic Turbo-drill Components ........................................................................................ 4
1.2.5.1 Thrust and radial Bearings ............................................................................................ 4
1.2.5.2. Power Housing ............................................................................................................ 5
1.2.5.3.Drill Bits ....................................................................................................................... 6
1.2.5.4.Rotor and Stator ............................................................................................................ 7
1.2.5.5. Intermediate Stabiliser ............................................... Error! Bookmark not defined.
1.2.5.6. Steerable Turbines Bent Housing .............................. Error! Bookmark not defined.
1.2.6. Turbo-Drill 2D drawing................................................ Error! Bookmark not defined.
1.3.Turbo-Drill Principle of function: ...................................................................................... 9
Chapter 2.Project Plan 2.1.Project Concentration .................................................................. 10
2.2.The purpose of the Project ................................................................................................ 10
2.3.Methodology .................................................................................................................... 10
Chapter 3. Full Study of original Blades ................................................................................ 11
3.1.Company data inputs ........................................................................................................ 11
3.2.Manual Calculations ......................................................................................................... 12
3.3. ANSYS Study: ................................................................................................................ 21
3.3.1. ANSYS general view .................................................................................................... 21
3.3.2.BLADEGEN Cell .......................................................................................................... 22
3.3.3.TURBO-GRID............................................................................................................... 29
3.3.4. CFX Simulation ............................................................................................................ 30
3.3.4.1.Setup Cell : ................................................................................................................. 31
3.3.4.2.CFX Solution .............................................................................................................. 34
3.3.4.3. CFX-Results ................................................................................................................ 35
3.3.5. Static Structural Analysis ............................................................................................. 41
3.3.6. Erosion Rate ................................................................................................................. 44
Chapter 4.Blade Optimisations ............................................................................................... 46
4.1.Overview........................................................................................................................... 46
4.2. Factors of Optimisations:................................................................................................. 48
4.3. Blade regulation methods: ............................................................................................... 49
4.4. Original Blade Side effects: ............................................................................................. 51
4.5. First Optimisation: .......................................................................................................... 51
4.5.1.Blade regulations ........................................................................................................... 51
4.5.2.Beginning of simulation: ............................................................................................... 55

Page II

4.6.Second Optimisation...61
4.6.1. Blade Regulations .......61
4.6. 2.Beginning the simulation..62
4.7. Third Optimisation ....65
4.7.1.Blade Regulations.....65
4.7.2.Beginning the simulation.........66
4.8. Fourth Optimisation........69

Chapter 5.Adjustable Double Bent

5.1. General view...73
5.2.Double-bent assembly75

Projects Conclusions85

Page III

List of Figures
Fig 1.1. Cedar Turbo-drill Assembly...2
Fig 1.2.TCI Radial Bearing......4
Fig1.3.PDC Thrust Bearing...5
Fig 1.4. PDC and Impregnated Drill Bit.......6
Fig 1.5. Drill Bit (Solid works 3D view).................................7
Fig 1.6. Set of Rotor and Stator........8
Fig 1.7. Middle Stab, Male and Female Coupling.......9
Fig 1.8. Flexible Shaft, Male and Female Bent Housing.....9
Fig 1.9. Turbo-Drill 3D View......9
Fig 1.10. Power Section 2D Drawing..10
Fig 1.11. Bearing Section 2D Drawing...10
Fig 1.12.: Cedar Power and Bearing Section......12
Fig 2.1. Stator Row specifications...15
Fig 2.2. Rotor Row specifications...16
Fig 3.1: Schematic of velocity Diagram of one row Stator-Rotor..17
Fig 3.2. Stream Velocity through a rotating Blade.........19
Fig 3.3: Stage power and torque in function of N..21
Fig 3.4. General view of ANSYS study.26
Fig 3.5. Blades characteristic Points..27
Fig 3.6. Pressure Side Characteristic Points....28
Fig 3.7. Uppers Suction Side Characteristic Points.28
Fig 3.8. Lower Suction Side Characteristic Points..28
Fig 3.9. General View of Blade generation.29
Fig 3.10. Stator Position..30
Fig 3.11: Meridional configuration.30
Fig 3.12. 3D view of stator Row (Shroud Hidden).....31
Fig 3.13.Theta and beta angle..32
Fig 3.14.Thickness variations..32
Fig 3.15. 2D view of too consecutive blade with flow throat.....31
Fig 3.16: Rotor Position...33
Fig 3.17. Rotor meridional Configuration...33
Fig 3.18. Mesh View of stator row......34
Fig 3.19: Background view of CFX setup: 2 blades from rotor and stator are presented..36
Fig 3.20. Rotor/ Stator axial interface..38
Fig 3.21. Rotor radial interface....38
Fig 3.22. View of surface roughness...37
Fig 3.23. The global residual error in function of iteration number...39
Fig 3.24. Pressure distributions on Blade Surfaces.40
Fig 3.25.Turbulence distributions on Blade Surfaces.....40
Fig 3.26. Fluid Pressure distributions......41
Fig 3.27. Fluid Velocity distributions..41
Page IV

Fig 3.28. Fluid Turbulence distributions..41

Fig 3.29. 2D Velocity distributions..42
Fig 3.30. Pressure distributions42
Fig 3.31. Velocity distributions43
Fig 3.32. Tangential Velocity distributions..43
Fig 3.33.Axial Velocity distributions...43
Fig 3.34. Stage Report...44
Fig 3.35. Hub and Shroud as fixed support..35
Fig 3.36. 3D mesh performed on stator row.47
Fig 3.37. Only Hub as fixed support.47
Fig 3.38. Deformation/Stress/Strain distributions on Blades48
Fig3.39. Erosion rate density distributions on blades areas..50
Fig 4.1. Beta Tangential Angle...54
Fig 4.2. Beta Tangential Chart....53
Fig 4.3. Blade Thickness..54
Fig 4.4. Blade Thickness Chart.54
Fig 4.5 Bezier curve..........55
Fig 4.6. Original Blade Thickness Chart...56
Fig 4.7. New Blade Thickness Chart55
Fig 4.8 Original Blade Tangential Angle......57
Fig 4.9. New Blade Tangential Angle...........56
Fig 4.10. Original Blade ....58
Fig 4.11. New Blade Tangential Angle......57
Fig 4.12. Original Blade outlet Thickness.........57
Fig 4.13. 2D shape of original Blade........59
Fig 4.14. 2D shape of new Blades.57
Fig 4.15. fluid Velocity stream distribution.......60
Fig 4.16. CFX Report...60
Fig 4.17. Soot Erosion Rate Density distributions..61
Fig 4.18. Stress/Strain/Deformation distributions across new designed blades.....62
Fig 4.19. Previous 2D Profile Shape.......63
Fig 4.20. New 2D Profile Shape......61
Fig 4.21. CFX Report...64
Fig 4.22. Fluid velocity stream across the new Stage......65
Fig 4.23. Soot Erosion Rate Density distributions.........65
Fig 4.24. Stress/Strain/Deformation distributions across new designed blades.................66
Fig 4.25. Tangential angle from second optimisation....65
Fig 4.26. Tangential angle of new blade....................65
Fig 4.27. 2D shape of previous blades.......68
Fig 4.28. 2D shape of the new blades....66

Page V

Fig 4.29. CFX ...69

Fig 4.30. Soot Erosion Rate Density distributions......69
Fig 4.31. Stress/Strain/Deformation distributions across new designed blade...70
Fig 4.32. CFX Report...69
Fig 4.33. Erosion Rate Density....70
Fig 4.34. Previous 2D profile Shape.71
Fig 4.35. New 2D profile Shape....72
Fig 4.36. CFX Results....72
Fig 4.37. Erosion Results...73

List of Tables
Table 1.1. Number of stages effect on turbine output parameters..3
Table 1.2. Housing and Shaft Linear tolerances according to the tool size....5
Table 3.1: Company Hydraulic Calculation.16
Table 3.2. Characteristic parameter of the Blades.30
Table 3.3. Data Comparison.........44
Table 6. Comparing Results of Optimisation ...... .82

Page VI

Page VII

Chapter1. Turbo-Drill history and general definition

1.1. Turbo-Drill history
1873 An American, C. G. Cross, was issued the first patent related to a downhole turbine
motor for rotating the drill bit at the bottom of a drillstring with hydraulic power . This
drilling concept was conceived nearly 30 years before rotary drilling was introduced in oil
well drilling. Thus the concept of using a downhole motor to rotate or otherwise drive a drill
bit at the bottom of a fluid conveying conduit in a deep borehole is not new.
1924 The first practical applications of the downhole motor concept came when engineers
in the United States and the Soviet Union began to design, fabricate and field test both
singlestage and multistage downhole turbine motors . Efforts continued in the United States,
the Soviet Union and elsewhere in Europe to develop an industrially reliable downhole
turbine motor that would operate on drilling mud. But during the decade to follow, all efforts
proved unsuccessful.
1934 In the Soviet Union a renewed effort was initiated to develop a multistage downhole
turbine motor. This new effort was successful. This development effort marked the beginning
of industrial use of the downhole turbine motor. The Soviet Union continued the development
of the downhole turbine motor and utilized the technology to drill the majority of its oil and
gas wells. By the 1950s the Soviet Union was drilling nearly 80% of their wells with the
downhole turbine motors using surface pumped drilling mud or freshwater as the activating
hydraulic power.
1950 With the growing need in the United States and elsewhere in the world for directional
drilling capabilities, the drilling industry in the United States and elsewhere began to
reconsider the downhole turbine motor technology. There are presently three service
companies that offer downhole turbine motors for drilling of oil and gas wells. These motors
are now used extensively throughout the world for directional drilling operations and for
some straight-hole drilling operations.
The downhole turbine that are hydraulically operated have some fundamental limitations.
One of these is high rotary speed of the turbine and drill bit. The high rotary speeds limit the
use of downhole turbine when drilling with roller rock bits. The high speed of these direct
drive motors shortens the life of the roller rock bit.
1980 In the United States an effort was initiated to develop a downhole turbine motor that
was activated by compressed air. This motor was provided with a gear reducer transmission.
This downhole pneumatic turbine has been successfully field tested.
1982
1988
1993
2002
2003
2010
2011
2012

Neyrfor developed 1st steerable turbo drill

Weir acquired Neyrfor
1st bent housing turbo drill by Neyrfor-Weir
Smith International acquired Neyrfor
Turbo power is incorporated in the Middle East
Schlumberger acquired Smith-Neyrfor
Halliburton acquired Turbo power
Reservoir Group launches Cedar Turbo drills and runs 6-5/8 tools.

Page 1

1.2. General View of turbo-Drill

1.2.1.Tool Description
The downhole turbine motor (Turbodrill) is composed of two sections: turbine motor section
and bearing section i.e. thrust-bearing and radial support bearing. The turbine motor section is
a type of hydraulic axial turbomachinery that has multistage of rotors and stators and converts
the hydraulic power provided by the drilling fluid (pumped from the surface) to mechanical
power while diverting the fluid flow through the stator vanes to rotor vanes.
The fluid will run through the turbodrill and the bit nozzles to cool the bit and remove the
cuttings generated under the bit. It will finally carry the cuttings inside the annulus between
drilling turbine and the hole to The surface. (Figure 1.1) shows a typical Turbodrill assembly
and the fluid flow path through turbine stages. The energy required to change the rotational
direction of the drilling fluid is transformed into rotational and axial (thrust) force. This
energy transfer is seen as a pressure drop in the drilling fluid.
The thrust is typically absorbed by thrust bearing. The rotational forces cause the rotor to
rotate relative to the housing. The bearings, both radial and thrust, maintain the appropriate
turbine blade position, radially and axially, allowing them to perform as designed with
concentric rotation. In practice, multiple stages are stacked coaxially until the desired power
and torque is achieved.
A Turbodrill power section is entirely metallic (metallic turbine blades, metallic shaft,
metallic housing, etc.), therefore, the tool is extremely resistant to high temperatures and high
pressures. Historically, Turbodrills have proven to be the most reliable drive mechanism in
elevated temperature environments. In many cases, Turbodrills are the exclusive drive
mechanism used in high temperature/high pressure areas because of the tools ability to
reliably operate in extreme environments.

Fig 1.1. Cedar Turbo-drill Assembly

Page 2

The turbine motor section usually has bearing groups at the upper and lower ends of the
rotating shaft (on which are attached the rotors). The bearing groups only radial load
capabilities.
The drilling fluid after passing through the turbine motor section is channeled into the center
of the shaft through large openings in the Flow Converter. The drill bit is attached to the
lower end of the main shaft. The weight on the bit is transferred to the downhole turbine
motor housing via the thrust-bearing section. This bearing section provides for rotation while
transferring the weight on the bit to the downhole turbine housing.In the thrust-bearing
section is a radial support bearing section that provides a radial load-carrying group of
bearings that ensures that the main shaft rotates about center even when a side force on the bit
is present during directional drilling operations.

1.2.2.Turbine performance
The turbine motor section has multistages of rotors and stators, from as few as 25 to as many
as 300.
For a basic motor geometry with a given flowrate, an increase in the number of
stages in the motor will result in an increase in torque capability and an increase in the peak
horsepower. This performance improvement, however, is accompanied by an increase in the
differential pressure through the motor section (Table 1.1).
Number of
Stages

Torque
(Ft.lbs)

Bit Speed
(Rpm)

Differential
Pressure(PSI)

Power(kW)

122
152
300

1188
1480
2921

1242
1242
1242

1257
1566
3090

209
260
514

Thrust
Load
(1000 lbs)
21
26
51

Table 1.1. Number of stages effect on turbine output parameters

1.2.3.Turbo-Drill advantages
1-Hard to extremely hard competent rock formations can be drilled with turbine using
diamond or the new polycrystalline diamond bits.
2-Rather high rates of penetration can be achieved since bit rotation speeds are high. 3-Will
allow circulation of the borehole regardless of turbine horsepower or torque being
produced by the turbine Circulation can even take place when the turbine is installed.

1.2.4.Turbo-Drill disadvantages
1-Motor speeds and, therefore, bit speeds are high, which limits the use of roller rock bits. 2The required flowrate through the downhole turbine and the resulting pressure drop through
the turbine require large surface pump systems, significantly larger pump systems than are
normally available for most land and for some offshore drilling operations.
3-Unless a measure while drilling instrument is used, there is no way to ascertain whether the
turbine is operating efficiently since rotation speed and/or torque cannot be measured using
normal surface data (i.e., standpipe pressure, weight on bit, etc.).
4-Because of the necessity to use many stages in the turbine to obtain the needed power to
drill, the downhole turbine is often quite long.

Page 3

5-Downhole turbine can only be operated with drilling mud.

1.2.5.Basic Turbo-drill Components

1.2.5.1 Thrust and radial Bearings
Some of the most important developments
concerning the durability and reliability of this
drilling system are found in Turbo-drill bearings.
The bearings, both radial and thrust, maintain the
appropriate turbine blade position, radially and
axially, allowing them to perform as designed.
Since Turbo-drills are very long lasting tools that
run in high RPM ranges, the development of
bearing technology has been crucial to the
durability of the tool. One of the most important
developments in bearing technology has been the optimization of PDC thrust bearings.
Fig 1.2.TCI Radial Bearing

Bearings, through diamond to diamond contact, support the axial thrust and rotations created
by the turbine blades and reside in the bearing section.-Thrust Bearing are used to support
axial load and to Prevents contact between Stator & Rotors-Each stage of thrust Bearing
contain high durability low friction diamond thrust bearings & a disc spring to absorb and
share thrust loads evenly through the stack .
This diamond to diamond contact, between the rotor and stator components of PDC bearings,
provides the ultimate resistance to compression loads, rotational abrasion, and high
temperatures. PDC bearings have many advantages, but the most important of these are a
very low coefficient of friction and a very long life in demanding applications. Diamondtodiamond interfaces, particularly when lubricated by the drilling mud, produce very little
friction, thereby absorbing axial thrust with very little energy lost in the process, contributing
to overall higher tool efficiency.
Along with the development of PDC thrust bearings, several innovative technologies have
improved the wear resistance of Turbo-drill radial bearings. These technologies have
fundamentally focused on the development of more abrasion resistant materials and coatings,
but Turbo-drill designs are also a function of the development of exacting dimensional
tolerances.
A unique characteristic of the Turbo-drill is that the entire tool runs concentrically, with very
small radial bearing clearances. Since the tool is designed to be concentric, with very tight
tolerances on many parts to maintain balance, loads on the radial bearings are manageable,
and corresponding vibration levels are quite low. It is therefore possible to focus the
engineering effort of radial bearing development on the abrasion resistance of the bearing
surfaces in order to manage bearing wear, even at high RPM and on very long runs.

Page 4

Fig1.3.PDC Thrust Bearing

1.2.5.2. Power Housing

Housing are of one type and made in the form of a metal tube of 105 to 240 mm outer
diameter depending on the turbodrill size.
Housing and shafts are important components which govern not only efficient turbodrill
operation but also trouble-free drilling of wells. They are produced of alloyed
chromiumnickel-molybdenum steels 40 XH2MA and 38 XH2MA possessing a high
endurance and high impact toughness.
Shaft and Housing are heat treated after which they acquire hardness HB 269-341. Blanks are
heated in the vertical position in special shaft furnaces.
Shafts and Housing should be free of any internal and external flaws (cracks, microcracks,
etc.). Linear tolerances should not exceed values given in (Table 1.2):

Table 1.2. Housing and Shaft Linear tolerances according to the tool size
In case of necessity shafts and Housing can be subjected to stress relief at all stages of
production. Having been straightened immediately after the heat treatment, they are subjected
to high-temperature tempering (450 to 700C) to relieve internal stresses .
Thread is the most important elements of the turbodrill housing and shaft. Turbodrill threads
are made in pipe-threading programmable machines applying special measuring tools and
gauges.To increase the strength and resistance to fatigue failure, turbodrill threaded joints are

Page 5

made fitted with threaded ducts. To additionally increase the fatigue resistance of threaded
joints, the zone of the highest stress concentration is plastically strained when threading.

1.2.5.3.Drill Bits
Turbodrills are generally used either with PDC drill bits or impregnated drill bits. The
development of this system has basically excluded rock bits, due to their obvious limitations
at high speeds and relatively short drilling life in extreme environments. Although there are
many applications well suited to the use of PDC drill bits and Turbodrills, those applications
do not tend to be applications where durability is the limiting performance factor.
When PDC bits are used with Turbodrills, it is normally for the enhanced ROP of that
system, in comparison to the impregnated bit/Turbodrill system, and therefore, durability is
not the primary driver for performance development. In contrast, the Turbodrill impregnated
bit system is often used in applications where durability is the most important factor. In these
applications, the ROP tends to be low, due to high compressive strength rock and deeper
drilling intervals.
Therefore, a critical factor in improving overall performance is staying in the hole for as long
as possible, to reduce, or eliminate, the costs associated with making long bit trips. In the
recent past, impregnated bits have made great strides in improved durability for these
applications. These improvements have been a combination of material science advancements
coupled with bit design improvements. With the development of very durable impregnated
bits, and the utilization of the very reliable Turbodrill, it has become possible to drill long
intervals in very difficult formations, thus reducing trip time and the overall drilling time.

Fig 1.4. PDC and Impregnated Drill Bit

Page 6

Fig 1.5. Drill Bit (Solid works 3D view)

1.2.5.4.Rotor and Stator

The main turbodrill unit is a multistage turbine where each stage consists of working blades
(stator,rotor). As a rule, turbine blades of modern turbodrills are a metalic structure made of
steel by semi permanent mold casting.
The steel blades are cast in metal permanent molds with sand cores. Steel grades 40L-1,
45L1, 35GL-1, 35XML-1 are used for manufacturing. Before machining castings are sand or
shot blasted followed by heating furnace annealing.
Manufacturing turbine blades by the above technology is complicated because of the need to
join various thickness cross sections in castings and radially arranged thin blades with the
comparatively thick hub body.
Sometimes this produces casting flaws that reduce the turbine strength.
Casting the output blade edge, whose manufacture quality is of a significant influence on the
turbine efficiency, is difficult. Rough surfaces of the flow-through part of the turbine, which
undergo no machining, produce energy losses in the turbine, and reduce performance below
calculated values-Casting molds are used to form the annular grid of the turbine blades by
simply joining two half-matrices in the axial direction and form the basis for manufacturing
turbines by investment casting.
The principle of joining two half-matrices was used also in the mold for manufacturing strong
turbine parts of polymer materials described below.

Page 7

The investment casting method allows significant improvement in turbine performance due to
achieving precise geometric dimensions, relative surface smoothness and absence of under
filling of output blade edges.

Fig 1.6. Set of Rotor and Stator

In addition to steel, turbine blades are manufactured with flow-through components made of
polymer materials (plastics) and hubs of steel tube rolled stock. The blade section of these
turbines is distinguished by a high surface finish, precise geometric dimensions and forms.
Complicated conditions of turbine operation define specific requirements for physical and
mechanical properties of polymer materials used to manufacture the flow-through section.
These requirements concern, primarily, mechanical strength, resistance to vibration, heat
resistance, resistance to wear; and chemical stability as well as dimension and shape stability.
Polyamid-12 with a low (up to 10%) addition of the same grade plasticized material, and also
polyamid 610, meet the above requirements. Turbines with the flow-through parts made of
these materials are widely applied in drilling and show a high working capacity and
reliability.
At present, new methods of manufacturing turbines are being designed. One is stamping
which ensures not only a high-quality blade unit surface and precise geometric parameters,
but also improved physical and mechanical blade properties.

Page 8

1.3.Turbo-Drill Principle of function:

Drilling Turbine are commonly used to provide rotational force to a drill bit when drilling
earth formations. Drilling motor used for this purpose are typically driven by drilling fluids
pumped from surface equipment through the drill string. This type of motor is commonly
referred to as a mud motor. In use, the drilling fluid is forced through the mud motor(s),
which extract energy from the flow to provide rotational force to a drill bit located below the
mud motors. There are two primary types of mud motors: positive displacement motors
(PDM) and turbodrills.
A PDM is based on the Moineau principle. Drilling fluid is forced through a stator. An
eccentric rotor is located inside the stator. Drilling fluid circulating through the stator imparts
a rotational force on the rotor causing it to rotate. This rotational force is transmitted to a drill
bit located below the PDM.
A Turbo-drill uses one or more stages to provide rotational force to a drill bit. A typical
prior art turbodrill is shown in (Fig 1.11)
In (Fig1.11 ), a turbodrill 8 is connected to a drill string 4.A drill bit 3 is connected to a shaft
1 on a lower end of the turbodrill 8. In operation, drilling fluid (not shown) is pumped
through the drill string 4 until it enters the turbodrill 8. The flow path of the drilling fluid
through the turbodrill 8 is indicated by arrows. When the drilling fluid enters the turbodrill,
the flow is substantially in the axial direction in line with the axis -A- of the turbodrill 8. The
drilling fluid is diverted from the center of the turbodrill 8 to an outer radial position of the
turbodrill 8. The drilling fluid then passes through a stator which is rotationally fixed relative
to the housing 2 and the drill string 4. A plurality of curved stator vanes 9 are positioned
around stator 6. As the drilling fluid passes through the stator 6, it accelerates and the flow
direction is changed by a selected angle, which is typically referred to as the swirl angle. The
resulting flow direction is helical with respect to the axis A.
After passing through the stator 6, the drilling fluid passes through the rotor 7. A plurality of
curved rotor vanes 10 are positioned around the rotor 7. The rotor vanes 10 are curved to
direct flow in an opposing direction to the helical flow resulting from the stator 6. The rotor
vanes 10 are shaped similarly to an airfoil so that the drilling fluid passes efficiently through
the rotor 7.
The energy required to change the rotational direction of the drilling fluid is transformed into
rotational and axial (thrust) force. This energy transfer is seen as a pressure drop in the
drilling fluid. The thrust is typically absorbed by thrust bearings (not shown). The rotational
force causes the rotor 7 to rotate relative to the housing 2. The rotor 7 rotates the shaft 1,
which may be connected to a drill bit 3.
(FIG 1.11) also illustrates the use of multiple stages in a turbodrill 8. A stage includes a
stator blade 9 and a rotor blade 10, each having an arrangement of blades thereon. The rotor
blades 10 of each stage are typically attached to the same rotor 7,Each stage generates an
amount of power and torque, and results in a corresponding pressure drop for a given flow
rate. Multiple stages are stacked coaxially until the desired power and torque is
achieved.Because a pressure drop results from each stage, the total pressure drop must be
considered based on the pumping ability of the pumps (not shown) used to convey the fluid
downhole. The stacking of stages also increases the overall length of the tool.

Page 9

Chapter 2.Project Plan 2.1.Project Concentration

The project is concentrated on the power section of turbo-Drill. Its the source of power that
activates the drilling action. Power section is the most interested part in the turbine. Its
convenient to have an interesting study through updating the most important factor in
releasing energy for Drillings. The general concept of the study will be concentrated on
optimizing the behaviour of this section by controlling the performance of its stages.
This performance highly depends on blades profiles in the stator and rotor of each stage.

More into the Core:

The full Study of the power section will be concentrated on studying one stage of
StatorRotor. When designing and simulating a hydraulic multistage turbo-drill, it was
assumed that each Stage is identical and that the flow rate, pressure drop, rotary speed,
generated torque and power transmitted to the shaft are the same for each of the stages.
As a result, Turbo-drill's performance is composed of performance of several identical stages
stacked close to each other connected to the Turbo-drill shaft.

2.2.The purpose of the Project

The purpose of the project is improving blade design for hydraulic optimization The
Study will release different profiles of new designed Blades from the rotor and stator for
the ability to undertake different Challenges concerning:
1) Decreasing Number of Stages in the Power Section where delivering an increased total
power output at a same total pressure drop for the same flow rate.
OR Decreasing Number of Stages and delivering same total power output at a decreased total
pressure drop for the same flow rate.
2) Decreasing the Thrust Load at same pressure drop, power released and flow rate.
3) Providing an adapted power section for high flows.
N.B: Each released profile will be followed by an analysis study of the Erosion rate and
Stress/Deformation on blades areas.

2.3.Methodology
The Methodology of the Study will be based on using an Engineer Simulating-Software
[ANSYS (BLADEGEN, TURBO-GRID, CFD and FSI) (Discussed later)] that will be
powered by a coordination with fully explained and generated manual calculations of the
blading system to generate concepts affecting the project goals. ANSYS simulator represents
the reality performance of the power section .Its used to have an accurate results on reality.

Page 10

Chapter 3. Full Study of original Blades

The project begins with a full study of the original blades used by CEDAR company on one
stage by using ANSYS and Manual Calculations:
Manual calculations includes:
Fully demonstrated equations in generating torque , power , pressure drop, hydraulic
efficiency and optimal rotational speed in one stage , with their relations to the fluid
properties ( Flow and density ) , blades geometries.
ANSYS simulations includes:
a) Importing the current blades to the ANSYS and performing simulation on one stage with
same conditions used by the company (rotating speed , input pressure and fluid flow ).
b) Generating output values including torque , power , pressure drop and hydraulic efficiency
from the stage with 2D and 3D distributions of pressures , velocities , turbulences and
viscosity on blades areas.
c) Generating Structural Loads on blades surfaces including: Strains, Deformations and
stress distributions.
d) Generating Erosion Rate on Blades surfaces.
After obtaining results from ANSYS and manual calculations for the same current blades, we
will have an opportunity to compare the manual and ANSYS calculations with the output
values calculated by the company concerning generated Power, torque, pressure drop and
hydraulic efficiency. This concept leads to have confidence in manual calculations and
ANSYS simulations performed, when all the compared results are highly near to each other.

3.1.Company data inputs

The Concept of optimization needs input data from Company generated from original used
blades. These data will include all needed parameters for the study. Hydraulic

calculations:

Cedar 6-5/8" Engineering Report

Units
Data Type
PARAMETER
Nb
Input parameter
Stages in the Turbine
Kg/s
Input parameter
Flow
SG
Input parameter
Mud Density
%
Input parameter
Hydraulic Efficiency
RPM
Output calc.
Operating Speed
m
Output calc.
Head Loss / Stage
N.m
Output calc.
Torque / Stage
W
Output calc.
Power / Stage
Pa
Output calc.
Pressure Drop / Stage
Table 3.1: Company Hydraulic Calculations

122
31.41
1
77
1242
7.24
13.22
1721.3
71038

Page 11

3.2.Manual Calculations
Generation of :
1.
2.
3.
4.

Torque.
Power.
Optimal Angular velocity and the corresponding Torque and Power.
Pressure drop across the Stator and Rotor.

Manual calculation begins by understanding the velocity triangle's diagram of the Stator-rotor
System.
The well-known method of building velocity triangles is used when generating manual

equations and designing the blade unit profile (see Fig 3.1).
Fig 3.1: Schematic of velocity Diagram of one row Stator-Rotor

Page 12

This method is useful for visualizing changes in the magnitude and direction of the fluid flow
due to its interaction with the blade system.
In general, the flow in a turbo machine has components of velocity along all three cylindrical
axes (axial x, radial r, and tangential r axes).

However, for turbo-drill as an axial turbo machinery, to simplify the analysis it is usually
assumed that the flow only vary in the tangential and axial direction. In this case, the flow
moves through the machine on axi-symmetric stream surfaces.
Fluid enters the stator with an absolute velocity c1 and at an absolute velocity angle 1. That
accelerates to an absolute velocity c2 at absolute velocity angle 2.
The rotor inlet relative velocity w2, at a relative velocity angle 2, is found by adding
vectorially the blade speed U to the absolute velocity c2.
The relative flow within the rotor accelerates to relative velocity w3 at an angle 3 at rotor
outlet.
The outlet absolute velocity c3 at an absolute velocity angle 3 are respectively the same as
c1 and 1 that is obtained from adding vectorially the blade speed U to the relative velocity
w3.
All angles are measured from the vertical direction.
In the study, the analysis of the flow-field within the rotating blades of a turbo-drill is
performed in a frame of reference that is stationary relative to the blades. In this frame of
reference the flow appears as steady, whereas in the absolute frame of reference it would be
unsteady.

N.B : 2 and 3 are the characteristic fluid outlet angles respectively for the stator and
rotor that remain always constant with rotational speed and flow rate's variations. And there
variations affect the performance of the turbine.

Defining recommended variables for generating equations:

Cx : Defined as the axial component of absolute velocities through the stage. It remains
constant for a given flow rate
Where A is the axial surface of the region generated by blade.
. Q the flow rate
: The mass flow :
: Radial distance from axis of rotation to the upper limit of the blade.
: Radial distance from axis of rotation to the lower limit of the blade.

Page 13

: The root mean square radius of the blade :

W2o : The tangential component of the relative velocity of the fluid at rotor inlet
W3o : The tangential component of the relative velocity of the fluid at rotor outlet
C2o : The tangential component of the absolute velocity of the fluid at Stator outlet
C3o : The tangential component of the absolute velocity of the fluid at Stator inlet
N : The rotational velocity of the rotor in RPM.
The Stagnation enthalpy:

' is the radiant rotational velocity of the rotor :

T : The torque generated in one stage.
W : The output power :
: The pressure drop in one stage :
where H is the head loss in meter.

The Hydraulic efficiency:

Generating the source of Equations:

The Euler Turbine Equation
The Euler turbine equation is based on the concepts of conservation of angular momentum
and conservation of energy.
We will work with the model of the blade row shown in (Fig 3.2),

Page 14

Fig 3.2. Stream Velocity through a rotating blade

Applying conservation of angular momentum, we note that the torque T must be equal to
the time rate of changing in angular momentum of the stream that flows through the device.
In this case :

and
are the values of tangential momentum of the fluid respectively
at the inlet and outlet of the rotors row.
Vb and Vc are respectively the inlet and outlet tangential relative velocity components to the
Rotor
Returning to the Previous Schematic of velocity Diagram of one row Stator-Rotor (Fig12)
The tangential momentum of the fluid at rotor inlet:

The tangential momentum of the fluid at rotor outlet:

The moment of momentum at inlet :
The moment of momentum at exit :

So the generated torque :

.
.

Where it's generated from the inlet relative tangent velocity of the rotor and from the outlet
relative tangent velocity at a given distance rm for a given flow mass m .

Page 15

Generating Torque equation for one Stage :

So
We have

And

So

Generating Power equation for one Stage :

So

Power and torque variations in one stage are presented in function of Rotational Speed N
(See Fig3.3)

Page 16

Fig 3.3: Stage power and torque in function of N

Generating the optimal angular velocity Nopt

The Optimal rotational velocity represents the optimal rotational speed of the rotor in which
the power is on maximum value , where
We know that

opt

So

Generating Torque equation at Nopt

From the equations related W and T to the rotational velocity we can release :

Page 17

We have

So

Generating Power equation at Nopt :

So

We have

So

The formulas of W (Nopt) and T (Nopt) are in function of an input flow rate with the
parametrical characteristics of blading system.

Calculation of the pressure drop across the entire stage

Taking the flow through a turbo-drill as isentropic, the equation of the second law of
thermodynamics, Tds=dh-dp/ can be approximated by dh=dp/, and ignoring
compressibility effects.
So the pressure drop is generated through a variation of enthalpy energy in stator and rotor.
As no work is done in the stator row, the stagnation enthalpy across it remains constant and
.
So the enthalpy drops through the stator is :

Page 18

Same concept in rotor where the relative stagnation enthalpy across it remains constant
So the enthalpy drops through the rotor is :
The enthalpy drop across the entire stage is :

Calculating P stator in function of rotating speed N

We have

So

Taking in count that pressure drops equal stagnation drop for a given density
(
) and theres losses (L1) added to pressure drop due to frictions, So

Calculating P stator at Nopt:

So

Page 19

Calculation of P rotor in function of rotating speed N

We have

Taking in count that pressure drops equal stagnation drop for a given density (
) and theres losses (L2) added to pressure drop due to frictions, So

Calculating P rotor at Nopt:

Page 20

Generating Total pressure drop of the Stage

Where L represent the pressure losses du to frictions in turbo stage.

Generating Torque and Power values from the current blades using the manual calculation
will be released when completing ANSYS simulation.

3.3. ANSYS Study:

3.3.1. ANSYS general view
ANSYS Simulations will be concentrated on one stage study.
Definition of its different parts: (Fig 3.4)
a) BLADGEN for Stator and Rotor: responsible of fully constructing one row of Stator
and one row of rotor.
b) TURBO0GRID for Stator and Rotor: responsible of generating a mesh for all the row.
c) CFX simulation: Takes the fully constructed stage with all necessary boundary
conditions( Flow , rotating speed , pressures ) .
It activates a simulation for the entire stage and release output results including :
Torque , power generation and pressure drops distributions with a visual Charts ,2D
and 3D representations of other Important parameters including (Pressure , velocities ,
turbulences )
d) Static Structural for Stator and Rotor: responsible of studying Stress/Strain and
deformations across the blades areas.
e) CFX Erosion: responsible of studying the erosion rate on blades surfaces.

Page 21

Fig 3.4. General view of ANSYS study

3.3.2.BLADEGEN Cell
Definition
BLADEGEN (Blade Generation) is a geometry-creation tool for turbo machinery. It
incorporates extensive turbo machinery expertise into a graphical environment.
Its a specialized tool for 3-D design of the rotating machinery components. It`s used to
create a 3D shape of a blade and construct an entire row of one stator and rotor.

Importing Stator-Rotor rows

Importing one row of a Stator and Rotor begins by Importing the 2D shape of the blade for
each row
Stator and Rotor blades are Symmetrical. Its convenient to import a 2D shape of the stator
blade then by a symmetrical action, the entire Rotors row will be constructed.

Stator row Construction

In General, a 2D blades profile is designed using its characteristic points. ANSYS
BLADEGEN accept the 2D Shape by importing the characteristic points. To retrieve these
points, the 2D Blade is imported from SOLIDWORKS to the Data import wizard in
ANSYS.

Page 22

The Characteristic points are picked as :

1)

12 points for the Upper Suction Side.

2)

7 points for the Lower Suction Side.

3)

16 points for the pressure side.

Fig 3.5. Blades characteristic Points

Data Import Wizard generates the following

characteristic points: (Fig 3.6 , 3.7 and 3.8)

Fig 3.6. Pressure Side Characteristic Points

Page 23

Fig 3.7. Uppers Suction Side Characteristic Points

Fig 3.8. Lower Suction Side Characteristic Points

Starting BLADEGEN: (Fig 3.9)

Page 24

Fig 3.9. General View of Blade generation

Stators row construction methodology:

a) Model Property Dialog:
Turbine mode is chosen with an axial rotation as a configuration type at a stationary status
with Unit sets in Millimeter.

b) Meridional Configuration Dialog :

For selecting machines type and mains dimensions for Stator row :
Selecting a Normal Axial turbine as a machine type
Importing the main Dimension of the stator row from Company data :

Page 25

Stator Row first Position:

Stator Row end Position:

Fig
3.10. Stator Position

Stator Shroud radius :

Stator Hub radius :
inlet position :
Blade end position:

Blade

Fig 3.11: Meridional configuration

c) The characteristic points generated from Data Import Wizard are imported to the 2D
shape block (Fig:3.9) . N B: After the construction of the suction and pressure side,
leading edge and trailing edges are automatically generated.
d) Blade count Dialog: Blade number is selected to be 28 blades.

After completing these steps , a 3D view of the original stator row is visible: (Fig 3.12)

Page 26

Fig 3.12. 3D view of stator Row (Shroud Hidden)

Stators row properties Results :

Blade & Layer Parameters

3D Meanline Length = 15.5091

Bezier Parameters:
Standard Parameters:

Camber Length = 15.5091

Stagger Angle = 30.2

Cord Length (C) = 13.5614

LE Theta Angle = -0.3

Meridional Length = 11.9512

LE Beta Angle = -26.4

Stagger Angle = 28.2

TE Beta Angle = 63.9

Solidity (C/S) = 1.19671

Pitch Cord Ratio = 0.835621

LE Wedge Angle = 22.2

TE Wedge Angle = 4.3
LE Thickness = 1.87845
TE Thickness = 0.998822

Table 3.2. Characteristic parameter of the Blades

Graphical representation of important geometrical parameters affecting the blade
profiles shape

Page 27

Fig 3.13.Theta and beta angle

Fig 3.14.Thickness variations

Fig 3.15. 2D view of too consecutive blade with flow throat:

Rotor row construction

Rotor row construction will have the exact same methodology in constructing Stators row
but with an additional action of reversing the rows geometry using a reverse rotation
direction option dedicated in BLADEGEN and editing rotor row position.

Page 28

Editing the rotor position

Firsts row Position:

Ends row Position:

Fig 3.16: Rotor Position

Identifying Main Dimensions of the stators row as:

Rotor Shroud radius :
Rotor Hub radius :
Blade inlet position :
Blade end position:

Fig 3.17. Rotor meridional Configuration

3.3.3.TURBO-GRID
TURBO-GRID comes after generating stator and rotor rows.
Meshing the Intier Stage is needed for simulations. TURBO-GRID is responsible for
generating meshes

Definition:

Page 29

Its a powerful tool that creates high-quality hexahedral meshes using an automatically
created mesh topology for the blade geometry: (ATM) technology. It facilitates an
accurate and fast Computations fluid Dynamics analysis.
The ATM method adapts the block topology for the given blade geometry, yielding a smooth
mesh with high resolutions.
The final mesh size , the blade boundary layer resolution and other steps are performed
automatically to produce a mesh of extremely high quality elements.
ANSYS Turbo-Grid imports geometry definitions from BLADEGEN.
By Clicking update on Turbo-grid Cell, meshing is automatically generated for the entire
Stator and rotors Row. The Turbo-Grid meshing for the Stator and Rotor is performed in the
exact same way.

Fig 3.18. Mesh View of stator row

3.3.4. CFX Simulation

After creating meshes in Turbo-Grid for the Stator and Rotor rows, the initiation of
simulation begins with ANSYS CFX for computation of fluids dynamics in the stage of
turbine.

It enables to perform analysis of incompressible fluid flow through blade geometries. We

import meshes, specify boundary conditions and solution parameters, solve the
calculations and view the corresponding results

Page 30

Too links is activated from 2 cells of TURBO-GRID form the rotor and stator to the CFX
cell.
Three components of simulation are presented inside CFX: (See Fig. 3.4)
1) Setup
2) Solution
3) Results

3.3.4.1.Setup Cell :
Definition:
Simulation begins by selecting the TURBO mode in Setup Cell. A specialist mode allowing
to setup turbo machinery simulations.
Each component the Stator-Rotor rows are defined by importing there meshes from
TurboGrid then Identifying some basic parameters and boundary conditions.
Interfaces between the Stator and Rotors Rows need to be generated.
Based on the stage interface model included in CFX-Setup, where the flow field is
repeated in multiple identical rotational regions, then only one region needs to be solved and
the boundaries are specified as Periodic (via a rotation ).
Consequently, only one blade region in stator row and one blade region in rotor row are
presented for simulation. They interact together, and computational expenses will be reduced
significantly.(See Figure 3.19.).

Page 31

Fig 3.19: Background view of CFX setup: only 2 blades from rotor and stator are presented
for simulation

Fluid Properties:
Fluid Type is a Clean water (a Newtonian fluid) considered as the main drilling fluid and
therefore for the simulation purposes water was used with default properties dedicated in
CFX-Setup:
Dynamic Viscosity= 8.89910-4 (kg/ms)
Density = 997.0 (kg/m3)
Molar mass = 18.02 (kg/kmol)
Specific heat capacity = 4181.7(J/kgK)
Thermal conductivity = 0.6069 (W/mK) Thermal
expansivity = 2.5710-4 (1/K).

Starting Turbo mode

a)

Basic Settings :

Specifying machine Type as an Axial Turbine

The analysis Type: Steady State:The time dependence of the flow characteristics can be
specified as either steady state or transient. Steady state simulations, by definition, are those
whose flow characteristics do not change with time and are assumed to have been reached
after a relatively long time interval.
They require no real time information to describe them. On the other hand, transient
simulations require real time information to determine the time intervals. Here, only the
simulation results for steady state conditions are reported in which stage interface and
general grid interface (GGI) models have been used to model the stator and rotor interface.
General Grid Interface (GGI) connections refer to the class of grid connections where the grid
on either side of the two connected surfaces does not match. The stage interface model
provides steady state solutions by circumferential averaging of the fluxes through bands on
the interface.

b)

Generating Components of the system analysis composed of the Stator and Rotor
Cells:

1) Specifying first component as the Stator with Stationary status.

2) Adding the second component as the rotor with Rotating Status.

Page 32

3) Selecting a value of rotational velocity as N = 1242 RPM (Same as Company Input

rotational speed).

c)

Physics Definition:

The equations relating to fluid flow can be closed (numerically) by the specification of
conditions on the external boundaries of a domain. It is the boundary conditions that produce
different solutions for a given geometry and set of physical models.
The boundary conditions specified should be sufficient to ensure a unique solution. For all of
the CFD simulations of this paper, it was achieved by specifying a total pressure and a mass
flow rate respectively at the stator inlet and rotor outlet of the stage.
The total pressure at the inlet is set to 2000 PSI.
The outlet mass flow rate for the stage is 31.41 KG/s. No-slip walls were specified for the
domain walls.
Heat Transfers not included in analysis. Turbulences selected as K-epsilon.
N.B: The inlet flow angle
on stator row is taken equal to zero by default. It can be
specified in CFX-Setup and its calculated using velocity triangles: (See manual calculations)

is the only unknown.

After performing the simulation, the constant rotors fluid outlet

angle is released.

is calculated and simulation will restart with a truth value of inlet flow angle.

d) Interface Definitions :
It represents connections applied between rotor and stator cells (See Fig 3.20 and 3.21)
Domain interfaces are always required when multiple assemblies are presented.

I.

Interface between Rotor and Stator by

selecting
Side 1 : Stator outflow
Side 2 : Rotor Inflow
Type of Interface : Stage

Fig 3.20. Rotor/ Stator axial interface

Page 33

II.

Rotational Interfaces in the ROTOR

Cell and Stator Cell to activate the
same radial connections between all
blade regions in one row by selecting :
Periodic radial interfaces for each row

Fig 3.21. Rotor radial interface

e) Inserting
1.
2.
3.
4.
5.

surfaces roughness by selecting a roughness of 24 micrometers for each of

Rotor Blade
Rotor Hub
Stator Blade
Stator Hub
Stator Shroud

A 24 Micrometers are applied in the Setupcell in form of Sand Grain

Roughness thats equal to =5.863Ra Where
(See fig 3.22)
Fig 3.22. View of surface roughness
So = 0.000140712 m
This value is selected for each of the boundaries presented.

3.3.4.2.CFX Solution
CFX Solution performs a number of iterations to obtain results.
It contains a number of iteration, with a global residual error between too consecutive
iterations.
The Solution activates its Ideal convergence when the global residual converge to zero.
Lower residuals mean a more accurate solution.
The magnitudes of the global residual decreases as the result get closer to the final solution.
In this study, in order to achieve the convergence of solution to an acceptable level, a number
of Iteration has been set to a value of 100 Iterations.

After Executing 100 Iterations, a converged solution has been noticed with minimum
residuals. (See Fig 3.23)

Page 34

Fig 3.23. The global residual error in function of iteration number

3.3.4.3. CFX-Results
After a converged solution, CFX results have the ability to visualise different parameters
including velocity, turbulence and pressure distribution of fluid across the entire stage.
These parameters can be viewed in the form of 2D, 3D and charts with a Turbine Report.

a) Plotting 3D presentations on blade Surfaces:

Page 35

Fig 3.24. Pressure distributions on Blade Surfaces

Fig 3.25.Turbulence distributions on Blade Surfaces

a) Potting 3D presentations concerning fluid Domain :

Fig 3.26. Fluid Pressure distributions

Page 36

Fig 3.27. Fluid Velocity distributions

Fig 3.28. Fluid Turbulence distributions

a)

Plotting 2D fluids velocity streams distribution on blades where fluid separations

are visualised at leading edges:

Page 37

Fig 3.29. 2D Velocity distributions

b)

Plotting Charts of different parameters in function of distance from stages inlet to

outlet:

Fig 3.30. Pressure distributions

Fig 3.31. Velocity distributions

Page 38

Fig 3.32. Tangential Velocity distributions

Fig

3.33.Axial Velocity distributions

N.B: In streamwise location included in the charts :
a) 0 to 1 indicates streamwise limits of the stator row.
b) 1 to 2 indicates streamwise limits of the rotor row.

c) Plotting the Turbine stage report :

Page 39

Fig 3.34. Stage Report

Generating ANSYS output values on one stage: (Fig 3.34)
a)
b)
c)
d)
e)
f)
/
(See Fig 3.30)
Flow inlet outlet angles for the stator and rotor blades are obtained from tangential and axial
velocity charts (See Figure 3.32 and 3.33):

Calculating the value of

Page 40

We can assume that the inlet fluid angle in the stator in CFX-Setup considered equal to zero
by default is truth and theres no need to restart the simulation.

Generating Torque and power values from manual calculations : a)

So

b)
Comparing ANSYS output values to the Company data and Manual calculation values:

Torque (N.m)
Power (W)
Pressure Drop (Pa)
Head Loss (m)
Hydraulic Efficiency

Company Input
Data
13.22
1721.3
71038
7.24
77.15

ANSYS output
Data
13.1663
1712.46
72880
7.02671
79.09

Manual Calculation
Data
13.4
1742.8
----

Table 3.3.Data Comparisons

We can assume that all compared values are highly close to each other.
Confidence is activated from ANSYS simulations and generated manual calculation.
Conclusion: Any further optimisations will be accurate and confidential.

3.3.5. Static Structural Analysis

Definition:
A static structural (SS) analysis has the ability to determine displacements, stresses and
strains distributions on blade surfaces in Stator and Rotor Rows caused by fluid pressure
loads through the stages, where Steady loading is assumed. It contains the finite element
analyses of the stresses that are performed based on the pressure distributions calculated from
the CFX modeling.
The structure analysis evaluates, plots and animates deformations, equivalent (Von-Misses)
stresses and Strain distributions resulted across the blades after importing the CFX simulation
results (pressure data on the blades surfaces) from CFX-Solution as main boundary

Page 41

conditions for the structural analysis. This process helps to control loads on blade areas and
locate maximum load effects on blade areas.
The Static Structural Cell is composed of: (See Fig 16)
1) Geometry: Imports rotor-Stator rows from BLADEGEN 2)
Model: Activates Rows meshing.
3) Setup: Specify recommended boundary conditions 4)
Solutions: Performing iterations.
5) Result: Plots deformation, Stress and strains variables.
The Study will be concentrated on one blade of rotor and one blade for stator where loads are
identical to all blades on the same row. And it has an advantage in decrease the simulation
time.

Performing Static Structural Analysis on the Stator Blade:

a) Importing stator row geometry from BLADEGEN to the geometry cell in static structural.
Both hub and shroud are designed and modeled as fixed support for analysis where Stator
Blades are connected to the hub and housing and there is no hub or shroud tip clearance
for them.(Fig 3.35)

Fig 3.35. Hub and Shroud as fixed support

b) Performing Meshes on rows areas. (See Fig 3.36)

Page 42

Fig 3.36. 3D mesh performed on stator row

c) Importing Pressure distribution data on stator blade from CFX-Solution. By activating a

link between Stator Bladegen cell and SS-Setup cell. (See fig 3.4). And defining blade
material as a Structural Steel.

Performing Static Structural Analysis on the Rotor Blade

The exact same methodology is used for simulating the structural loads on rotors blade
surfaces. But with ignoring the presence of Shroud structure in the Rotor row.
Where the Blades is connected only to the hub and there is shroud tip clearance for them.
Therefore, considering only the hub as fixed support for blade with no presence for shroud
support (See Fig 3.37).

Figure 3.37. Only Hub as fixed support

Results for stator and rotor Rows:

1. Plotting Deformation Results :

Page 43

2. Plotting Equivalent Elastic Strains :

3. Plotting Von-Mises Equivalent Strain distribution :

Fig 3.38. Deformation/Stress/Strain distributions on Blades

3.3.6. Erosion Rate

Definition:
Erosion is a natural process by which, a material is worn away from a surface by the effect of
solid particles presented in the fluid, like pure water.

Page 44

Erosion rate, E, is a function of the impact angle and velocity (Vp) of solid particles,
material combination, temperature and particle shape.

Introduction:
Surface erosion of materials by solid particle impact is considered as an issue in the domain
of turbomachinary.
Its advantageous to control erosion rates because this will lead to significantly controlling
the life services of the blades.
A new CFX-Erosion simulation is performed on the Rotor and Stators blade.
The Study is based on the emission of solid particles with water flow into the turbine.
Solid particles are taken as soot particles, usually presented in the actual turbines fluid.
ANSYS CFX was used to simulate the particle trajectories and consequent erosion through
hub, shroud and blades areas in one stage.
The erosion study is concentrated on simulating and calculating of the Erosion Rate Density
(ERD) in CFX.
Thiss an important parameter affecting the duration of duty of power section.

Methodology:
A link is activated between the TURBO-GRID cells of the Stator and rotor with a new cell of
CFX-Erosion. (See fig 3.4)
A steady-state non-buoyant incompressible flow of water is simulated using the Grant and
Tabakoff model responsible for predicting the local erosion rate E as a function of the
particle impact rate m, velocity Vp and the angle of attack with a k- turbulence model.
Erosion Model Tabakoff is chosen with its default parameters dedicated in CFX,
concerning the interactions between solid particles and Steel Surface of the blade. The
same turbo Mode is performed on the stage considering a total pressure at inlet: 2000 PSI
and a flow of 31.41 KG/s using water as a continuous fluid with a Roughness of 24
micrometer on blades areas.
The particle is defined as Soot of density 2000 Kg/m^3. Morphology of Soot particle is
selected as Particle Transport Solid responsible of activating erosions.
Particle tracking is performed using the standard transport model with turbulent dispersion,
and 300,000 of soot particles were released in equally spaced uniform distribution at the
stators inlet with zero-slip velocity.
The mass flow for Soot is considered about 0.5 % from the water flow rate (m= 31.41Kg/s)
Particle mass flow rate = 0.005 X m = 0.1570492Kg/s.

Page 45

Water and Soot particles coupling:

The fluid affects the particle behaviour through forces and momentums.
This effect is termed as coupling between phases. If the fluid is allowed to influence
trajectories but particles do not affect the fluid, then the interaction is termed one-way
coupling.
One-way coupling simply predicts the particle paths as a post-process based on the flow field
Its is an acceptable approximation in flows with low mass loadings where particles have a
negligible influence on the fluid flow.
Results:
After performing Erosion Simulation, results plot the soot Erosion rate Density distributions
across the domain. A maximum ERD value of
has been noticed at
trailing edges. (See Fig 3.39)

Figure 3.39. Erosion rate density distributions on blades areas.

Chapter 4.Blade Optimisations

4.1.Overview
In order to understand how the projects goals can be achieved, we need to know how to
control the following recommended actions:

a) Increasing total generated power at same total pressure drop and flow.
OR Decreasing total pressure drop at a same total generated power and flow.

Page 46

b) Decreasing Number of Stages in the Power Section.

c) Decreasing the Trust Load.

The concept begins by taking in count one stage study:

The original number of stages:
The head loss in one stage:
The power output from one stage:
N1.P1: Total power generated from turbine.
N1.H1: Total head loss in turbine.

Assuming: P2: The new power generated from one stage

n2: The new number of stages
H2: The new head loss in one stage
N2.P2: The new total power generated from turbine. N2.H2:
The new total head loss in turbine.

1) Increasing total power at same total pressure drop.

Having the same total pressure drop:

So

In order to increase the total output power:

(2)

Inserting equation (1) into (2):

So
Decreasing total pressure drop at a same total generated power:

Having same generated power:

So

In order to decrease the total pressure drop:

Inserting equation (1) into (2):

(2)

So
Conclusion: By increasing the hydraulic efficiency of one stage the first action is released.

Page 47

2) Decreasing Number of Stages in the Power Section:

Increasing the head loss (H2) or the generated power (P2) in one stage leads to decrease the
total stage number.
Consuming same total head loss:
Delivering same total power:

If H2 increases, n2 Decreases.
If P2 increases, n2 Decreases.

3) Decreasing the Thrust load

Power sections thrust load came from the pressure drop activated in the rotor rows.
The rotor is connected to the main shaft, while the stator is connected to the housing body of
turbo-drill. The pressure drop generated in the stator rows is absorbed by the housing, while
the pressure drop in the rotor rows is absorbed by axial bearings.
Pressure drop across a row causes the axial trust load:
F: The axial load in one stage.
A: The axial surface of region generated by rotor blades of a row:

Decreasing the axial forces is important It affects a decreased number of axial bearings
which has an advantage on the Turbo drill

4.2. Factors of Optimisations:

In order to release these goals, the main concentrations of optimisation In the blade profile will
be based on Controlling :
A) The hydraulic efficiency and pressure drop in one stage using manual calculations and
ANSYS simulations.
B) The stress, strain, deformations and erosion rate effects resulted on the new designed
stages blades.

A) Dealing with Hydraulic efficiency and pressure drop of one stage:

1) Pressure Drop :

Page 48

From the manual calculations, the final equations concerning the pressure drop in stator and
rotor are:

Controlling the difference between the inlet and outlet fluid angles across blades in each of
these rows (
, leads to control the pressure
drop across each of these too rows.
Ex: Increasing the geometrical trailing edge of the stator blades activates an increasing in
fluid angle that leads to increase the stators pressure drop.

2) Hydraulic Efficiency :
The main cause affecting the stages hydraulic efficiency is the fluid separation at leading
edges of the blades.
This process potentially reduces the velocity at blades inlet causing a drop in fluids kinetic
energy and generates frictions at this location.
This consequence leads to activate energy losses and reduce the stages efficiency.
Fluid separation is controlled by:
a) Decreasing inlet thickness of the blade.
b) Decreasing the error between inlet fluid angle and inlet constructive angle of a blade.
B) Dealing with load and erosion rate effectuations on new designed blade:

In order to control the Stresses, Strains, deformations, and erosion rate effects on blade
profile caused by fluids energy, an increasing in blade thickness is proposed.
Boosting thickness builds blades endurance and stability and increase the blade life time
against erosions. This process has to be coordinated with controlling hydraulic efficiency.

4.3. Blade regulation methods:

Regulations in Blades profile begin in BLADGEN Cells of the stator and rotor.
Modifications in Hydraulic Efficiency, pressure drop and Blade endurance highly depends on
the following too parameters:

1) Beta (Tangential) angle across Blades midline :

Page 49

Its defined as the angle between the tangential and axial segments at each point of the
midline curve of the blade. (See Figure 4.1)
This angle can be modified using a Chart. (See Figure 4.2)
This Parameter plays an important role in controlling inlet and outlet angle of the fluid
across the blade.

Fig 4.1. Beta Tangential Angle

Fig 4.2. Beta Tangential Chart

2) Blades Thickness:
Its defined as the distance between the Pressure and Suction Sides of the blade on a
perpendicular segment to a tangential segment of midline curve at each point. ( See Fig 4.3 )
This distance can be modified using a Chart. ( See Fig 4.4 )
This parameter plays an important role in controlling the hydraulic efficiency and Blades
rigidity.

Fig 4.3. Blade Thickness

Fig 4.4. Blade Thickness Chart

Beta (tangential) and Thickness Curves in Charts are regulated using: Bezier curve method.

Bezier curve definition:

Page 50

Bezier curves are a parametric curves composed of origin point (P0), end point (P3) and
interpolation points (P1, P2 ). (See Fig 4.5)
These curves are mainly used in interpolating and approximating curves.

Fig 4.5 Bezier curve

[P1; P0] and [P2; P3] segments remain tangential respectively to the first and end edges of
the curve.
Changing the positions of P1 and P2 leads to change the general behaviour of the curve.
This type of curve is widely used in determining and controlling the general curve shape in a
rapid and easy way.

4.4. Original Blade Side effects:

1. Factors affecting the stages hydraulic efficiency:
a) Thickness of the blades leading edge in the stator and rotor is elevated.
b) Angle of attack between the fluid and the leading edge of blade do not match.
c) Fluids axial velocity

value is elevated and causing hydraulic losses.

2. The factor affecting a limited pressure drop:

Low fluid outlet angles in the Stator and rotor blades caused by limited constructive
outlet blade angles.

4.5. First Optimisation:

4.5.1.Blade regulations
Is based on improving the previous factors to retrieve the first goal.
Symmetric blades is constructed

Page 51

The content of the first optimisation includes the stator blades. The rotor row is constructed
by symmetry.
1.
a) Using Thickness Chart to Decrease the inlet thickness of the leading edge:
(Fig 4.6 ,4.7)

Fig 4.6. Original Blade Thickness Chart

-

Fig 4.7. New Blade Thickness Chart

P1 is decreased 0.277 mm
P2 is moved to the right 9.1 % and decreased 0.667 mm

b) Using Beta (Tangential) angle Chart to :

Decrease the inlet angle of the leading edge in order to have a lower error between the
entrance fluid angle and the inlet constructive angle of blade. (See Fig 4.8,4.9)

Providing a low of Derivative value of Beta (Tangential) angle at Blades inlet to reduce
fluid deviations at inlet. (See Fig 4.8,4.9)

Page 52

Fig 4.8. Original Blade Tangential Angle

Fig 4.9. New Blade Tangential Angle

P1 is decreased 25 degrees
P2 is moved 25.6 % to the right and decreased 23.9 Degrees P3 is moved 25% to the right and decreased 17.5 Degrees

c) Decreasing the hub radius to boost the axial area (A) in order to reduce the axial
velocity
in the stage. Where
Original
New

(See Fig 1)

% . This process reduces hydraulic losses

2. Using Beta (Tangential) angle Chart to :

Provide a decreased tangential angle value at trailing edges of blades to increase the outlet
fluid angle.
In order to boost Pressure drop value in the row. (See Fig 4.10,4.11)

Activate a low Derivative angle value at Blades outlet to have a more accurate value of
the fluid angle exiting the blade. (See Fig 4.10,4.11)

Page 53

Fig 4.10. Original Blade Tangential Angle

-

Fig 4.11. New Blade Tangential Angle

P4 is deleted.
P5 is decreased 0.479 Degrees.

These too steps will lead to slightly increase the outlet thickness the blade to provide more
stability and endurance. (See Fig 4.12 and 4.13)

Fig 4.12. Original Blade outlet Thickness

-

Fig 4.13. New Blade outlet Thickness

P3 is increased 0.577 mm and moved 1.9% to the left.

P4 is increased 0.064 mm.

Comparison between 2D profiles of the original blades and new designed blades
(Fig4.13and4.14)

Page 54

Fig 4.13. 2D shape of original Blades

Fig 4.14. 2D shape of new Blades

4.5.2.Beginning of simulation:
Performing the first simulation of the new designed stage at a random rotating speed to
determine the outlet fluid angle in the stator blades and rotor blades. (
In
order to release the fluid entrance angle
) and the recommended optimal number of
speed.

Activating a new simulation with a rotating speed (1280 RPM) and inlet flow angle of zero
degree

Investigating Results:
The Fluid Attacks the blades at an optimized entrance with reduced separations, enters the
blade profiles with minimum deviations, activates a changing in direction at the middle of the
blade and exits the profile at a constant increased angle. (See Fig 4.15)

Page 55

Fig 4.15. fluid Velocity stream distribution

i.

CFX-Results:

Fig 4.16. CFX Report

After Comparing these results with Company results for a same total pressure drop
consumption:

1) New Number of stages :

2) Decreased number of stages = 3.2 %
3) Increased Total Power output = 3.8 %

Page 56

4) Increased hydraulic efficiency = 2.8 %

ii.

Erosion Results:

A maximum ERD value of

has been noticed at blade trailing
edges. This value is decreased by 45 % comparing with original blades. At the
result of decreasing Axial velocity .

Fig 4.17. Soot Erosion Rate Density distributions

iii.

Static Structural :

Fluid Loads effects are approximately the same comparing with loads on original blades as a
result of decreased fluid separations at leading edges and increased thickness at trailing
edges: (Fig 3.38 and 4.18)

Page 57

Fig 4.18. Stress/Strain/Deformation distributions across new designed blades

4.6. Second Optimisation

The second optimisation is concentrated reducing furthermore the number of stages from the
first optimisation, by increasing the pressure drop through the stator and rotor.
It will use the new designed blades from the first optimisation, perform regulations on there
shapes and produce a symmetric Stator-Rotor Rows.
Regulation begins in stator blades and by symmetric action, rotor row is constructed.

Page 58

4.6.1. Blade Regulations

Methodology:
1) Increasing pressure drop in the stator row by boosting the outlet blades constructive angle.
2) Increasing the overall blade thickness to provide more stability at a higher pressure drop.

1) Using Beta (Tangential) angle Chart:

Decreasing the tangential angle value at trailing edges of the blade (P4 point in chart) by
1.57 Degrees.
2) Using Thickness Chart:
Increasing all blade thickness by 0.25 mm
Comparison between 2D profile of the previous blades and new designed blades:
( Fig 4.19 and 4.20 )

Fig 4.19. Previous 2D Profile Shape

4.6.2.Beginning the simulation:

Fig 4.20. New 2D Profile Shape

Performing a first simulation of the new designed stage at a random rotating speed to
determine the outlet fluid angle in the stator blades and rotor blades (
) In
order to release the Optimal number of speed and the fluid entrance angle
).

Page 59

is higher than the normal range of rotational speed. Choosing

is more confortable to the bit.

Activating a new simulation with rotating speed of 1280 RPM and inlet flow angle of 7.18
degrees

Investigating Results:
1. CFX-Results:

Fig 4.21. CFX Report

After Comparing these results with Company output data for a same total delivered power,
we obtained:
a)
b)
c)
d)

New Number of stages :

Decreased number of stages = 20 %
Decreased Total Pressure Drop = 1.7 %
Increased hydraulic efficiency = 1.3 %

Page 60

Fig 4.22. Fluid velocity stream across the new Stage.

2. Erosion Results:
A maximum ERD value of
has been noticed at blade trailing
edges.This value is increased by a rapport of 1.1 comparing with original blades.

Fig 4.23.Soot Erosion Rate Density distributions

3. Static structural results:
Fluid Loads effects are approximately the same comparing with loads on original blades as a
result of decreased fluid separations at leading edges and increased thickness of trailing
edges: (Fig 3.38 and 4.24)

Page 61

Fig 4.24. Stress/Strain/Deformation distributions across new designed blades

4.7. Third Optimisation

The third optimisation is concentrated reducing the thrust load at the same total pressure drop
Second optimisation is taken as an input where the designed stator blade handles a higher
pressure drop.
Reducing trust load highly depends on the rotor pressure drop.

Page 62

This optimisation will focus on decreasing rotors pressure drop to have the same stages
pressure drop of the Original stage used by Company.

4.7.1.Blade Regulations
Methodology:

Decreasing pressure drop in the rotor row by reducing the outlet blades constructive angle.
Using Beta (Tangential) angle Chart:
Decreasing the tangential angle value at trailing edges in rotor blade (P4 point in chart) by
6.57 Degrees. (See fig 4.25 and 4.26)

Fig 4.25. Tangential angle second optimisation

Fig 4.26. Tangential angle of new blade Comparison
between the 2D profiles of the previous and new rotor blades: (Fig 4.27 and 4.28)

Page 63

Fig 4.27. 2D shape of previous blades

Fig 4.28. 2D shape of the new blades

4.7.2.Beginning the simulation:

Performing a first simulation of new designed stage at a random rotating speed to determine
the outlet fluid angle in the stator blades and rotor blades.
To release the Optimal number of speed and the fluid entrance angle (1).

Activating a new simulation with rotating speed of 1215 RPM and inlet flow angle of 8.53
degrees

Investigating Results:
a) CFX-Results:

Fig 4.29. CFX Report

Page 64

After Comparing these results with Company output data for a same total delivered power,
we obtained:

Decreased thrust load = 20.6 %

New Number of stages :
Same Total Power output.

b) Erosion Results:
A maximum ERD value of
has been noticed at blade trailing
edges. This value is increased by 22% comparing with original blades.

Fig 4.30. Soot Erosion Rate Density distributions

c) Static structural results:
Fluid Loads effects are approximately the same comparing with loads on original blades as a
result of decreased fluid separations at leading edges and increased thickness of trailing
edges: (Fig 3.38 and 4.31)

Page 65

Fig 4.31. Stress/Strain/Deformation distributions across new designed blade

4.8. Fourth Optimisation:

Designing blade profile that can handle high flow:
Original flow rate
New flow rate

Performing high flow simulation through the original blades:

Searching recommended

and inlet flow angle for simulation:

1) All fluid angles across the stage at the different flow do not change with flow variation
So the stages inlet fluid angle remains equal to zero.
2) Searching new

Flow rate is increased by 16% So

Page 66

Simulation Results :
a) CFX-Results:

4.32. CFX- report

a) Erosion Results:

Page 67

4.33.Erosion Rate density

Investigating High Erosion rates:

Increased erosion values presents at blades trailing edges
Maximum value of
.
By comparing with the original blades working low flow (See fig3.39), the erosion rate
density is 60% higher.
Using the original blades do not present real advantages in high flows.
Designing new blade profiles is recommended.

High erosion causations:

Increased value of the erosion rate density at trailing edges is caused by high velocity and
fluid impact angle at blade outlets.
Where High velocity values are caused by increased flow rate
between too consecutive blades

Beginning optimisation:
The optimisation produces symmetric blades.
Beginning by regulating stator blades, then rotor blades are constructed by symmetric action.
Methodology:
1) Decreasing the High Erosion rate at trailing edges:
a) Reduce velocity can be solved by decreasing throat area upon decreasing
decreasing the outlet constructive angle of blades

and

b) Reduce Impact angles can be reduced by decreasing the outlet constructive blades angle
2) Increasing blade thickness to provide more stability on high flow. Because
high flow produces more pressure drop across the stage.

The study uses the designed blades from first optimisation as an input
BLADEGEN:
1) Increasing Beta (Tangential) value at the end point of curve by 5.5 Degrees.
2) Increasing thickness by

Comparison between 2D profile of the previous blades and new designed blades

Page 68

(Fig 68 and 69)

Fig 4.34 . Previous 2D Profile Shape

Fig 4.35 . New 2D Profile Shape

Beginning the simulation:

Performing a first simulation of the new designed stage at a random rotating speed to
determine the outlet fluid angle in the stator blades and rotor blades (
) In
order to release the Optimal number of speed and the fluid entrance angle
).

Activating a new simulation with rotating speed of 1212 RPM and inlet flow angle of 0
degrees

Simulation Results:
1) CFX-Results:

Page 69

4.36 .CFX Result

2) Erosion result :

4.37.Erosion Result

Investigating results :
The higher EDR value is
Its decreased by 68% comparing with original blades working on the same high flow
Using the new designed blades is more comfortable.

Page 70

Page 71

Table 6 : Comparing Results of Optimisation

Chapter 5: Adjustable Double Bent

5.1. General view
The oil and gas industry increasingly relies on directional drilling to develop petroleum
reserves in environmentally sensitive areas or in restricted surface areas, using multilateral,
horizontal, and extended reach wells. Today, two different methods are used for directionally
drilling a well: rotary steering and drilling with a downhole motor system.
The motor system is designed with a downhole motor and a bent housing. The motor rotates
the entire drillstring to drill a tangent section, and turns only the bit to produce a curve or
bend.There are a number of variants types of bent housing subs, such as fixed-angle types and
adjustable types, and most steerable system runs are with bent-housing motors (one or two
bends) and stabilization on the motor.
To build angle with this steerable system, the driller orients the tool face toward the high side
of the hole. Weight is applied to the bit without
rotation of the drillstring. The drillstring slides along
the low side of the hole, allowing the bottomhole
assembly to build angle. To drop angle, the driller
follows the same procedure, except that he orients the
tool face toward the low side of the hole. Therefore,
rate of build is achieved in the sliding mode, while in
the rotary mode, the achieved angle is maintained.

Drilling with steerable motors is an essential method

for building angle and controlling well trajectory,
capabilities necessary to the industry. To accomplish
steerable drilling, engineers need to calculate the
deflection rate of an existing steerable motor and need
to design or select a steerable motor assembly on the
basis of the expected deflection rate.
Single bent assembly Steerable motor drilling has
steadily improved over the past years. The industry
now better understands of rig and pump requirements
for successful application of these tools. Today, the
service industry offers various steerable motors, which
are classified for different bit types and rig
capabilities. Steerable motor systems can drill a well
and control the well trajectory without tripping.
Because of short length, high rigidity, and low weight
on bit (WOB), the shape of a bent-housing motor

Page 72

basically determines its deflection rate. A benthousing motor will tend toward its original
rigid shape when it reaches stable mechanical equilibrium. Consequently, it is reasonable to
calculate the deflection rate of a bent-housing motor
based on its geometrical shape

Fig 5.1. Single Bent Housing

5.2.Double-bent assembly
With high deflection rates and steady performance, double-bent housing
motors have been widely used to drill highly deviated and horizontal wells. Compared
with single-bent motors, they have smaller bent angles and bit offsets to minimize over
gauged borehole sections, and run more easily through casing with the same deflection rates.

Assembly design
The selection and design of a bottomhole assembly according to a given deflection rate is a
prerequisite during the planning process and drilling. Even though there are many factors
influencing wellbore curvature, including borehole geometry, formation conditions, operating
conditions, and a number of equipment variables, the bottomhole assembly is a primary and
controllable factor.
The presented formulas, assuming that a bent-housing motor is relatively rigid and directs the
bit along a circular arc trajectory that continually minimizes the side force at the bit with its
side-cutting capability, directly describe and emphasize the contribution of major tools'
structural factors to deflection rate. Accordingly, using these formulas is an effective way to
select and design a bottomhole assembly.

Page 73

Research shows that there are five tool structural parameters for a single-bent assembly and
seven structural parameters for a double-bent assembly that affect the deflection rate, which
relate to stabilizer placement and size, bent-angle value, and location. An engineer can
calculate any one of them to satisfy the given deflection rate. Bent angle, classified in
intervals of 0.25, has only a few optional values available. Through enumerating all values,
one can find the best one for a single-bent assembly or the best bent-angle combination for a
double-bent assembly to satisfy the expected deflection rate. The calculation process of
enumerative technique is similar to these examples.
Because deflection rate is a linear function of bottom
stabilizerborehole wall clearance, it is easy to calculate
the value of the clearance. Moreover, because a stabilizer is
a standard component, thus one can use enumerative
techniques to determine stabilizer gauge.

Adjustable bent description:

-Referring to FIG. 5.4, a planar view of the first housing 2
of the most preferred embodiment will now be described.
The first housing 2 has a first outer cylindrical surface 4
that extends to surface 6, and wherein the surface 6 has a
generally helical profile 8. The first outer cylindrical
surface 4 will have an inner portion (not shown in this
view), and wherein the dashed line 10 depicts the center
axis of the portion formed from cylindrical surface 4. Extending from the surface 6 will be the threaded opening
25 seen generally at 12, sometimes referred to as the pin
connection 12. The threaded opening 12 includes the outer
cylindrical surface 14 that extends to the outer spline
members seen generally at 16 which in turn extends to the indentation 18. The splines are
teeth-like projections extending from the pin connection 12. As seen in FIG. 5.4, the
indentation 18 stretches to the external threads 19, and wherein the threaded opening
surface 12 has external threads 19.
Fig 5.4.planar view
The external threads 19 terminate at the outer cylindrical surface 20. The center axis of the
threaded opening 12 is represented by the dashed line 22. As per the teachings of the present
invention, the center axis 22 is offset from the center axis 10, as shown in FIG. 1 by the
numeral 99.

Referring now to FIG. 5.5, a planar view of the preferred embodiment of the collar 26 will
now be described. The collar 26 includes an outer cylindrical surface 28 that extends to the
first radial end 30. It should be noted that like numbers appearing in the various figures refer
to like components. The collar 26 has a center of axis 31. The collar 26 also contains the
collar helical end profile, seen generally at 32, and wherein the collar helical end profile 32 is
reciprocal to and configured to engage the helical profile 8 (helical profile 8, seen in FIG. 1).
The helical profile 8 may also be referred to as a cam surface 8, and the collar helical end
profile 32 may be referred to as a ramp 32.

Page 74

Fig 5.5

FIG. 5.6 is a top view of the collar 26 seen in FIG. 5.5. The collar helical end profile 32 is
shown, along with the outer cylindrical surface 28. The collar 26 contains the inner diameter
surface 34, and wherein the inner diameter surface 34 contains the splines 36 (sometimes
referred to as the female 55 set of splines 36). The splines 36 will engage with the splines 16
in order to lock the collar 26 in position relative to the first housing 2 as will be more fully
explained later in the description.

FIG. 5.6

Page 75

Referring to FIG. 5.8, a cross-sectional view of the preferred embodiment of the second
housing 42 will now be described. The
second housing 42 is generally cylindrical
in shape. The second housing 42 has a
first outer surface 44 that extends to the
second, smaller outer diameter surface 46
which terminates at the radial end 48.
Extending radially inward is the inner
diameter portion 50. The inner diameter 5
portion 50 has a center of axis denoted by
the dashed line 52, which is also the center
of axis for the cylindrical outer surfaces
44, 46.
FIG. 5.8 also illustrates the threaded
opening, seen generally at 54 (sometimes
referred to as the box connection 54), and
wherein the threaded opening 54 is
configured to engage the threaded opening
12. As shown in FIG. 5.8, the threaded
opening 54 is tilted (i.e. inclined) relative
to the outer surfaces 44.

The threaded opening 54 contains internal

threads 55. As illustrated in FIG. 5.8, the
threaded opening 54 has a center of 15 axis
denoted by the dashed line 56 (sometimes
referred to as the titled box angle), and
wherein the center of axis 56 is offset
from the center of axis 52 by the angle
denoted 58, which in the most preferred
embodiment is between 1.5 and 2.0
degrees. The box connection 54 extends to
the indentation 60 which in turn extends to
the inner surface 62. The inner surface 62 then extends to the eccentric inner surface 64, and
wherein the eccentric inner surface 64 allows for the junction of the inner diameter portion 50
and the inner surface 62. The second housing 42 contains the radial end 66.
Fig 5.8 : cross-sectional view
FIG. 5.9 is a planar view of the assembled apparatus 68 (sometimes referred to as the
adjustable bent sub 68) of the preferred embodiment at a zero degree angle of inclination
orientation. As shown, the shoulder 40 of the collar 26 abuts the shoulder 69 of the first
housing 2. Also, the radial end 30 of the collar 26 abuts the radial end 66 of the second
housing 42. As shown, the center of axis 10 of the housing 2 and the center of axis 52 of the
housing 42 are aligned, and therefore, at zero orientation.
FIG. 5.10 is a cross-section view of the assembled apparatus 68 taken along line I-I from FIG.
5.9. FIG. 5.10. depicts the engagement of the collar helical end profile 32 with the helical
profile 8 as well as the radial end 30 abutting the radial end 66. The first housing 2 is
threadedly connected to the second housing 42. As oriented in FIGS. 5.9 and 5.10, the axis of
the assembled apparatus 68 would be aligned with the drill bit axis.

Page 76

Fig 5.9.

Fig 5.10.

FIG. 5.11. is a planar view of the assembled apparatus 68 of the preferred embodiment at a
180 degree angle of inclination orientation. In this embodiment, the first housing 2 and the
second housing 42 have been separated, and the collar 26 has been repositioned by removing
from the spline means, rota- tionally repositioning the spline means, and then threadedly
connecting the first housing 2 and the second housing 42. Hence, the shoulder 40 of collar 26
has been rotationally separated from the shoulder 69 of first housing 2, as seen in FIG. 5.11.
FIG. 5.12. is a cross-section view of the assembled apparatus 68 taken along line II-II of FIG.
5.11. FIG. 5.12. depicts the center axis 10 of the first housing 2 as well as the center of axis
52 of the second housing 42. The numeral 98 depicts the angle of inclination which is 2 to 4
degrees.

The numeral angle 98 would be the sum of the tilted box angle 58 and the first housing angle
99 (angle between item 10 and item 22 seen in FIG. 5.4) with 180 degree angle of inclination
rotation.As oriented in FIGS. 5.11 and 5.12, the center of axis 52 would be offset from the
drill bit axis. Put another way, the assembled apparatus 68 represents an adjustable bent sub

Page 77

of a downhole motor assembly in the tilted mode due to the 2 to 4 65 degree angle of
inclination, or more preferably a 3 to 4 degree angle of inclination.

Fig 5.11.

Fig 5.12.

Referring now to FIG. 5.13, a planar view of the first housing 2 and the collar 26 at zero (0)
degree angle of inclination orientation will now be described. This view is the view of FIGS.
5.10. and 5.11, except the second housing 42 has been removed. Note that the line 70
represents the level of the radial end 30 and line 85 represents the level of helical collar end
32 adjacent shoulder 40. In FIG. 5.14, which is planar view of the first housing 2 and collar
26 at a one hundred and eighty (180) degree angle of inclination orientation, the collar 26 has
10 been rotationally displaced by lifting the collar 26 from the splines and repositioning the
collar 26 onto the splines (i.e. the collar 26 has been rotated relative to the first housing 2).
Hence, the collar 26 was disengaged from the spline means, rotated, and the spline means
were then re-engaged to the position seen in FIG. 5.14. The line 72 represents the level of the
radial end 30 relative to the previous level 70 after this rotational displacement. The line 86
represents the level of the helical collar end 32 adjacent shoulder 40. Moreover, the delta H
represents the amount of lateral movement of radial end 30 after the rotational displacement
and the delta H2 represents the amount of lateral movement of helical shoulder end 32
adjacent shoulder 40 afterthe rotational displacement.

Page 78

Fig 5.13.

Fig 5.14.

Page 79

Projects conclusions:

A)
1) Original Blades Study:
Full confidence of any Blade optimisation, where results form manual calculations, ANSYS
simulation and Company data Input values for the original blades was identical

2) First Optimisation:
Providing a power section working with 96.8% of stage number and offering an Increased
power of 3.8% , when working under a same pressure drop and flow rate with an increased
hydraulic efficiency of 2.8 %.

3) Second Optimisation:
Providing a power section working with 80% of stage number and offering the same power
at a same flow rate under a decreased pressure drop of 1.7% with an increased hydraulic
efficiency of 1.3%

4) Third Optimisation:
Providing a power section with 20% lower axial thrust when generating same power under a
same pressure drop and flow rate

5) Fourth Optimisation:
Providing a power section that can handle high flow rate

B)
Successfully Designing a Double bent system for Directing Drilling

Page 80