RCD3: ROTATING CONTROL DEVICE TESTING SYSTEM
TEAM MEMBERS (from left)
Blake Lawson Grant Guzman Jesse St. Clair Matthew Rangitsch
OU MENTORS Jackson Autrey Farrokh Mistree COMPANY MENTOR Matt Green
Global Re-Engineering Collaboration
PROBLEM
● Collaborate with a team of engineers in Houston, Bangalore, China, and El Reno ○ On-site resources in El Reno, OK used to make design determinations ● Coordinate with multiple RCD teams to deliver a desirable end product ○ Bearing and seal specifications received from RCD2 ○ RCD Bowl and Bearing Assembly CAD models received from RCD1 ● Contact vendors for quotes and specifications for required components
METHOD
Solution Process RCD Performance Analysis
RCD Design Analysis
Test Rig Design
● Background RCD Research ● API 2016 Standards ● Key Variables
● RCD Testing Procedure ● Component Requirements List ● OSHA/NIOSH Safety Standards
● Selection of Components ● Functional Redesign ● Operational Safety Standards
RCD Performance Analysis
● Research specifications for similar RCDs ● Testing Standards from American Petroleum Institute ● Variables defined: Pressure, Temperature, Rotational Speed
Results - CAD Model Assembly
OUTCOMES
● Background RCD Research ● API 2016 Standards ● Key Variables
● CAD Models and Drawings of RCD Testing System parts created ○ Designed based on RCD Bowl and Bearing Assembly models received from RCD1 and Weir EnSci
● Parts assembled in SolidWorks to ensure safety, precise dimensional tolerance, ease of assembly, and operational effectiveness ● FEA completed on relevant structural components KEY REFERENCES 1. pruitt.com - PRCD500 Series Spec Sheet. Available online. Accessed 2/12/2017.
Problem Description and Deliverables Pressure Testing System
PROBLEM DESCRIPTION
Rig Air
Weir requires a safe and effective way of checking Rotating Control Device (RCD) performance before units are sent into the field. RCD3 is required to first determine what variables are of interest for measuring RCD performance and second to design an in-shop Testing System capable of running the RCD through a field-simulated experience. Should time allow, RCD3 is then tasked with developing a system of sensors and data acquisition tools to allow operators to measure and log performance of the RCD during testing.
Results - Bill of Materials ● Bill of Materials generated
On/Off Valve
Hydraulic Cylinders (4)
Water Pump
Bearing Lubrication System A/C Motor
Lubricating Oil Reservoir
Fluid Pump (Flowback Line)
Table Pres Gauge
Open/Close Valve
Open/Close Valve
RCD Flange
● Develop Testing Procedure for analysis of RCDs ● Determine required components ● Determine relevant safety standards
Flow Diverter
Air Regulator/ Pressure Gauge
Open Reservoir
Design of RCD Testing System Bill of Materials for components in design Sample of safe operating procedures for testing system Recommendations for sensor implementation
RCD Design Analysis
Filters (2) Hydraulic System
Pump
● RCD Testing Procedure ● Component Requirements List ● OSHA/NIOSH Safety Standards
Hydraulic Power Unit
Pres. Transducer
DELIVERABLES ● ● ● ●
Motor Lifting System
Test Rig Design
Ballistic Wall Manifold
RCD Outlet
Ballistic Wall Manifold
Aux Outlet Pres. Hose Transducer
RCD Bearing
● Selection of Components ● Functional Redesign ● Operational Safety Standards
● Select and design individual components per Requirements List ● Iterate component design for safety and functionality ● Determine safe operation procedures
Next Steps and Learning Statement ● Intelligent System and IoT Features
○ Contains relevant part numbers and manufacturers ○ Cost: Per Item, Overall ○ Contains drawings for 15 designed parts and assemblies
○ Will require upgrades to sensors, adaptations for possible modular capabilities
● Data Acquisition System ○ Implemented sensors must feed into on-site Weir data acquisition system
Estimated Cost: $19,991.69
● By collaborating with the other RCD teams and groups from Weir, we learned the importance of detailed communication regarding project progress and goals, which is valuable in helping us ensure that our design criteria matches the desired results of a given project.
The members of RCD3 would like to thank the following: Matt Green, Varun Inamdar, Dave Mathena Members of RCD1 and RCD2 Jackson Autrey and Farrokh Mistree 2017 AEROSPACE AND MECHANICAL ENGINEERING CAPSTONE POSTER FAIR