2017
ME CAPSTONE PROJECTS
ME Capstone Projects 2017 Categories CATEGORY: PROTOTYPE DESIGN P1 Design of device to detect and correct the orientation of the bags as it enters the case packer
1
Student Team: Jose Velazquez, Daniel Goree, Ciore Taylor, Andrew Savvides, Senzosenkosi Khumalo Sponsor: Kimberly Clark Corporation Advisor: Dr. Dalton
P2
Method/means to track web on centerline in real time
2
Student Team: Joshua Blaine, Drew Walther, Patrick Ahearn, Caleb Monigold, Ann Marie Berryhill Sponsor: Kimberly Clark Corporation Advisor: Dr. Dalton
P3
The development of an iHub robotic tourguide
3
Student Team: Eric Gaskell, John Collette, Hunter Bonham, Nathan Smith, Nour El Yakine Bel Bekri Sponsor: iHUB Advisor: Dr. Stalford
P4
MEMS
4
Student Team: Michael Kruta, Ryan Davis, Wiens Joshua Sponsor: Dr. Stalford Advisor: Dr. Stalford
CATEGORY: STUDIES S1 ESP power cable design with a light weight, cost effective, robust, HS&E friendly alternative
5
Student Team: Anson Kunjappy, Neil Watson, Joel Jimenez Cortez, Garrett Miller, Brinkley Richard Sponsor: Baker Hughes Advisor: Dr. Liu
S2
Bearing Machine Upgrade to Include Sensing Elements and Capability to Evaluate Thrust Bearing
6
Student Team: Brandon Tolbert, Jacob Bertelli, Vanecek Russell, Blaise Newman, James Roecker Sponsor: Baker Hughes Advisor: Dr. Stalford
S3
Determining the effect of various slot geometry on burst and collapse of a tubular product
7
Student Team: Ethan Bean, Garrett Gore, Mario Perez, John Haley Sponsor: Baker Hughes Advisor: Dr. Hekiri
S4
Determine the effects of tie back seal assemblies to improve collapse resistance for liner hanger extension analyzing parameter variations Student Team: Gonzalez Jonathan, Keaton Whitaker, Jason Lenamond, Trenton Turner, Andreas Slettehaugh Sponsor: Baker Hughes Advisor: Dr. Hekiri
8
2017
ME CAPSTONE PROJECTS
S5
Polycarbonate Repair Procedure for Aircraft Crew Compartment
9
Student Team: Aaron Sinkler, Joshua Tims, Mason Arnold, Steven Moua Sponsor: GCoE/OC-ALC Advisor: Dr. Liu
S6
Airflow Dynamics Optimization for Aircraft Corrosion Control Coatings Application
10
Student Team: Christopher Biehler, Hamid Ouabdenbi, James Irwin, John McGinty Sponsor: GCoE/OC-ALC Advisor: Dr. Hekiri
S7
RCD Re-Engineering Drawing Package
11
Student Team: Zachary Pivarnik, Fnu Nkegoah Asaba Nguafor, Elisha Moncrief, Okechukwu Atukpawu Sponsor: Weir Pressure Control Advisor: Dr. Mistree
S8
RCD Re-Engineering Design and Performance Specification
12
Student Team: Jacob Mcauliff, Mark Haley, Robinett Nickolas, Matthew Garde Sponsor: Weir Pressure Control Advisor: Dr. Mistree
S9
RCD Re-Engineering: RCD-IS and Test Design
13
Student Team: Matthew Rangitsch, Jesse St Clair, Lawson Blake, Grant Guzman Sponsor: Weir Pressure Control Advisor: Dr. Mistree
S10
Rod Rotator Intelligent System Project (PRR-ISC)
14
Student Team: Jacquelyn Ogle, Thomas O'Connor, Bui Kenni, Carter David Sponsor: Weir Pressure Control Advisor: Dr. Mistree
S11
Conceptual design alternatives to the current compression tube design
15
Student Team: Cole Lindley, Robert Dooman, Scott Dominic, William Nelson Sponsor: GE OIL & GAS Advisor: Dr. Hekiri
S12
Gearboxes with Fixed Form Factors and Architectures for a Wide Range of Torques
16
Student Team: Ryan Melton, Kyle Smith, Brandon Boggs, Mark Means Sponsor: Dr. Allen Advisor: Dr. Mistree
S13
Bearing Factor Engineering Design Guideline
17
Student Team: Andrew Gilland, Garrett Boyd, Jacquelyn Bradshaw, Celeste Clary, Adam Fitzpatrick Sponsor: Baker Hughes Advisor: Dr. Liu
S14
Surfboard Student Team: Beau Bellamy, Brandon Groh, Andres Perilla, Cameron Fielden Sponsor: Dr. Stalford Advisor: Dr. Stalford
18
2017
ME CAPSTONE PROJECTS
CATEGORY: TESTING T1 Design of an experimental setup to evaluate metal barrier rings
19
Student Team: Lueke Matthew, Din Kaamil, Khalil Yasser, Pappoe Felix Sponsor: Schlumberger Advisor: Dr. Siddique
T2
Rotary Electro-Mechanical System
20
Student Team: Hassan AlDarwish, Saeed Alzaki, Kevin Song, Calhoun John, Mansur Brandon Sponsor: Schlumberger Advisor: Dr. Siddique
T3
Design an experimental setup to measure the He permeability of given grease/Oil/custom formulations
21
Student Team: Devin Odonnell, Jason Elkin, Matthew Butzer, Mbouombouo Salomon, Vuochlin Veung Sponsor: Schlumberger Advisor: Dr. Siddique
T4
Design of a modular experimental setup to measure the He permeability
22
Student Team: Robert Chancellor, Garrett Clark, Jason He, Derian Hughes, Phillip Nguyen, Salah Uweiti Sponsor: Schlumberger Advisor: Dr. Siddique
T5
Design of experiments & Simulations to capture friction effects with polymer rings
23
Student Team: Jeffrey Brown, Mohammed Al Hamdan, Bradley Thompson, Travis Treese, Brianna Mcguire Sponsor: Schlumberger Advisor: Dr. Siddique
T6
Increasing the Performance of Li-Ion Batteries by Employing Transition Metal-Oxide Films Prepared in Flames
24
Student Team: Miles Burnett, Kirsten Perry, Edvin Coyoy Lopez, Bohan Yu, Mejia Octavio Sponsor: Dr. Merchan-Merchan Advisor: Dr. Siddique
T7
An experimental test rig for precise characterization of the hydrodynamic and thermal behavior of PCM slurry flows
25
Student Team: Aaron Arambula, Blaine Cate, James Walker, Trevor Wilkinson Sponsor: Dr. Shabgard Advisor: Dr. Siddique
T8
Design and build a testing assembly to determine shrinkage or expansion 26 of the slurry product as it dries and cures in lab and field conditions Student Team: Halle Smith, Alec Swain, Quinten Zoch, Karnes Carl, Joseph Peshehonoff Sponsor: ACG Materials Advisor: Dr. Liu
2017
ME CAPSTONE PROJECTS
CATEGORY: INTERDISCIPLINARY I1 Control Humidity in multiple Facilities; B3902, B2210, B3907 Student Team: Nghia Pham, Khalid Jawabreh Sponsor: GCoE/OC-ALC
I2
I3
I5
29 Advisor: Dr. Stalford
Stator build process lean-out Student Team: Juliana Shindler, Grant Brann Sponsor: GE OIL & GAS
28
Advisor: Dr. Hekiri
Radial dimensional stack-up analysis ESP Student Team: Brett Widmer, Johnathan McClary Sponsor: GE OIL & GAS
I4
Advisor: Dr. Dalton
Paint Booth/Hangar Pressure Drop Electronic Monitoring Student Team: Andrew Nantze, Ian Wright Sponsor: GCoE/OC-ALC
27
30 Advisor: Dr. Stalford
Process documentation and lean-out
31
Student Team: Hiep Chuong, Kaleo Cook, Margaret Chesnut Sponsor: GE OIL & GAS Advisor: Dr. Siddique
I6
Improved design and functioning prototype of a “dead-man” brake mechanism Student Team: Benjamin Edwards, Lindsey Cox Sponsor: HDS 1 (ID 3)
I7
32
Advisor: Dr. Liu
BHI-coop
33
Student Team: Dallas Milligan, Pamela Duarte Cardona, Christopher Sanders Sponsor: BHI/AME Advisor: Dr. Mistree
I8
Aerospace
34
Student Team: Hunter Herzfeld, Dane Schoelen, Samuel Ayeni, Chad Draper Sponsor: AE Advisor: Dr. Siddique
CATEGORY: VEHICLE DESIGN V1 Sooner Racing Team
35
Student Team: Samuel Faux, Zachary Maxwell, Wesley Reynolds, Ryan Miller, Connor Millican Sponsor: OU Advisor: Dr. Siddique
V2
Sooner Off-Road Student Team: Jonathan Moore, Kelsey Chofey, Ryan Hill, Bryson Simer Sponsor: OU Advisor: Dr. Dalton
36
2017
ME CAPSTONE PROJECTS
V3
Sooner Powered Vehicle Student Team: Evan Fernandez Sponsor: OU
V3
Bass Family Bike Project
37 Advisor: Dr. Dalton
38
Student Team: Samuel O'Neal, Cody Greenfield, Nicholas Pine, Kaleb Kadavy, Mahmood Bu Huliga Sponsor: AME/Bass Family Advisor: Dr. Dalton
INDUSTRY SPONSORS
39
CAPSTONE POSTER FAIR JUDGES
42
2017
P1
CATEGORY: PROTOTYPE DESIGN
Bag Rejection
Kimberly-Clark Corporation produces diaper packages that vary in size and color. While traveling down the assembly line, these diaper bags occasionally become misaligned. When a misaligned diaper bag reaches the case packer, the case packer jams or breaks, resulting in down time for the assembly line and loss of capital for Kimberly-Clark. Kimberly-Clark requested that a capstone group from the University of Oklahoma School of Aerospace and Mechanical Engineering design a system that identifies misaligned bags and prevents them from entering the case packer. After researching current sensor and motor technology as well as existing industry solutions to similar problems, engineering students designed a prototype for a system that identifies and pushes misaligned diaper bags off of assembly lines. A prototype of the pushing assembly was created for Kimberly-Clark, and the bag identification design was documented in order to be used as a backup option to Kimberly-Clark’s recently acquired sensing system.
Representation of Design on Assembly Line
Partial Assembly
Prototype Design 1
2017
P2
CATEGORY: PROTOTYPE DESIGN
Methods to Track Web on Centerline
Kimberly Clark is unable to track the positioning of the web on their machinery. The purpose of this project is to provide a means to monitor the web position relative to machinery centerline. The system provided will save centerline data to create a history log for analysis of web movement and have a visual interface to be used on the manufacturing floor. The system the team has designed uses two 48mm ARIS sensors, an ARIS control box, and a PLC. The system is controlled by a program written in RSLogix. This code computes the web width and centerline, which may be linked to a data history log software called Historian used by Kimberly Clark. A graphical display is provided in ARIS software. The team has confirmed that the ARIS sensor is accurate beyond 1mm. Therefore, all requirements identified by the team and Kimberly Clark are met by this system.
2
2017
P3
CATEGORY: PROTOTYPE DESIGN
The development of an iHub robotic tourguide
The Innovation Hub is a recent addition to the University of Oklahoma, and a space designed for creation and collaboration. With many people looking to tour the facility to see the VR lab, co-working spaces, and fabrication lab, iHub personnel are often taken away from their work to give tours. The Innovation Hub has asked the department of Aerospace and Mechanical Engineering at OU to develop a fully autonomous, relatable and safe tour guide robot. Safety and autonomy were paramount to the successful construction of the robot, which engineering students were to design and construct using the resources and tools available at the iHub and the university. Using drafting software, recording equipment, image processing libraries, and communicating with experts in the field of robotics, engineering students were able to develop a working robotic tour guide platform for the Innovation Hub.
3
2017
P4
CATEGORY: PROTOTYPE DESIGN
Design of Off-Shore Oil Well Downhole Tubing Sub-Assembly – Phase I
The Oil and Gas Industry has developed Fiber Optic Distributed Sensing in ultra-deep water applications to eliminate the need for electronics down-hole, minimize well intervention, and provide continuous data acquisition over the life of the well. Currently, there are no deployment methods that allow two fiber optic cables to be joined laterally within the annular space below the production packer. Our solution is segmented into two phases; Phase one focuses on reaching the rendezvous point while phase two focuses on completing the lateral fiber optic quick connection. The phase one solution utilizes two custom hydraulic actuators: a linear module and an angular module. These actuators allow navigation to the rendezvous point with millimeter accuracy while operating on standard 7” tubing within a ¾” annular space. This solution uses no electronics or power down-hole over the life of the well and does not alter the casing above the packer.
4
2017
S1
CATEGORY: STUDIES
ESP Power Cable Design Alternative
Baker Hughes is one of the leading oilfield service companies in the world. They currently use a lead jacket as a protective barrier for the conductors within their current power cable design. Lead introduces problems due to its weight and is not environmentally friendly. The purpose of this project was to research a new material and/or design that could replace lead in the ESP Power Cable with a light weight, cost effective, robust, and health, safety, and environmentally friendly alternative. A technical document was to be produced that presented Baker Hughes with viable and inviable material alternatives. Soft metals, plastics, material coatings, copper alloys, and epoxies were specifically explored. Inviable options were eliminated and Epoxies were further explored as a potential material replacement. Permeability, strength, and saturation experiments were done on epoxy samples to mimic downhole conditions and understand the viability of using epoxies.
5
2017
S2
CATEGORY: STUDIES
Bearing Machine Upgrade
To enhance the reliability of their tri-cone drill bits, Baker Hughes requested assistance from the Mechanical Engineering Department at the University of Oklahoma. The tri-cone drill bit is one of the most productive applications that Baker Hughes uses in drilling operations. Our team was tasked with improving the current bearing test set up that simulates the weight on a bit’s journal bearing. The current test design does not allow them to test thrust forces on the bearing, sense early failure detection or accurately measure torque on the bearing. Our team has proposed a redesign of the current test set up with an additional piston and rolling elements allowing a thrust force to be applied. An accelerometer and torque sensing element have been proposed to detect early failure and measure the torque applied to the test specimen. The team has also modeled and FEA tested the entire bearing machine.
Rotation of Bushing
Lubricant
Shaft
đ?œ?%&'() , Torque on Shaft đ?‘ƒ, Applied Force of Shaft on Bushing đ??š( , force of the rotating bushing on the shaft
6
2017
CATEGORY: STUDIES
S3 Determining the effect of various slot geometry on burst and collapse of a tubular product The Project 8 Capstone team for Baker Hughes analyzed the effects of slots on the structural integrity of a cylindrical pipe. The team used finite element analysis (FEA) through ANSYS software to run simulations on different geometries and find the failure of the pipe under exterior and interior pressures. The geometry of the slotted pipe was altered slightly and results were plotted by calculating the failure pressure using a .0002 inch offset. Preliminary results show that increasing slot width causes small decreases in failure pressure while increasing slot length caused large initial decreases in failure pressure that leveled off after 4 inches. Slot depth increases gave a linear decrease in failure pressure. Slot numbers between 1 and 4 showed varying results while 5 and greater tended to remain constant. The geometries made from Super 13 Chrome failed at higher pressures and those made from 825 Nickel failed at lower pressures.
Displacement Constraint
Fixed Support
Internal and External Pressure
Deformation Probe
7
2017
CATEGORY: STUDIES
S4 Determine the effects of tie back seal assemblies to improve collapse resistance for liner hanger extension analyzing parameter variations The objective of this project is to further understand the variables affecting the collapse pressure rating of Oil Country Tubular Goods (OCTG), in particular, casing pipe used in a linear tieback system in well completion operations. The project primarily focuses on analyzing the extent at which ovality, eccentricity, temperature, and length affect the collapse pressure of a pipe. Research studies were required to obtain the most up to date equations and methods of analysis. Finite Element Analysis is used to singularly test the effects of specific pipe variables. This report sums up our research and includes the final deliverable which consists of an Excel spreadsheet that calculates the collapse pressure of OCTG pipes using several analysis methods.
8
2017
S5
CATEGORY: STUDIES
Polycarbonate Repair Procedure for Aircraft Crew Compartment
Capstone Project #12 is sponsored by the System Program Office (SPO) at Tinker Air Force Base. The SPO is responsible for ensuring that the U.S. military aircrafts get repairs and maintenance. Polycarbonate panels in the crew compartment in aircrafts can be damaged due to fatigue, impact, and harsh environment conditions. The SPO does not have an effective repair method. The SPO would like to investigate detailed instructions and recommendations that can be applied to the panel repair. The capstone team has developed both adhesives and plastic welding based repair methods for polycarbonate panel repairs. Experiments demonstrated that the adhesive based method can be used as a patch. The plastic welding is a strong method for repair for a variety of crack sizes. The repair procedures and experimental data were documented and reported to the SPO as key deliverables.
9
2017
CATEGORY: STUDIES
S6 Airflow Dynamics Optimization for Aircraft Corrosion Control Application The team analyzed and modeled the current heating, ventilation, and air conditioning (HVAC) system in Building 2280 at Tinker Air Force Base using SolidWorks and SolidWorks Flow Simulation in order to find solutions to improve airflow conditions in the building’s two hangar bays. Based on the results of the simulations, the team contrived system modifications that would help to reach the client’s goals of increased system redundancy, 100 feet per minute (fpm) of horizontal airflow parallel to the aircraft’s fuselage, and increased energy efficiency. These modifications were tested in SolidWorks Flow Simulation to determine which would lead to the greatest improvement. The team has determined that the addition of air curtains and one exhaust fan to each hangar bay would provide the greatest improvement for the least cost. If the budget would allow, the team recommends relocating some of the supply diffusers to the wall at the nose of the aircraft for optimal airflow.
10
2017
S7
CATEGORY: STUDIES
RCD1: Drawings Package and Parts List
Our project was to reengineer a rotating control device (RCD) for Weir Pressure Control. It was a collaborative project between multiple teams and employees from Weir. An RCD is a device that is used in the oil and gas industry to keep gasses from escaping while drilling. It is used at ground level to keep the drilling shaft in place. Weir Pressure control currently purchases their RCDs from a Chinese company. To make operating the RCD easier, cheaper, and safer Weir has decided it would be beneficial for the RCD to be reengineered. We visited Weir’s facilities several times to get an idea of how the RCD worked and to intelligently measure the many parts and assemblies. We produced hand sketches, SolidWorks models, and SolidWorks drawings for the re-engineering process Weir is undergoing.
Team RCD1:
Okechukwu Atukpawu
Elisha Moncrief Fnu Nkegoah Asaba Nguafor Zac Pivarnik
11
2017
S8
CATEGORY: STUDIES
RCD2: Specifications and Vendor Selection
Our sponsor, Weir Pressure Control, has tasked us with a collaborative project that involves the reengineering of a rotating control device (RCD). Our portion of this project involved critical part analysis, part specification analysis, and vendor origination. Through critical part analysis we determined the consumable parts and created a six month consumable parts list. By providing the specifications, we are ensuring that every part on the RCD is being utilized within its limits for performance and safety reasons. Moreover, by providing the vendors for each part with the part numbers, we are allowing Weir to select the vendor that best fits their needs for standard parts, competitive prices, assistance, short lead times, and locality. Our project is highly interconnected with two other capstone groups, so in order to be successful we had to establish communication protocols, groups meeting times, and a medium for collaborating on reports and presentations to ensure connectivity. Group RCD1 passed on a parts list to us, we research specifications of parts and research vendors to supply those parts, we then pass on bearing specifications to RCD3 which they use to design their RCD testing system, and, finally, we compiled the information we researched into a bill of materials which will be delivered to Weir as our end of semester deliverables.
Team RCD2:
Nick Robinett Jacob McAuliff Matt Garde Mark Haley
12
2017
S9
CATEGORY: STUDIES
RCD3: RCD Testing System
This project is part of a three-team collaborative effort to re-engineer a rotating control device (RCD) for our sponsor, Weir Pressure Control. As the third team contributing to this RCD Re-Engineering project, our primary objective was to design a testing system and procedure for monitoring an RCD assembly as it is subjected to realistic operating conditions. This is necessary to ensure the functionality and integrity of the RCD before field application can be seen. RCD3 has developed a design for such a testing system, which incorporates the readily available testing equipment Weir can provide with the various auxiliary equipment we have selected or designed ourselves based on extensive research of field conditions and RCD functionality. SolidWorks models and drawings of the testing system and its components have been produced, as well as a detailed procedure for operating the system and monitoring conditions inside the RCD.
Team RCD3:
Blake Lawson
Grant Guzman Jesse St. Clair Matthew Rangitsch
13
2017
CATEGORY: STUDIES
S10 Rod Rotator Intelligent System Project (PRR-ISC) Weir Oil & Gas allots a portion of its internal resources to servicing mechanical components of onshore well pumpjacks. Currently, maintenance for these systems is on a set schedule, making them susceptible to unnecessary downtime and expensive losses in profit if mechanical failure occurs. In order to save its customers both time and resources, our team was tasked to design a system capable of remotely monitoring day-to-day performance of the rod rotator system on each well. The proposed design is an intelligent device that will monitor rotational and translational movement of the polished rod, the top-most shaft of the pumpjack rod string which forces extraction of oil from the well, using the combination of a 3-axis accelerometer and a through-hollow rotary encoder. If deterioration of motion is detected and persists over time, the device will send an alert notifying the company of maintenance needs.
14
2017
CATEGORY: STUDIES
S11 Conceptual design alternatives to the current compression tube design Current electrical submersible pumps (ESP) require a custom cut compression tube to maintain a compressive force on the diffuser and impeller stack. These compression tubes require precise custom cutting and are prone to thermal expansion during the pump’s operating temperatures. Errors in custom cutting in addition to thermal expansion can result in over compression or under compression on the diffuser and impeller stack. This change in compression periodically leads to pump failure due to buckling diffusers (over compression) or spinning diffusers (under compression). Our group has proposed two alternative designs to alleviate these issues with minimal change in the current design. The first design consists of a modified diffuser stack with interlocking spur gears to prevent diffuser spinning. The second implements a pre-loaded hard rubber insert into the compression tube to compensate for any change in compression during pump operation. Both designs can be manufactured with minimum change to the current GE Oil and Gas manufacturing process.
15
2017
CATEGORY: STUDIES
S12 Gearboxes with Fixed Form Factors and Architectures for a Wide Range of Torques Tata Consultancy Services is a large consultancy service within Tata Group. TCS is looking to enable Tata to become the world leader in gearbox manufacturing and steel specialization, possible with its connection to Tata Autocomp Systems, Tata Steel, and Tata Motors. Team Gearbox developed the goal to use the Compromise Decision Support Problem construct to develop a tool that can aid TCS in designing gearboxes of the same architecture and factors, but a wide range of torques. Our program enables a designer to look at various gear and shaft sizes and torque values and find the strengths required for attaining a minimum factor of safety of 2. This program can be used to write a design manual that will aid Tata in deciding to design new steel materials or change their gearbox design for their given circumstances.
16
2017
CATEGORY: STUDIES
S13 Discovering Bearing Factor Baker Hughes postulates that the maximum allowable contact stress before bearing failure occurs at the contact area between two metals under compression is typically higher than tensile yield strength by a factor of 1.25 to 2.00. This factor, known as the bearing factor, is multiplied to the tensile yield strength to attain a more applicable yield strength at the contact area. The objective of this project is to create a standard testing method; collect compression testing data for MP35N on MP35N, MP35N on Ni Alloy 718, and Ni Alloy 718 on 13% Cr; and compile a bearing factor design manual outlining procedures and analysis for the determination and justification of bearing factors in various material configurations and temperatures. With these deliverables, Baker Hughes can justifiably design their components, with a known amount of uncertainty, to withstand stresses greater than the tensile yield strength to safely and effectively reduce material costs.
17
2017
CATEGORY: STUDIES
S14 Gold Coast Surfboard Improvements The team was assigned the task of evaluating Gold Coast’s current product line of surfboards and finding areas for improvement. Two material changes for the skin were researched; woven basalt fibers and the ZNTBoost epoxy additive. Basalt fiber replaces fiberglass, while ZNT-Boost additive modifies the epoxy. Through experimental testing, standard E-glass failed at 344 lbs. Simulation was conducted to determine the increase in bending strength by using the new materials. With basalt fiber, the 7’ Ruccus can withstand 410 lbs (19% increase) while increasing impact resistance 8.9%. Substituting ZNT-Boost yields 460 lbs (34% increase), while increasing impact resistance 140%. One manufacturing change was determined: an “IBeam”-type stringer inside the surfboard. For the same 7’ Ruccus, replacing the current inserts with a 2mm thick 7’ aluminum I-Beam results in 570 lbs (66% increase) to failure. Alternatively, a 4mm thick aluminum I-Beam results in 850 lbs (145% increase) to failure.
18
2017
T1
CATEGORY: TESTING
Design of an experimental setup to evaluate metal barrier rings
Metal seals are used throughout the oil and gas industry to prevent valve leakage. These seals come in many different geometries in order to accommodate the size of the valve and the pressure that it experiences. In this project, two different types of seals were tested experimentally to determine which geometry is most effective for use in pressurized dynamic applications. The first seal that was tested is a C-ring cross section seal. These are a very common type of metal seal that is relatively inexpensive due to its simple geometry. Typically, C-ring seals are used in high pressure static applications. When pressure is applied to the opening of the seal, the contact forces between the seal and the bore are increased, creating a better seal. In order to prevent deformation in the C-rings, plastic support rings were designed and used in the testing. The second seal that was examined is a spring loaded seal that is more commonly used in dynamic reciprocation. However, the spring loaded seals are more expensive than the Cring seals. In order to effectively compare the two seals, the lifespan, assembly force and pressure holding capabilities were tested. The seals were assembled to a shaft and then compressed into the bore of a cylinder. The assembly forces of the two seals were then compared. The seals are then reciprocated through the cylinder to determine their deformation during dynamic motion. In order to determine the seals ability to hold pressure and test the lifespan, the cylinder was heated and pressurized. If the C-rings are determined to be effective for use in a dynamic application, their use would potentially save Schlumberger a considerable amount of money. However, if the C-rings are infective, then their use in real world applications could cause leakage and damage to the entire system. Therefore, it is essential to test these seals and compare the sealing capabilities before they are used in pressurized valves.
19
2017
T2
CATEGORY: TESTING
Rotary Electro-Mechanical System
Our capstone team has been tasked by Schlumberger to design and build a test setup for rotary-mechanical seals. The seals, which are housed in a hydraulic motor, are to be tested under axial and torsional loading at various rotational speeds. The system was designed to be modular, so in the future we can implement different motors with different seals and seal configurations. To monitor the hydraulic motors performance, we were required to measure the systems temperature, pressure, flow rate, axial loading force, torsional force and motor speeds. We utilized National Instruments Data Acquisition Software to digitally monitor the systems temperature as well as the axial loading applied force with room to incorporate the rest of the systems measurements. The data obtained from our experiments is not only valued for its characteristic properties, but will also serve as baseline data when new prototype seals are tested in our test setup.
20
2017
CATEGORY: TESTING
T3 Design of an Experimental Setup for Grease Permeability Measurements Schlumberger has had economic challenges with short-life drilling equipment including sensors to measure differential pressures and temperature at a given depth. Because of the nature of fluid and reservoir compositions, sensors must be protected from harmful fluids and thus encased in grease or hydraulic fluid. The goal of this project is to design an experimental setup to test how much He gas permeates through fluids such as hydraulic oil and grease which determines pressure change, permeability coefficient and flux. The setup was designed and experiments were conducted for data analysis. Initial data showed no leakage within the setup by examining pressure change. To ensure the creditability, comparison of coefficients when testing with membrane between Nooshin’s (0.2-0.3 Barrer) and the setup is made (0.22-0.27 Barrer). Any test gives pressure loss of less than 1 psi. Changing heights of oil at 1500 psi and 22℃ shows increasing of permeation coefficient but decreasing flux.
21
2017
CATEGORY: TESTING
T4 Design of a modular experimental setup to measure the He permeability Schlumberger is the world's leading provider of technology for reservoir characterization, drilling, production, and processing to the oil and gas industry. During these applications, sensitive electronics are used to gather important data that will be used to optimize performance and minimize down time. To protect these electronics from being damaged from the varying pressures and temperatures, O-rings are used to isolate these sensitive tools from the harmful environment. The O-ring Permeability Team at the University of Oklahoma was asked to design a modular setup to test the sealing performance of multiple O-rings under simulated industry conditions. Parameters of focus were pressure, temperature, fill percentage, and compression percentage. A test fixture was designed and manufactured leading to experimental testing and results that provided the means for a design of experiments analysis of the parameters for efficient future testing. The delivered product will continue to add value as more parameters are analyzed.
22
2017
CATEGORY: TESTING
T5 Design of experiments & Simulations to capture friction effects with polymer rings Schlumberger is an oil and natural gas company dedicated to efficiency in all aspects of their operation. Schlumberger proposed a project to our team of junior engineers aimed at understanding the characteristics of friction in a reciprocating piston-shaft setup that uses polymer O-Rings as a fluid boundary. This includes understanding how different parameters – such as O-Ring size, squeeze percentage, and ring configuration – have unique effects on the system. Throughout the project development, we’ve sought to understand simulation setup and evaluation within the ABAQUS simulation software, and have started to come up with results to understand the contact force and contact area between a reciprocating shaft and glands of different size and squeeze percentage. Recently, the team initiated running experiments using one past insert to the setup and looks forward to using the three new modules to understand the effects of the different parameters.
23
2017
CATEGORY: TESTING
T6 Design of Method to Improve the Performance of Lithium-ion Batteries With potential wide-ranging applications including electric vehicles, renewable energy storage, and ability to meet the world’s growing energy needs, a large amount of research is currently being focused on improving the performance and cost of lithium-ion batteries. The Lithium-ion Battery Team has worked towards improving the performance of these batteries by coating one of the electrodes with crystalline transition metal-oxide (TMO) nanostructures to increase both their overall surface area and the battery’s lithium-ion transfer rate. Through reading a number of scientific papers on similar battery research and working closely with Dr. Merchan-Merchan, the team developed a set of procedures detailing the three stages of battery development for this project: TMO flame synthesis, battery assembly, and battery testing. These procedures were then used to build a physical battery within Dr. Merchan-Merchan’s lab to determine the overall effectiveness of these altered electrodes on battery performance.
24
2017
CATEGORY: TESTING
T7 Test Rig for Characterizing Thermal Behavior of Microencapsulated Phase Change Material Microencapsulated phase change material (MPCM) slurries have great potential for use as heat transfer fluids, as their apparent specific heat is significantly greater than those of single phase fluids, allowing them to absorb/release greater amounts of heat over smaller changes in temperature. To explore the thermal and hydrodynamic behavior of MPCM slurries, and more specifically determine the best concentrations for producing heat capacities which exceed water, our team designed and constructed an experimental test rig capable of measuring these properties over a wide range of conditions. The test rig utilizes a long heated tube with a number of instruments capable of measuring flow, pressure drop, as well as temperature as the slurry undergoes phase change. The slurry is then pumped through a chilled reservoir where it is reverted to a solid phase before returning through the test section again. Unlike existing studies already performed on MPCM slurries, our device’s test section can achieve angles of up to 90 degrees, which enables us to explore the relationship between slip velocity and heat transfer for further research into new applications.
25
2017
T8
CATEGORY: TESTING
ACG Slurry Measurement Team
ACG Materials makes slurry solutions in their laboratory that are laid on top of concrete floors to make buildings fire retardant. The slurry solution needs to be fully characterized to understand the materials’ compression or expansion coefficient, and be compared to other samples to ensure quality slurry compositions for their clientele. Their current testing device uses a triangular-prism tray design. This shape causes the slurry to dry and expand differently than it would in the field. To better model the expansion or shrinkage of the slurry in the field, a lab testing device with a rectangular-prism tray was designed, fabricated, and tested in this capstone project. Additionally, a field testing device was designed, and components for the design have been identified. This field testing device will measure the expansion and shrinkage of the slurry in the field over a section of 10 feet.
26
2017
I1
CATEGORY: INTERDISCIPLINARY
Control Humidity in multiple Facilities; B3902, B2210, B3907
Tinker Air Force Base manages a wide range of aircraft and their components. Quality tests and repairs on fuel accessories and parts are performed in buildings 3902 and 3907. Currently, the HVAC systems of both buildings do not adequately control room temperature and relative humidity levels. The team was tasked to evaluate the buildings’ HVAC systems and recommend a design that will maintain a relative humidity level below 50% and room temperature between 70°-75°F. After examining the buildings’ systems, the team determined that the inability to control humidity was due to the inadequacy or lack of reheat coils. By applying the Radiant Time Series method to calculate the total cooling load of the buildings, the capacities of the reheat coils were determined. Rather than replacing the entire HVAC systems, the team recommends that reheat coils be installed where none currently exist and that inadequate coils be replaced.
27
2017
I2
CATEGORY: INTERDISCIPLINARY
Paint Booth/Hangar Pressure Drop Electronic Monitoring
The Oklahoma City Air Logistics Complex (Tinker AFB) is granted a Title V permit, which requires them to monitor their VOC exhaust levels and ensure they stay under 250 tons per year. Inconsistent hand logging has led the paint booths to operate out of compliance. An updated system needs to be implemented to continually measure the pressure across the filtration system and automatically notify personnel when the system is out of compliance. This system is required to interface with the Honeywell Building Management System. We have designed a physical model to refine our requirements for implementing the monitoring system which simulates a filtration system, and uses a pressure gauge to measure the pressure drop. The gauge is connected to a microcontroller that sends data to Excel, which monitors the data for an out of compliance event. If one is detected an email will be sent to designated personnel.
28
2017
I3
CATEGORY: INTERDISCIPLINARY
Radial dimensional stack-up analysis ESP
GE Oil & Gas has 6 series of ESP pumps that they wanted to meet standardization for each series. The team the inspected the drawings of the ESP pumps to find the dimensions and clearances of the skirt/skirt bore, hub/hub bore, and balance ring/balance ring bore. An optimization model was created to remove material from the skirt, while keeping the clearances the same, to standardize each series so that each clearance was the same deviation from RC9. For the TD Series, the new hybrid standard was set to a max of 0.017in and a min of 0.010in. The new standard will allow for the ESP pump stages to be more efficient and reliable, reducing the time that ESP have to be removed from the hole. The new standard reduces material allowing modification of the current inventory, while not increasing future manufacturing cost.
29
2017
I4
CATEGORY: INTERDISCIPLINARY
STATOR BUILD PROCESS LEAN-OUT
Our sponsor GE Oil & Gas is a leading provider of products, services, and solutions in the oil and gas industry. The objective of this project Stator Build Process Lean-Out is to lean out the stator press operation. The stator press operation is the first step in the stator assembly process. Completed stators are then assembled into downhole motors, used to drive pumps during oil and gas producing operations. The mission of this project is to generate a 30% process improvement in terms of throughput, quality, ergonomics, and process-time reduction. The goal is accomplished using a DMAIC (defined, measured, analyzed, improved, and controlled) approach. The team’s proposed solution yields a total process improvement of 43% resulting in a production capacity increase of 350 stators and a yearly savings of $65,000 in labor costs.
30
2017
I5
CATEGORY: INTERDISCIPLINARY
Seal Process Assessment
The GE Oil & Gas manufacturing plant, located in Oklahoma City, specializes in Well Performance Services. They manufacture Electric Submersible Pumps. The Seal component is not meeting on-time delivery (OTD) due to an undetermined set of problems. GE Oil & Gas asked for assistance from a team of Industrial & Systems and Mechanical Engineering students from the University of Oklahoma to determine why OTD is low. GE Oil & Gas requested standard task times, value stream maps, a control plan, and recommendations for improving the seal assembly process. The team used the DMAIC approach to meet these deliverables. Properly executing the approach helped the team identify the gap that is causing the poor OTD. The team was able to highlight bottlenecks, waste, failure modes, and high-risk areas. This gave the team means to develop recommendations and an implementation plan to report to GE Oil & Gas.
31
2017
I6
CATEGORY: INTERDISCIPLINARY
Dead Man Braking System
The equipment Hitachi Computer Products Inc. manufactures is mounted in 19� server racks that use casters for mobility. These racks can weigh up to 1000+ lbs. when loaded causing unattended racks capable of rolling away to be hazardous to people and equipment. In order to prevent this from happening, we were challenged with designing a dead man’s braking mechanism that can be easily installed and removed from a loaded rack and is ergonomic for the user. Our design consists of a handle located on the right hand side that when pulled toward the user will pull the brake chocks away from the front two wheels and allow for movement. If the handle is let go, the weight of the brake chock will activate the brake causing the chock to swing down and wedge itself between the wheel and the ground.
32
2017
CATEGORY: INTERDISCIPLINARY
I7
Baker Hughes Co-Op
Method to Mitigate Dependence on Waste Water Injection Problem •
Wastewater disposal via injection wells is linked to induced seismicity in Oklahoma
Hypothesis • Eutectic Freeze Crystallization (EFC) can be used as an environmentally sustainable alternative to injection for waste brine disposal Semester Outcomes 1. Critical review of literature to identify gaps and research plan 2. Preliminary modelling work with freeze crystallization software 3. Thesis outline and chapter titles are structured Way Forward • Determine cost for field scale EFC units or extent of existing pipeline infrastructure for central treatment • Identify potential market or disposal for associated crystallized salts • To deliver thesis, ensure connectivity between research questions and relate back to the requirements list
Characterization of Rotary Seals Problem • Rotary seals affect the performance of certain oil and gas technologies (e.g., drilling motors, artificial lift pumps, rotary steerable systems, etc.); the performance of these seals can be benefited by improved characterization. Hypothesis • The performance of rotary seals can be characterized using a finite element method/computational fluid dynamics (FEM/CFD) simulation and verified through experimentation. Semester Outcomes 1. Identified knowledge gaps through literature review 2. Problem definition 3. FEM contact analysis set-up a) Rotary seal model (Figure 1) b) Contact contour plot (Figure 2) c) Contact pressure profile (Figure 3) d) Calculations for CFD analysis (Figure 4) Way Forward • Develop CFD flow analysis • Conduct experiments • Use insights gained to finish Master’s thesis
Decline Curve Analysis Techniques in Unconventional Reservoirs Problem • Decide on the most appropriate DCA (decline curve analysis) method for forecasting the production of the wells and estimating EUR (estimated ultimate recovery) to improve the economics of shale development in natural gas reservoirs. Hypothesis • Calculating the EUR for a well using several DCA methods for wells with longer life and calculating the EUR for the same wells but with short term production data, the results can be compared and the method with close agreement will be chosen as the most accurate for shale gas in the Barnett and Eagle Ford Shale Plays. Semester Outcomes 1. Critical review of literature to identify gaps and research plan 2. Outline of chapter topics 3. Connectivity between research question to ensure consistency throughout thesis 4. Identification of the DCA methods that will be used for the analysis of the project Way Forward • Complete compilation of production data for natural gas wells • Generate production forecasts and calculate reserves (EUR) • Generate connectivity between DCA and economics
33
2017
I8
CATEGORY: INTERDISCIPLINARY
Design Build Fly
Crimson Skies is a university competition team that is participating in the AIAA Design Build Fly aerospace competition. The aerospace-focused team has enlisted the help of mechanical engineering students to design and build a storage tube and self-locking hinge mechanisms for the aircraft to meet the competition requirements. The storage tube must be a rigid, sealed right cylinder and must protect the stored aircraft from impact damage when dropped. We designed a composite tube made from carbon fiber sleeve and epoxy, with one end sealed and the other end covered by a locking plug. The aircraft must be foldable to fit within the tube and must deploy utilizing self-locking clip mechanisms. Over a dozen 3D-printed hinge and locking mechanisms with carbon fiber reinforcement were developed to meet the folding requirements and to support airframe in flight. The tube and hinge components were integrated into the team’s competition vehicle and tested in a flight demonstration at the 2017 DBF Competition in late April.
34
2017
V1
CATEGORY: VEHICLE DESIGN
Design of an FSAE Racecar
The objective for the Sooner Racing Team is to win the FSAE Lincoln 2017 competition. Using data collected from other team’s competition results and historical data from the Sooner Racing Team it was decided that in order to win the 2017 car, “Victoria”, would have to complete the Acceleration event in 4.125s and the Skidpad event in 5.000s. These goals were designed for by focusing criteria towards a car weight of 370lbs and a center of gravity height at 10.5”. To better reach these criteria the team implemented the use of working drawings and a CAD model of every part on the car and created a Chief Chassis Engineer and Chief Powertrain Engineer to check these designs.
35
2017
V2
CATEGORY: VEHICLE DESIGN
Sooner Off-Road Gearbox
The goal of the Sooner Off-Road (SOR) capstone project was to enhance SOR’s maneuverability through the design, manufacture, and implementation of a gearbox. The design includes a limited-slip differential, forward, neutral, and reverse with a forward gear ratio of 6.67:1. The capstone team concluded that this was the optimum gear ratio for SOR’s application based on speed, torque, and gear force calculations. The team used finite element analysis (FEA) to calculate the forces on the gear case as well as AGMA bending and contact equations in order to calculate and analyze the forces of the gears on one another. The theory behind the design has been validated through calculations, CAD models, and analysis. The capstone team has received the raw materials and parts for the gearbox. Machining and building of the gearbox will occur over the next few weeks. Once the gearbox is built, testing will begin.
36
2017
V3
CATEGORY: VEHICLE DESIGN
Cable-Driven Continuously Variable Bicycle Transmission
The Sooner Powered Vehicle team’s capstone group designed a cable-driven continuously variable transmission for a bicycle. There is only one bicycle CVT and one cable-driven bicycle on the market, and utilizing a combination of these system would be beneficial in replacing the inefficient chainline that is inevitable with long wheelbase recumbent bicycles. It was found that in order to maintain simplicity and lightweight, previously designed CVTs used in vehicles could not be utilized. A ratcheting lever arm mechanism was pursued for the design, which was determined to be compact enough to be retrofitted onto existing bicycle frames. The entire CVT features a custom hub, a lever arm ratchet on either side of the hub that allows for gear ratios greater than 4:1, compression springs to engage the ratchet, a return spring, pedaldriven power cables, and shifter cables to adjust the effective length of the lever arm.
37
2017
V4
CATEGORY: VEHICLE DESIGN
Bass Family Bike Project
The Bass Family asked the team to find a way to allow their son Titus, who is physically and mentally handicapped, to participate with their other son, Tobias, in the cycling portion of a triathlon. Tobias loves to compete in triathlons, and his goal is to be the youngest person to complete the Ironman Triathlon while accompanied by a disabled partner. After considering several ideas and consulting with the family, the team decided to develop a sidecar for Titus that can attach to Tobias’ bike. Using minimal steel and a fiberglass nose shell for the design yields a light-weight way for Titus to ride with Tobias. After designing a 3D model of the sidecar, the team constructed a prototype. The sidecar provides a low-cost and light-weight solution to the Bass Family’s problem. This will help allow Tobias to achieve his dream.
38
2017
INDUSTRY SPONSORS
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2017
INDUSTRY SPONSORS
40
2017
INDUSTRY SPONSORS
41
2017
CAPSTONE POSTER FAIR JUDGES
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