Oslc G HP Distribution and Ohwm Stress Analysis

OSLC G HP DISTRIBUTION AND OHWM STRESS ANALYSIS
Appendix Z
Document Type
Software
Microsoft Word XP
Source File
Document3
Other Source File
SPC_manual.dot
Author
Antonio De Ita Ventura
Author info
Review & approval
Marcelo Santamaria
Yuliana Casas Casas
Revision History
July 12, 2012 First review

July 21,2012
August 17, 2012
OHWM FEA WITHOUT
SAFETY FACTOR
Last saved
17-Aug-12 11:17
Confidential
Copyright Schlumberger
Contents
1 OVERVIEW.....................................................................................................1-1
2 OSLC G HORSE POWER (HP) DISTRIBUTION ...........................................2-1
2.1 OSLC G ENGINE HORSE POWER AVAILABLE. ................................................................ 2-2
2.2 WINCH PUMP POWER SPECIFICATIONS .......................................................................... 2-3
2.3 WINCH HYDRAULIC MOTOR. .............................................................................................. 2-5
2.4 AUBURN GEARBOX MODEL 10 .......................................................................................... 2-8
2.5 Interaction of Winch pump - Winch Motor Gearbox -Cabledrum. ................................ 2-8
3 OHWM STRESS ANALYSIS ........................................................................3-13

4 Conclusion ..................................................................................................4-24
5 References ..................................................................................................5-24
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HORSE POWER DISTRIBUTION & OHWM FEA
17-August-2012
1 OVERVIEW
The OSLC G truck is rated to develop a constant Up Hole cable pulling force of 8000 Lbf
without compromise performance and safety of any of the system components. Actual
logging applications demand to do the job at deeper levels therefore more pulling force may
be demanded to the entire systems of the truck.
This document shows how the available engine horse power is distributed through the
systems ending up with the available HP at the cable. With this information we can validate
that the OSLC G can develop a constant Up Hole cable pulling force of 12000 Lbf without
compromising performance and safety of any of the system components.
2 OSLC G HORSE POWER (HP) DISTRIBUTION

The following picture shows the cinematic chain of the systems. It will be used in order to
clearly identify how horse power is used.
Picture 1 OSLC G cinematic chain of systems
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2.1 OSLC G ENGINE HORSE POWER AVAILABLE.

The OSLC G is equipped with a RENAULT DXI 11 engine rated to 280 KW@1900 RPM
however It does the logging job at constant speed set at 1300 engine RPM, this speed CAN NOT
be change by means of the SWCT so the engine performance graph has to be studied in order to
find out the available power at such speed.
Picture 2 OSLC G DXI 11 ENGINE POWER CURVE
From the power curve we can see that the engine can deliver up to 245 KW@1300 RPM in a
laboratory conditions. So it is known that in real conditions the efficiency of the combustion
engine can be estimated to about 80% of reported data. Also notice that at such speed the engine
delivers its maximum torque output 1800 Nm.
So the engine in real conditions can deliver up to 196 KW@1300 RPM.
Power is consumed by the following components of the engine:
a) Fan for cooling purposes
(3 KW)
b) Air compressor
(3KW)
c) Alternator & A/C
(2KW)
Therefore the engines crankshaft available output power is around 188 KW@1300 RPM This
power is used to drive a full hydraulic system.
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The hydraulic system is a close loop circuit with an efficiency close to 90%. Appling this percent
factor to the crankshaft output power we found that the hydraulic system input power is 169KW
Taking a look to picture 1 we can see that the Generator is rated to 40KW of power so 40 KW
will be taken out from the hydraulic system input power therefore the remaining power is
169KW 40KW = 129 KW
The 129 KW is the power available to produce the Up Hole pulling force on demand.
Converting this 129 KW to Horse Power it results: 173HP
2.2 WINCH PUMP POWER SPECIFICATIONS

The OSLC G is equipped with a SAUER Series 90 100 CC which has the following operation
capabilities:
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As shown in the picture the pump delivers a torque of 970 lbf In per each 1000 psi a maximum
displacement (100 cc).
The winch pump rotates at higher speed than the engines crankshaft due to the Power Take-Off
ratio after the trucks gear box. It rotates 1.35 times faster than the engine, so applying this factor
to the engine RPM it results:
Winch pump Speed (WPS) = 1300*1.35 = 1755 RPM
It is possible to find out the power that the pump can handle per every 1000 psi developed. To do
so the following formula is used:
HP = ((Speed)*(Torque))/63000
Equation [1]
HP = ((1755 RPM)* (970 lbf in))/63000= 27

The maximum working pressure already set in the pump for UP Hole is 5000 psi so the maximum
power that the pump can handle is:
Maximum Allowable horse power for winch pump: 5*27 = 135 HP
Notice that the input power can be higher than the one that the Winch pump handles. This power
will be demanded in function of pressure and speed.
The following formulas will be used (section 2.5) to compute the full interaction of the pump,
hydraulic motor, gearbox and cable drum sizes in order to determine the amount of cable tension
developed based on system pressures, flow rates and drum diameter.
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We can get the pump output flow in order to understand how this formulas work:
Qe =
Equation [1]
Notice that the divider is only 1 instead of 1000 it is because the units must be consistent in all
calculations.
Qe =
= 168480 cc/min
So the maximum output flow from the pump will be 168480 cc/min@100cc of displacement and
1775 RPM
2.3 WINCH HYDRAULIC MOTOR.

The OSLC G is equipped with a hydraulic motor from SAUER Series 51 80cc/32cc 2 speed
which has the following specifications:
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The maximum output power from the hydraulic motor will be at maximum displacement (80cc)
and of course it will be in function of the speed.
From the following formula It is possible to find out the maximum output power that can be used
to create a pull force into the logging cable:
Output power (KW) =
Equation [2]
Where:
Qe: input flow (L/min)
P: Effective hydraulic pressure (Bar)
nt: efficiency
What is known is as follows:

Qe = 168480 cc/min = 168.48 L/min
P: 344.73 bar (5000 psi) 24.13 bar (350 psi) = 320.6 bar
ETm: 0.94
By input the values the result is:
Output power (KW) =
= 84.62 KW
Converting this value to horse power results in:
Outputpower (HP) = 113.47
The following formula is used to calculate the motor output rpm (MS) based on maximum winch
pump flow at maximum displacement.
MS =
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Equation [3]
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Where:
Vg: Displacement of the motor (cc)
Qe: input flow (cc/rev)
EVm: Volumetric efficiency
What is known is as follows:
MD: 80 cc
Qm from section 2.2 = 168480 cc/min
EVm: 0.94
So by input the values to equation 3 give us:

MS =
= 1969.64 RPM
So the maximum power available for cable tension is going to be 113.47 HP@ maximum
displacement of the winch pump and at maximum displacement of the motor with a pressure
system in the UPHOLE line of 5000 psi.
The following formulas will be used (section 2.5) to compute the full interaction of the pump,
hydraulic motor, gearbox and cable drum sizes in order to determine the amount of cable tension
developed based on system pressures, flow rates and drum diameter.
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2.4 AUBURN GEARBOX MODEL 10

The OSLC G is also equipped with an Auburn Gearbox Model 10 coupled to the Sauer Series 51
hydraulic motor as final drive. This gearbox has a ratio of 52.35:1.
The following picture shows its technical information:
This information is used to compute the full interaction of the pump, hydraulic motor, gearbox
and cable drum sizes in order to determine the amount of cable tension developed based on
system pressures, flow rates and drum diameter.
2.5 Interaction of Winch pump - Winch Motor Gearbox Cabledrum.

Since the Winch pump does not operate at full displacement at all times and the cable drum
diameter varies depending on the amount of cable into the well the final speed and pull force is
changing at every cable layer.
In order to find out the capabilities of the hydraulic system It is studied at its maximum and
minimum capabilities so this allow to come up with graphs that show the performance as the
conditions are changing. The following chart shows the hydraulic system parameters all based in
the formulas listed above.
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CHART 1.- Hydraulic system maximum and minimum working parameters .
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The following pictures show the expected performance of the hydraulic system under many cases,
all the data was taken from chart 1. Picture 3 shows the cable tension to be developed based on
the drum diameter. Notice that the drum diameter changes as the cable is spooled out or in.
Picture 3 Cable tension based on pressure system and drum diameter
So the OSLC G will work with a cable drum WDR59E that has a core diameter of 24. It is
expected to pull 12000 lbf while the cable drum has only 14 layers of cable. Each layer increases
the core diameter by 0.48 times 2 so the diameter of the drum will be:
Drum Diameter= 24 + ((0.48*14)*2)=37.44 in
Looking at picture 3 it shows that to generate a cable tension of 12000 lbf with a cable drum
diameter of 37.44 in the hydraulic system will develop an UP HOLE pressure of 4000 psi or even
4500 psi depending on the distance to log the well at such tension and the speed of the cable.
Notice that as the drum diameter increases the cable tension will be lower if the pressure is
constant.
Picture 5 shows the speeds allowable based on cable diameter and displacement of the hydraulic
pump and hydraulic motor
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Picture 4 Maximum cable tension based on drum diameter
Picture 5 Cable speed based on drum diameter
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2.6 STRESSES ON 120H CHAIN WITH A REPORTED TENSILE

STRENGHT OF 45100 Lbs
The chain drive is a critical part that must be properly calculated in order to minimize the likely
of an unexpected failure while logging. So the following chart shows the expected chain tension
based on cable drum type, depth and cable tension. Keep in mind that the Schlumberger standard
says that a safety factor of 6:1 must be accomplished.
Picture 6
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CHAIN TENSION CHART BASED ON DETPH AND CABLE TENSION
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The no color zone is for a 6:1 factor, the cream color zone is for a 4:1 safety factor, red color
zone is for a lower safety factor. This zone never can be used.
3 OHWM STRESS ANALYSIS

Since the desired pulling cable force is going to be higher than recommended pulling force a
stress analysis to the OHWM frame is recommended in order to assure no any structural damage
will be associated when pulling to a constant force of 12000 lb f.
The OWHM frame is Aluminum alloy 5083 made. The stress analysis will be done with a safety
factor of 2.5 times the desired working load (pulling force) the weight of the cable drum is also in
account. This factor is most recommended in engineering design but also most standards (like
DNV 2.7-1) recommend it.
The criteria to understand the stress in the OHWM will be the Von Misses Stress and the
maximum principal stress. This criteria is used to predict yielding of materials under any
loading condition from results of simple uniaxial tensile tests. The von Mises stress satisfies the
property that two stress states with equal distortion energy have equal von Mises stress.
One main data needed is the Yielding stress of the Material, it is:
y= 190 Mpa.
In order to know when the material will be in the safe range, the maximum allowable working
stress in the results must be no higher than 2/3 of y.
Therefore:
A= (2/3)*190Mpa =
126.6 MPA.
A is the maximum stress that can be in the results of the stress analysis in order to work in a safe
mode.
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The following picture is a free body of the structure with the loads that are going to be applied to
calculate the stresses generated under such loads. The pulling force will be with an angle related
to the horizontal plane so that force will have 2 components, one component will be in the Y axis
(vertical or pointed up) this component creates a tension stress and the other one will be in the X
axis (horizontal) which creates a shear stress.
The worst case is the shear stress. The material may fail by shear stress before it fails by tension
stress. So the analysis is focused in full shear stress.
3.1 OHWM FEA WITH A SAFETY FACTOR OF 2.5
Picture 7 OHWM FRAME body free with loads with safety factor of 2.5
To analyze the stresses in the OWHM frame the software CREO SIMULATE from Parametric
Technology Corporation (PTC) was used. The results are as shown:
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Picture 8 OHWM FEA Results 1: Maximum principal stress
From picture 7 it is noted that most of the frame will be in compression this is because of the
cable drums weight. The highest stress is at the red spots which has a value of 113.8 MPa this
stress is acceptable due to it does not goes beyond the allowable working stress for the material
(A= 126.6 MPa).
A closer look at the locations where the highest stress was found is presented in the following
pictures.
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Picture 9 OHWM FEA results 2. Stresses at pillow block mounting holes of frame.
As expected the highest stress area is located at the mounting holes for the pillow block. It is
because all the loads are transmitted there by means of the bolts. Picture 8 shows the way the
stress are distributed in the top plate of the OHWM.
As mentioned above the maximum principal stress is shown in red and has a value of 113.8 MPa
which is acceptable.
Picture 9 is a close look to the turnbuckles pin mounting plate. These plates will be working
under high stress but beyond the allowable stress.
Picture 10 OHWM FEA RESULTS 3. Stresses at turnbuckle reaction force
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Picture 11 OHWM FEA RESULTS 4. OHWM stresses at frame mounting holes.
The holes to secure the OHWM to the chassis truck are under high stress also. However the
maxim stress is 113.9 MPa.
This stress is a contact stress which is not critical for this application.
The maximum deflection has to be found out to check for any issue that may be present. The
following picture shows a maximum displacement of 0.76 mm. This displacement is not critical.
Note that the picture has a zoom X of 279 times that is why the frame looks like deformed kind
bad.
Picture 12 OHWM FEA RESULTS 5. OHWM deflection.
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3.2 OHWM FEA WITH NO SAFETY FACTOR

In order to figure out the expected stresses while doing a logging job the OWHM is analyzed
under loads without a safety factor. Remind that the safety factor is used to guarantee no any
issues will come up if a unexpected event of overload happens and to countermeasure variations
of the fabrication method.
The analysis with the safety factor does not replace any non destructive test procedure of the
welds. The following picture shows the stresses to be expected in the OHWM without safety
factor
Picture 13 OHWM FRAME body free with loads without safety factor
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Picture 14
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OHWM FEA ANALISYS RESULTS WITHOUT SAFETY FACTOR: PRINCIPAL

MAXIMUM STRESSES
As expected the maximum principal stresses to be present under actual load conditions is 51.6
MPa which is a value low compared against the allowable stress for the material of the OHWM.
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Picture 15
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MAXIMUM STRESSES @ PILLOW BLOCK MOUNTIG HOLES
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Picture 16
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MAXIMUM STRESSES @ TURNBUCKLE SUPPORTING PLATES
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The following picture is in regards of the maximum deflection expected:
Picture 17
OHWM FEA ANALISYS RESULTS WITHOUT SAFETY FACTOR:MAXIMUM

DEFLECTION
NOTE: The picture is showing the deflection scaled 744 times up.
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4 Conclusion
The OSLC G can develop a constant pulling force (UP Hole) of 12 000 lbs without sacrifice
performance of any of the systems however a rigorous maintenance, tests and inspections prior to
job must be done in order to keep all the hardware in good condition.
Safety rules must be followed as per working with high pressure standards. It is because the
working pressure while pulling 12000 lbf is going to be from 3500 psi to 4000 psi.
.
On the other hand all the results in regards of stresses in the OHWM are considering a good full
penetration of all the welds, so Non Destructive Test is recommended in order to guarantee good
performance of the frame.
From the chain analysis it is highly recommended to replace the chain after each job if the cable
tension was equal or more to 12000 lbs. It is because the working safety factor is going to be 4.
Replacing the chain will not allow to go below such safety factor.
5 References
A) Dave Richardson, PULL ON LINE, excel file. He was the Manager for the Gulf Coast
Service Center for about 5 years before get retired. He did coordinate and design the
CAPSTAN project. He deployed the first CAPSTAN system to the NGC geo market.
B) OSLC_G_MM_Vol2_V2_1__4368929_01 Manual
C) BENDIX TU FLO 550 Air compressor datasheet.
D) Sauer series 90 pump datasheet
E) Sauer series 51 bent axis motor datasheet
Confidential

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Review & approval

July 12, 2012 First review

3 OHWM STRESS ANALYSIS ........................................................................3-13

HORSE POWER DISTRIBUTION & OHWM FEA

2 OSLC G HORSE POWER (HP) DISTRIBUTION

Picture 1 OSLC G cinematic chain of systems

HORSE POWER DISTRIBUTION & OHWM FEA

2.1 OSLC G ENGINE HORSE POWER AVAILABLE.

Picture 2 OSLC G DXI 11 ENGINE POWER CURVE

c) Alternator & A/C

2.2 WINCH PUMP POWER SPECIFICATIONS

HORSE POWER DISTRIBUTION & OHWM FEA

Winch pump Speed (WPS) = 1300*1.35 = 1755 RPM

HP = ((1755 RPM)* (970 lbf in))/63000= 27

Maximum Allowable horse power for winch pump: 5*27 = 135 HP

HORSE POWER DISTRIBUTION & OHWM FEA

2.3 WINCH HYDRAULIC MOTOR.

HORSE POWER DISTRIBUTION & OHWM FEA

Output power (KW) =

What is known is as follows:

By input the values the result is:

Output power (KW) =

Converting this value to horse power results in:

Outputpower (HP) = 113.47

So by input the values to equation 3 give us:

2.4 AUBURN GEARBOX MODEL 10

2.5 Interaction of Winch pump - Winch Motor Gearbox Cabledrum.

HORSE POWER DISTRIBUTION & OHWM FEA

CHART 1.- Hydraulic system maximum and minimum working parameters .

Picture 3 Cable tension based on pressure system and drum diameter

Drum Diameter= 24 + ((0.48*14)*2)=37.44 in

HORSE POWER DISTRIBUTION & OHWM FEA

Picture 4 Maximum cable tension based on drum diameter

Picture 5 Cable speed based on drum diameter

HORSE POWER DISTRIBUTION & OHWM FEA

2.6 STRESSES ON 120H CHAIN WITH A REPORTED TENSILE

CHAIN TENSION CHART BASED ON DETPH AND CABLE TENSION

3 OHWM STRESS ANALYSIS

3.1 OHWM FEA WITH A SAFETY FACTOR OF 2.5

HORSE POWER DISTRIBUTION & OHWM FEA

Picture 8 OHWM FEA Results 1: Maximum principal stress

HORSE POWER DISTRIBUTION & OHWM FEA

Picture 10 OHWM FEA RESULTS 3. Stresses at turnbuckle reaction force

HORSE POWER DISTRIBUTION & OHWM FEA

Picture 11 OHWM FEA RESULTS 4. OHWM stresses at frame mounting holes.

Picture 12 OHWM FEA RESULTS 5. OHWM deflection.

3.2 OHWM FEA WITH NO SAFETY FACTOR

OHWM FEA ANALISYS RESULTS WITHOUT SAFETY FACTOR: PRINCIPAL

OHWM FEA ANALISYS RESULTS WITHOUT SAFETY FACTOR: PRINCIPAL

OHWM FEA ANALISYS RESULTS WITHOUT SAFETY FACTOR: PRINCIPAL

The following picture is in regards of the maximum deflection expected:

OHWM FEA ANALISYS RESULTS WITHOUT SAFETY FACTOR:MAXIMUM

C) BENDIX TU FLO 550 Air compressor datasheet.

D) Sauer series 90 pump datasheet

E) Sauer series 51 bent axis motor datasheet

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Drum Diameter= 24 + ((0.4814)2)=37.44 in