lord corporation downhole test simulator …edge.rit.edu/edge/p17301/public/final documents...lord...

34
LORD Corporation Downhole Test Simulator Feasibility Study Vol. 3 Cost & Purchasing Overview Rochester Institute of Technology Multidisciplinary Senior Design May 2017 Matthew Biron, Mechanical Engineering Daniel Bowers, Electrical Engineering Nicholas Fewell, Electrical Engineering Hyungsuk Kang, Mechanical Engineering Abigail Tremont, Industrial Engineering Jason Whyte, Mechanical Engineering Sam Zimmerman, Mechanical Engineering

Upload: dokien

Post on 23-Apr-2018

224 views

Category:

Documents


3 download

TRANSCRIPT

Page 1: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

LORD Corporation Downhole Test Simulator Feasibility Study

Vol. 3 – Cost & Purchasing Overview

Rochester Institute of Technology – Multidisciplinary Senior Design

May 2017

Matthew Biron, Mechanical Engineering

Daniel Bowers, Electrical Engineering

Nicholas Fewell, Electrical Engineering

Hyungsuk Kang, Mechanical Engineering

Abigail Tremont, Industrial Engineering

Jason Whyte, Mechanical Engineering

Sam Zimmerman, Mechanical Engineering

Page 2: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Table of Contents I. Cost Analysis .............................................................................................................................................................................. 3

A. Cost Overview ........................................................................................................................................................................ 3

B. BOM Review ......................................................................................................................................................................... 3

C. Operational Cost Review........................................................................................................................................................ 4

D. Potential Cost Reduction Opportunities ................................................................................................................................. 4

1) Vibration Systems .............................................................................................................................................................. 4

2) Mud Systems...................................................................................................................................................................... 4

II. Conculsions ................................................................................................................................................................................. 5

III. Aknowledgements .................................................................................................................................................................. 5

Page 3: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

I. COST ANALYSIS

A. Cost Overview

Product testing requires significant investment on the order of a testing facility. This volume focuses on the cost of procurement and operation of the test equipment in this facility. It does not, however, address the cost associated with the infrastructure necessary to house this equipment. A Bill of Materials (BOM), by subsystem, containing the pieces of the simulator which were deemed to be most expensive are included in Appendices C1, C2, C3 and C4. Section one below addresses the $16,000,000 procurement cost and section two goes through operational costs given in Appendix C6. It should be reiterated that no amounts provided here include building costs, or the cost associated with housing this test apparatus. All system technical specs can be found in the technical volume.

B. BOM Review

The BOM is broken into four sections including the mud, loads and vibration, structural, and controls subsystems. For the mud subsystem the largest contributor to the cost is the mud pumps. Here it may be possible to incrementally purchase the expensive pumps. Before taking this approach one must thoroughly study the relationship between the number of pumps present and the pressure and flow attainable. It should be noted that National Oilwell Varco gave a complete design ROM and it was determined that very few if any other suppliers were available. Also, included in the mud section are the holding tanks for the mud and flush water as well as the immersion heater necessary to bring the mud up to temperature. In the case of the immersion heater the quote came from Chromalox, but heaters capable of performing the task are widely available. With respect to the valves they are simple spec driven and can have multiple sources.

Under the loads and vibrations category the largest contributors are the shakers necessary to reach the acceleration requirement while the system is under the maximum static load. Unholtz Dickie Corp. was specified as the supplier for these as they are the only company manufacturing shakers on this scale. Following this, the next largest cost at $40,000 a piece are the linear actuators needed to create the lateral and axial loads. These actuators were directly quoted from MOOG with the understanding that they would probably be customized when actually purchased. MOOG actuators were chosen based on LORDs familiarity with their controls. There aren’t any components here that present a large risk of hidden cost increases and all other components have multiple viable sources.

The most difficult category to handle is the structural category. With this system design the largest number of custom components fall into this category. The pressure vessel is the most important piece as far as safety is concerned and it is also the part that requires the most customization. With a ROM price of $1,300,000 the pressure vessel with customization represents a large risk of cost volatility as it is difficult to predict the cost of customization. In this case the high level of customization necessary opens the window to a couple suppliers, but the only supplier who currently advertises a pressure vessel close to the size needed is Hydropac. The next largest cost contributor is the inner pipe. This is the combination of the “inner pipe” and “inner pipe junction.” Again this piece will require a one off custom casting to produce the junction piece. At $600,000 the inner pipe is the piece that is meant to take the brunt of the wear and will need to be replaced. It may be desirable to acquire multiple diameter inner pipes and junction pieces in order to test multiple parts. Only the cost of purchasing a single inner pipe and junction piece is considered in the BOM. Included in the BOM is an estimate for the cost of the piping necessary to get the mud from the pumps to the pressure vessel. Clearly this is very dependent on the layout of the facility and how close the pumps can be located with respect to the pressure vessel. With this in mind the rough layout we came up with used less than the 500ft quoted in the BOM. Suppliers for this pipe are limited due to the thickness necessary. Another noticeable cost comes from the air compressor used to achieve the 20ksi air pressure. This should not present much risk for increase as it was a quote from Hydropac which was the only supplier we could find for an air pump of this magnitude. It is important to point out that the cost of a lubrication system for the seals is not included in the BOM and will be critical to the life and proper operation of the seals. The final part that may be difficult to source are the bearings required to prevent force from being transferred to the seals. Included in the BOM is a ROM cost for these, but it is likely that these will be custom bearings due to the size and force they will experience. The last thing not included in this BOM is any structural supports for the pressure vessel itself. Since all forces generated are transferred to the pressure vessel before getting to the seals it may be necessary to brace the pressure vessel to transfer forces to an external support system. The seals could be sourced from multiple suppliers it just happened to be that AHP seals provided us with the most information. With all of this in mind the structural category poses the most risk for budget increases.

The final category contains the costs for controls. This cost is closely tied to the cost of controlling the MOOG actuators and the shakers. All of the sensors are on the order of $1,000 and were specifically designed to be robust to vibration and the abrasive mud. Both of these main controllers are supplied with the products. None of the sensors require customization which makes them simple to acquire and replace. This also means that the sensors have many viable sourcing options. There are no surprises in this category and very little risk for cost increases.

Subsystem Total Cost

Loads/Vibrations 3,098,396.70

Mud 9,185,575.00

Structural 2,226,209.02

Controls 35,950.08

Acquisition Cost 1,454,613.08

Total 16,000,743.88

Page 4: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

The cost of housing the testing rig along with the infrastructure for supplying electricity to the system are not estimated in this study. It should be expected that the infrastructure necessary to support the entire system will be extensive. This stems partially from the space necessary for the mud and water tanks along with the large space taken by the pumps. For the electricity it is probable that the system will require infrastructure on the order of dedicated transformers and should not require anything as extreme as a dedicated substation.

C. Operational Cost Review

Two estimates are provided for operational cost which

includes running the simulator for half of the year, which

would cost 6.7 million dollars, and an estimate for running

the simulator for half the business hours in a year which

brings the cost down to 1.6 million dollars. A breakdown of

these costs can be found in Appendix C6. The cost

associated with operators was estimated based on the need

of 4 operators for setting up the system and 1 operator while

the system is running. This is probably a good long term

estimate under the assumption that for the first year more

operators will be needed to monitor the system while in

operation. Furthermore, it was estimated that setting up the

system would take 20% of the time and it would run with a

single operator for the remainder. It can be seen that the

estimated cost per hour of an operator is $100. The largest

contributor to operational cost is the price of diesel for the

pumps. This estimation is based on running at full capacity

the entire time which would require the use of 6 pumps.

These 6 pumps would go through 714 gallons per hour

which at the current diesel wholesale price would cost

around $1,100 per hour. The power usage is driven mainly

by the shakers (480KW/h each) and immersion heater

(166kW/h). Both the cost of water and electricity are

relatively cheap when compared to the other operational

costs and will only change incrementally depending on

usage.

It is known that the system will incur notable expenses

associated with maintenance which have been omitted from

the study. The rationale behind this is that wear and its

associated cost is highly dependent upon the specific

equipment selected. This should be addressed by LORD

after these decisions have been made. It can be said that the

parts most probable to need frequent replacement are the

seals. Each time the seals are replaced it will cost $7,135 in

parts alone. It is also foreseeable that the pipes will need

biannual cleaning which is in addition to the flushing

performed after every test. The pumps will need

maintenance on par with usual diesel engine care which is

specified by the manufacturer and is dependent on the exact

model purchased. It is known that the design sacrifices the

inner pipe to preserve the more costly pressure vessel. It is

unknown how fast this inner pipe will deteriorate.

D. Potential Cost Reduction Opportunities

It is possible to make incremental alterations to the

design and reduce the overall cost. In doing this, one must

first attain an end goal and keep this in focus. For example,

the pressure requirement drives a major portion of the cost

in both the structural and mud subsystems. One might

correctly observe that reducing this requirement in the short

term would reduce the cost associated with the pumps and

the cost associated with the pressure vessel. The pumps

could then be scaled up over time making the cost

incremental and built into the budget over several years.

This is not the case with the pressure vessel though. Every

time the pressure capability is increased the pressure vessel

would have to be entirely rebuilt. In this way, the end goal

must be the beginning of any discussion on cost reduction.

With this being said, the two largest contributors to the

overall cost are the pressure and dynamic load requirements.

To this point it may be possible to decouple the static and

dynamic loads which may results in a size reduction for the

shakers. It is also safe to say that the flow and pressure

requirements are driving the operational cost through the

consumption of diesel. In conclusion, there are extensive

possibilities for system redesign driven by the desire for cost

reduction.

1) Vibration Systems

The majority of the strength requirements of the system

are driven by the static torsional loads. By reducing this

load, the size of the through-shafts can be reduced

significantly, and the size of the linkage piece can be

reduced. Since the diameter of the inner pipe and the

diameter of the overall pressure vessel are dependent on the

size of the transfer linkage, both of these systems can also

be reduced in size. Reducing the load from 50 kip-ft to 1

kip-ft allows the inner pipe to maintain a uniform diameter

of 10 inches, though this drastic of a stress reduction is not

recommended for proper operation of the system. We do not

have a good indication of the cost savings from this type of

system, but any reductions in the size of the pressure vessel

should reduce the cost of casting by a significant amount.

The size of the shakers are entirely dependent on the

lateral and axial static loads. By reducing the amplitude of

these loads, it is possible to get smaller shakers. Since we

were only able to get a ROM quote for the shakers, further

investigation will need to be done to determine the full cost

benefits of such a reduction in load.

2) Mud Systems

Each of the pumps individually are capable of meeting

the mud pressure requirement, but significant cost

reductions can be gained by reducing the flow rate

requirements. Each of the seven pumps can generate

approximately 140 gallons per minute, and by reducing the

flow rate requirements by increments of 140 gallons per

minute can reduce the acquisition cost by $1.2M per pump.

This cost reduction will compound in the operational costs,

since each pump requires its own control tower, diesel,

maintenance, piping and connections.

Page 5: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

II. CONCULSIONS

After final consideration, it was determined that the

creation of a testing facility was indeed feasible. Through

the use of thorough research, analyses, simulations, and

prototypes the designs for the facility were determined.

Several recommendations were made regarding risks for the

implementation of the designs as well as future projects.

III. AKNOWLEDGEMENTS

The team would like to acknowledge LORD Corporation

for their contribution to this project. Specifically, at LORD,

Zach Fuhrer, Keith Ptak, and Cortland Chapman for their

input and consideration throughout the project.

Several subject matter experts at Rochester Institute of

Technology were vital to the validation of the tests as well.

Specifically, Dr. Amitabha Ghosh, Dr. Marca Lam, Dr.

Stephen Boedo, Mr John Wellin, and Dr. Ali Ogut.

A special thanks to the team’s faculty guide, Gary Werth.

Page 6: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix C1: Load and Vibration Subsystem Bill of Materials

Appendix C2: Mud Subsystem Bill of Materials

Page 7: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix C3: Structural Subsystem Bill of Materials

Appendix C4: Controls Subsystem Bill of Materials

Page 8: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix C5: Total System Costs

Appendix C6: Total Yearly Operational Costs

Page 9: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix C7: Rough Order of Magnitude v. Quoted Materials

Page 10: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

www.ftimeters.com

Appendix E1: AHPS Quote 38985

Page 11: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix E2: American Piping Quote Dec 5

Appendix E3: Hydropac Pressure Vessel Quote

Page 12: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix E4: Mud Pressure Sensor Nov 16

8930 S. Beck Avenue, Suite 107, Tempe, Arizona 85284

Phone: (480) 240-3400 Fax: (480) 240-3401 e-mail: [email protected] website:

www.ftimeters.com

11/16/2016

Rochester Institute of Technology

Nicholas Fewell

1 Lomb Memorial Drive

Rochester, NY 14623

Dear Mr. Fewell,

Thank you for your interest in FTI Flow Technology products and your request for quotation. I am pleased to offer the following quotation for your review.

This quotation is based on the application information that you provided. Please contact me with any changes to this information as it could impact the recommendation.

Fluid : Drilling Mud 80% Water

Flow Range : 25 – 1220.0 GPM

Operating Temperature : Ambient

Operating pressure: Unknown

Temp vs. Viscosity of: 0.0585 kg/ms

Page 13: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Please contact your local representative for order processing or place your order directly with FTI Flow Technology.

Please contact me if you have any questions

Best Regards,

Mark Evans, Application Engineer

FTI Flow Technology Inc.

E-mail: [email protected]

Tel: 480-240-3303

Fax: 480-240-3401

Page 14: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

8930 S. Beck Avenue, Suite 107, Tempe, Arizona 85284

Phone: (480) 240-3400 Fax: (480) 240-3401 e-mail: [email protected] website: www.ftimeters.com

11/16/2016

To: Rochester Institute of Technology

Nicholas Fewell

1 Lomb Memorial Drive

Rochester, NY 14623

RFQ #: FTIMarket 11/15/2016

Quotation #: 0627243242MAE Please refer to this number when ordering

Phone: 585-475-2411

Fax:

E-mail: [email protected]

*Unless otherwise agreed in writing, FTI Flow Technology Standard Terms & Conditions of Sale apply

PRICE QUOTE

Item Description Qty Unit Price Subtotal

1.00 68707-AGA-AAA - Electromagnetic Flow Measurement System Consisting of:

Flowmeter Included: EL2200-100A15FE5CA

Transmitter Included: MC608A 90-264 VAC

1 $3,021.00 $3,021.00

Page 15: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Total $3,021.00

Terms & Conditions

Proposed Shipping Date 7 Weeks After Receiving Order

Payment Terms* 07 - CREDIT CARD TRA* upon approval

Shipping Method TBD Shipping Terms Prepaid and Added to Invoice

F.O.B. Factory, Tempe, AZ This Quotation is valid until 12/16/2016.

Unless otherwise agreed in writing, FTI Flow Technology Standard Terms & Conditions of Sale apply.

*Payment terms quoted are subject to credit review and/or approval at time of order placement.

FTI’s world class liquid and gas flow calibration lab offers the following:

• NVLAP ISO 17025 Accredited, with one of the best accuracies in the industry. • 50+ years of experience • 24-Hour turnaround available for most calibrations • Flowmeter repair & programming • All meter types (Electromagnetic, Coriolis, Turbine, PD, Variable Area & more)

Your local representative is:

Sentrol, Inc.

1 Roberts Rd

Plymouth, MA 02360

Ph: 508-830-0458

Fax: 508-830-0248

Web: www.nesentrol.com

Page 16: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix E5: Pressure Sensor Quote – Nov 30

Appendix E6: Pressure Vessel – Dec 5

Page 17: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix E7: Reciprocating Buffer Seal 7174 – Feb 13

Page 18: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix E8: Reciprocating Rod Seal 7158 – Feb 13

Page 19: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix E9: Reciprocating Wear Ring 7175 – Feb 13

Page 20: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix E10: Reciprocating Wiper Seal 7173 – Feb 13

Page 21: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix E11: Rotary Seal 7159 – Feb 13

Page 22: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Appendix E12: UD Shaker

Page 23: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Samuel Zimmerman <[email protected]>

Moog EM Actuators Rough Quote 2 messages

Victor, Elizabeth <[email protected]> Tue, Jan 31, 2017 at 5:42 PMTo: "Sam Zimmerman (RIT Student)" <[email protected]>

Hello Sam,

 

This quote is for order of magnitude only.  Moog will provide formal quote once detailed specifications arefinalized.

I recommend a call to discuss the quote below, all of your performance requirements, and respond to yourquestions.

 

 

                                                Model                                  Description                                                                       Sell Price (each)                Extended

Actuator                              -883-894A0300G11-A      460 VAC, 300mm stroke, no brake                           $9300                                    $37,200

Drive                                     G392-004-520P002           Options to provide many control possibilities     $2500                                    $10,000

Resolver Cable                 C08335-013-010                10M                                                                                       $225                                       $900

Power Cable                     C08336-001-0xx                10M, 460 VAC                                                                    $430                                       $1720

Total Extended Price (Estimate):              $49,820

Lead Time:          Drives and Cables - 8 weeks ARO (you may want to get drives in advanceto experiment) Actuators – 20 weeks ARO

Terms:                  Moog standard terms and conditions apply (see attached)

 

In Response to Your Questions:

1.       We need to apply 1000 lb of force for extended periods. What frame size would you suggest for thisapplication? see above

2.       What are the power requirements of one of these actuators? 460V 3-Phase, 4A power line

3.       We will be sending large amplitude vibrations through the actuators (up to 200 gs of shock), what kindof vibrations are these actuators designed to handle?

Page 24: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

For high shock we have selected a resolver based actuator.  

4.       If we were to use one of these actuators to assist in creating low frequency vibrations (1 or 2 Hz), whatkind of wear or life expectancy can we expect? We would want to discuss micro-motion profile with you as it does create wear on screw, balls andbearings. 

5.       Do they come with a MOOG control system or will we be on our own to design a control scheme? The drive will come with some limited control capabilities but will be requiring commands from a systemmaster. Moog can assist by phone to some extent to explain requirements.  RIT is responsible for overall controlscheme.

6.       Can they be load controlled or are they purely displacement controlled? Force, Velocity, Displacement control are all available.  

7.       How much would purchasing four of these units cost, including installation? Moog sells hardware (actuators, drives and cables) but does not provide installation. RIT would mount drives to a panel  or in cabinet If installation is required we would see about quoting test system through another group (test group).  Ourtest group may have interest in quoting actuators with controls in a package.  We can discuss during thecall.

 

Elizabeth Victor | Americas Sales Manager, Industrial Products

 

direct:   +17166874920

mobile:  +17168709850

email:   [email protected]

Moog Industrial Group

Seneca St & Jamison Rd

East Aurora, NY 14052

www.moog.com/industrial

 

Sign up for our Industrial Newsletter

 

 

 

 

From: Sam Zimmerman (RIT Student) [mailto:[email protected]] Sent: Tuesday, January 31, 2017 9:08 AM To: Victor, Elizabeth <[email protected]> Subject: Re: Moog EM Actuators

Page 25: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

 

Hi Elizabeth,

 

I hope you had a fantastic holiday season and a good January. We're still interested in getting a quote for these linearactuators. 

 

Hope to hear from you soon,

~Sam Zimmerman

RIT Student

 

On Wed, Dec 7, 2016 at 10:36 AM, Sam Zimmerman (RIT Student) <[email protected]> wrote:

Thanks! 

 

I will be at school for some of our holiday break, and our exams are next week. Even if you have a ballpark estimate, itwould go a long way if we could get that by tonight (12/7) for our gate review tomorrow. If not that's ok, but it woulddefinitely help get our project rolling. Thanks again for the assistance.

 

Sincerely,

 

~Sam Zimmerman

RIT Student

 

On Tue, Dec 6, 2016 at 8:24 PM, Victor, Elizabeth <[email protected]> wrote:

OK,

I will work up a quote.

Will you be at school over the holiday period?

When are exams (my son is in exam week now at another University)? I wish you lots of success…

 

 

 

From: Sam Zimmerman (RIT Student) [mailto:[email protected]]

Sent: Tuesday, December 06, 2016 11:24 AM

 To: Victor, Elizabeth <[email protected]> Subject: Re: Moog EM Actuators

 

Elizabeth,

Page 26: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

 

We need as much stroke as possible, 10 inches should be plenty. The part we're testing has a lot of elastomeric

elements and will likely require large displacements to apply the appropriate loads.

 

The system will already have 460 VAC nearby, so the higher voltage is probably better.

 

The tests can last up to a week, and the actuators will be changing applied load throughout the test.

 

~20 ft is a good approximation for cable length. This may change as we finish designing the system.

 

~Sam Zimmerman

RIT Student

 

On Tue, Dec 6, 2016 at 8:14 AM, Victor, Elizabeth <[email protected]> wrote:

Dear Sam,

 

This looks like a good fit for our  -883-892AxxxxG11-A.   Where the xxxx represents the stroke of the

actuator.

 

We are assuming 230 VAC is a better choice than 460 VAC, please confirm.

We recommend an a resolver feedback instead of encoder to tolerate the shock and vibration.

 

Other System Components

·         Drive to run this would be G392-004-520P002, it is loaded this with lots of options to provide

many control possibilities.

·         Power cable C22294-002-0xx or C08336-001-0xx where xx is cable length in meters

·         Resolver cable C08335-013-0xx where xx is cable length in meters

 

Questions

1.       What stroke length will you need for the actuator?

a.       Total stroke

b.      Working stroke

 

2.       Please confirm the 230VAC is best choice for input voltage.

 

3.       How long will the actuator be under full load? 

Page 27: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

a.       What does the duty cycle look like?

 

4.       What length cables will you require?

 

Once we have your responses we can give you a quote for the actuators.

If you want to set up a call to review the questions, I am happy to do so.

 

Best Regards

 

 

Elizabeth Victor | Americas Sales Manager, Industrial Products

 

direct:   +17166874920

mobile:  +17168709850

email:   [email protected]

Moog Industrial Group

Seneca St & Jamison Rd

East Aurora, NY 14052

www.moog.com/industrial

 

Sign up for our Industrial Newsletter

 

 

 

 

 

 

 

From: Sam Zimmerman (RIT Student) [mailto:[email protected]]

Sent: Thursday, December 01, 2016 10:50 AM

To: Victor, Elizabeth <[email protected]>

Subject: Re: Moog EM Actuators

 

Hi Elizabeth,

Page 28: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

 

We are currently in the design phase of the project and will likely not need the actuators for at least a year. Weare currently looking at the Standard Electric Linear Servo Actuators (high lead lengths). We had a few additionalquestions about the actuators before we can go ahead with them:

 

We need to apply 1000 lb of force for extended periods. What frame size would you suggest for this application?

What are the power requirements of one of these actuators?

We will be sending large amplitude vibrations through the actuators (up to 200 gs of shock), what kind ofvibrations are these actuators designed to handle?

If we were to use one of these actuators to assist in creating low frequency vibrations (1 or 2 Hz), what kind ofwear or life expectancy can we expect?

Do they come with a MOOG control system or will we be on our own to design a control scheme?

Can they be load controlled or are they purely displacement controlled?

How much would purchasing four of these units cost, including installation?

 

Thanks for getting back to me, I hope we can keep in contact.

 

~Sam Zimmerman

RIT Student

 

On Thu, Dec 1, 2016 at 10:41 AM, Victor, Elizabeth <[email protected]> wrote:

Dear Samuel

 

I did receive your request for actuators.

We are looking into sizing them now.  If we have any questions we will let you know.

By when do you need the actuators?

 

 

 

 

 

Page 29: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Elizabeth Victor | Americas Sales Manager, Industrial Products

 

direct:   +17166874920

mobile:  +17168709850

email:   [email protected]

Moog Industrial Group

Seneca St & Jamison Rd

East Aurora, NY 14052

www.moog.com/industrial

 

Sign up for our Industrial Newsletter

 

 

 

Confidentiality Notice: This electronic mail transmission is intended for the use of the individual or entity to which it isaddressed and may contain confidential and/or proprietary information belonging to the sender. If you are not theintended recipient, you are hereby notified that any disclosure, use, copying, distribution, or the taking of any action inreliance on the contents of this information is strictly prohibited. If you have received this transmission in error, pleasenotify the sender immediately by e-mail and delete the original message. Thank you for your cooperation.

 

 

Confidentiality Notice: This electronic mail transmission is intended for the use of the individual or entity to which it isaddressed and may contain confidential and/or proprietary information belonging to the sender. If you are not the intendedrecipient, you are hereby notified that any disclosure, use, copying, distribution, or the taking of any action in reliance onthe contents of this information is strictly prohibited. If you have received this transmission in error, please notify the senderimmediately by e-mail and delete the original message. Thank you for your cooperation.

 

 

Confidentiality Notice: This electronic mail transmission is intended for the use of the individual or entity to which it isaddressed and may contain confidential and/or proprietary information belonging to the sender. If you are not the intendedrecipient, you are hereby notified that any disclosure, use, copying, distribution, or the taking of any action in reliance on thecontents of this information is strictly prohibited. If you have received this transmission in error, please notify the senderimmediately by e-mail and delete the original message. Thank you for your cooperation.

 

 

Confidentiality Notice: This electronic mail transmission is intended for the use of the individual or entity to which it is addressed and maycontain confidential and/or proprietary information belonging to the sender. If you are not the intended recipient, you are hereby notified that anydisclosure, use, copying, distribution, or the taking of any action in reliance on the contents of this information is strictly prohibited. If you havereceived this transmission in error, please notify the sender immediately by e-mail and delete the original message. Thank you for yourcooperation.  

Page 30: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Moog ICD Terms and Conditions of Sale 2016  (002).pdf 47K

Sam Zimmerman (RIT Student) <[email protected]> Wed, Feb 1, 2017 at 10:59 AM

To: Daniel Bowers <[email protected]>

Update on total price of MOOG actuators.

~Sam Zimmerman

RIT Student

[Quoted text hidden]

Moog ICD Terms and Conditions of Sale 2016  (002).pdf 47K

Page 31: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Rochester Institute of Technology February 20, 2017 Proposal 52802GF

Attn : Nicholas FewellSubject : LN2 air cooler

In response to your request, we are pleased to offer the following quotation for one Xchanger, Inc. heat exchanger with specifications per the attached data sheet.

Model C-050, ref data sheet #131377 . . . . . . $ 4,840.00 Each

Standard lead time to shipment is 8 weeks after drawing approval. Lead time options and commercial information are on the following supplement. Design options are shown on the configuration page.

Please contact me if you have any questions.

Sincerely,

Gregg Fayer

Page 32: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

Quotation Supplement

All units are built to order. Upon receipt of an order we will make a drawing for yourconsideration, you can make changes (e.g. nozzle sizes, types, location, etc.), and we willrevise the drawing and resubmit. With drawing approval, the order will be released forfabrication; we will then send certified drawings and a formal order acknowledgment notingthe scheduled ship-date.

Payment terms: US$ by check, wire, ACH, or credit card (+3%); Net 30 with approved credit(+1%/month to extend). Foreign orders under $300 are subject to a $30 processing fee.Xchanger's Terms & Conditions apply. Terms & Conditions and the standard Installation,Operation, and Maintenance manual can be downloaded here.

Expedited Manufacturing AddersAvailability varies based on current production scheduling

Lead TimeWorking days*

BG, C, D, TV Series(e.g. BG-200, C-150, TV-100)

Replacement orBare Core

LC Series(e.g. LC-24)

AA, HR Series (e.g. AA-250, HR-500)

5 50% 25%

10 50% 25% 50% 15%

15 25% 15% 25% 10%

20 15% 10% 10% 5%

30 10% Standard Standard Standard

40 Standard -- -- --

*Working days start the day after drawing and credit approval, subject to availability,excluding weekends and holidays. Heresite coating typically adds about 10 working daysafter fabrication; exact timing can be more accurately forecast at the time of order. In the rareevent that an expedited shipment is late, the invoice is reduced pro-rata.

Shipment within North America: F.O.B. Hopkins, MN, collect or prepay & add. International shipment: Ex Works.

Cost for export packaging(domestic skidding is included)

Model ISPM-15 Crate

AA-250 & AA-400 $250

AA-500 & AA-750 $300

AA-1000 & AA-1750 $350

AA-2000+ $400

Other Ask

Last updated: 02/01/2017

Page 33: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

���������������������������������������������������������������������������������1 �Xchanger, Inc. Rating for Model C-050 ref #131377 Page 1 of 1����������������������������������������������������������������������������������

2 �Engineer: Gregg Fayer February 20, 2017����������������������������������������������������������������������������������

3 �Prepared for: ����������������������������������������������������������������������������������

4 � Rochester Institute of Technology ����������������������������������������������������������������������������������

5 � Nicholas Fewell ����������������������������������������������������������������������������������

6 � ����������������������������������������������������������������������������������

7 � ����������������������������������������������������������������������������������

8 �PERFORMANCE �PROCESS MEDIA SIDE �SERVICE MEDIA SIDE ����������������������������������������������������������������������������������

9 �Fluid Circulated �Air �Nitrogen ����������������������������������������������������������������������������������

10 �Volumetric Flow Rate � 10.0 Std. ftÆ3/min � ����������������������������������������������������������������������������������

11 �Total Fluid Entering � 44.6 lb/hr � 25.9 lb/hr ����������������������������������������������������������������������������������

12 � Liquid � � 25.9 lb/hr ����������������������������������������������������������������������������������

13 � Water Vapor � 0.6 lb/hr � 0.0 lb/hr ����������������������������������������������������������������������������������

14 � Non-Condensibles � 44.0 lb/hr � ����������������������������������������������������������������������������������

15 � Vaporized or (Cond.) � (0.6 lb/hr) � 25.9 lb/hr ����������������������������������������������������������������������������������

16 �Temperature In � 68.0 °F � -249.0 °F ����������������������������������������������������������������������������������

17 �Temperature Out � 0.0 °F � -220.0 °F ����������������������������������������������������������������������������������

18 �Inlet Pressure (Absolute)� 14.700 lb/inÆ2 � 313.6 lb/inÆ2 ����������������������������������������������������������������������������������

19 �Velocity (Standard)� 57.6 ft/min � 1.8 ft/sec ����������������������������������������������������������������������������������

20 �Pressure Loss � 0.2 in. water � 0.0 lb/inÆ2 ����������������������������������������������������������������������������������

21 �Fouling Factor � 0.00010 ftÆ2-°F-hr/BTU � 0.00100 ftÆ2-°F-hr/BTU ����������������������������������������������������������������������������������

22 �Total Heat Exchanged: 1,380 BTU/hr (645 BTU/hr Latent) ����������������������������������������������������������������������������������

23 � ����������������������������������������������������������������������������������

24 �AVERAGE MEDIA PROPERTIES ����������������������������������������������������������������������������������

25 �Thermal Conductivity � 0.014 BTU/hr-ft-°F � N/A ����������������������������������������������������������������������������������

26 �Specific Heat � 0.242 BTU/lb-°F � N/A ����������������������������������������������������������������������������������

27 �Absolute Viscosity � 0.041 lb/ft-hr � N/A ����������������������������������������������������������������������������������

28 �Density (MW) � (28.7) � N/A ����������������������������������������������������������������������������������

29 �Latent Heat of Vapor � 1,081.3 BTU/lb � 45.8 BTU/lb ����������������������������������������������������������������������������������

30 � ����������������������������������������������������������������������������������

31 �CONSTRUCTION ����������������������������������������������������������������������������������

32 �Design Temperature � 300 °F � 200 °F ����������������������������������������������������������������������������������

33 �Design Pressure (Gauge)� 1.0 lb/inÆ2 � -14.7 to 350.0 lb/inÆ2 ����������������������������������������������������������������������������������

34 �Test Pressure (Gauge)� � 300.0 lb/inÆ2 ����������������������������������������������������������������������������������

35 �Test Procedure �No Test �Bubble Test ����������������������������������������������������������������������������������

36 �ASME Code Stamp �Not Applicable �Not Applicable ����������������������������������������������������������������������������������

37 � ����������������������������������������������������������������������������������

38 �Tube Material : 304L Stainless Steel�Housing Material : 304 Stainless Steel ����������������������������������������������������������������������������������

39 �Fin Material : Aluminum �Casing Material : 304L Stainless Steel ����������������������������������������������������������������������������������

40 �Sealant Material : Teflon �Phenolic Coating : None ����������������������������������������������������������������������������������

41 �Removable Core : Yes, Front Only �Mist Eliminator : None ����������������������������������������������������������������������������������

42 �Tube Circuit Type: Nontrapped �Gas Flow Dir. : Right Hand Horizontal����������������������������������������������������������������������������������

43 �Dry Weight : 69 lb �Wet Weight : 70 lb ����������������������������������������������������������������������������������

44 �Thermometers : None �Mod. Water Valve : None ����������������������������������������������������������������������������������

45 �Diff. Pres. Gauge: None �Auto. Drain Trap : None ����������������������������������������������������������������������������������

46 � ����������������������������������������������������������������������������������

47 �CONNECTIONS ����������������������������������������������������������������������������������

48 �Process Inlet : 1" Male NPT ����������������������������������������������������������������������������������

49 �Process Outlet : 1" Male NPT ����������������������������������������������������������������������������������

50 �Service Inlet : 0.75" plain end ����������������������������������������������������������������������������������

51 �Service Outlet : 0.75" plain end ����������������������������������������������������������������������������������

52 � ����������������������������������������������������������������������������������

53 �NOTES ����������������������������������������������������������������������������������

54 �Approximate unit dimensions (inches): A = 15, B = 32, C = 21, D = 8 ����������������������������������������������������������������������������������

55 �Construction material suitability must be determined by customer. ����������������������������������������������������������������������������������

56 �The process flow must be uniform, smooth, and free of pulsation. ����������������������������������������������������������������������������������

57 �This unit is not designed for cycling process gas pressure. ����������������������������������������������������������������������������������

58 �Frost development is possible. Periodic thawing may be required. ����������������������������������������������������������������������������������

59 �It is unlikely that condensate will carry-over in process stream. ����������������������������������������������������������������������������������

60 � ����������������������������������������������������������������������������������

61 � ����������������������������������������������������������������������������������

62 � ����������������������������������������������������������������������������������

xchanger.com 952-933-2559

Page 34: LORD Corporation Downhole Test Simulator …edge.rit.edu/edge/P17301/public/Final Documents...LORD Corporation Downhole Test Simulator Feasibility Study ... Suppliers for this pipe

C Series Heat Exchanger

C Series exchangers can heat, cool, dehumidify & filter air at pressures from -15 to +50 PSI with under 0.2 PSIpressure loss. Service can be cooling water, refrigerant, steam, & cryogenic liquids. C Series exchangers consist offin-tube core(s) inside an air-tight housing. The service fluid flows inside the tubes, air flows across the fins. The airshould be filtered and pulsating flow, such as that produced by rotary lobe blowers, should be dampened by achambered silencer prior to entering the heat exchanger. Cores can optionally be removed through the front or rearcovers.

SEE LINE #52 OF DATA SHEET FOR APPROXIMATE DIMENSIONS

Design Options:• Connection types: tube, pipe, flange, NPT, ferrule, etc• Materials of construction: carbon or stainless steel, copper,

aluminum, cupro-nickel, Hastelloy, etc• Epoxy phenolic coating for corrosion protection of the core• Mist eliminator to prevent condensate carryover• Inspection/Access ports• Air filters: HEPA pleated, metal, etc• Units can be built to required dimensions• Drainable tube circuiting for freezing protection

Accessories: • Instrument Coupling $ 60• Thermometer (Includes Coupling) $ 90• Differential Pressure Gauge $ 280• Automatic Drain Trap (3/4”, 330 lb/hr) $ 390• Temperature Control Valve (Regulates coolant flow to

maintain a constant exiting gas temperature)3/4”, 30 GPM $ 7501”, 50 GPM $ 7902”, 100GPM $ 2,500

• Others available upon request