Turbine Flow Loop Report

Performance beyond Expectation
Unit 3, 79 High Street, Pershore, Worcestershire. WR10 1EX. Tel: 05603121643

www.turbinedynamics.com
Turbine alternator flow loop test report.

Document Created 20th August 2008.
Revision 1.
Last Modified 26th August 2008.
Author: Greg Spring, Turbine Dynamics Ltd.
1.0) Introduction.
There are two types of independent electrical power source used for all down hole MWD/LWD
instrumentation, batteries and alternators/generators. Wireline has been eliminated from this
discussion because it derives its power from the surface and is therefore not an independent power
source. Batteries sub divide into low temperature alkaline and high temperature Lithium ion and
continue to serve the drilling industry very well. However, whilst batteries offer a very cost effective
solution for low power instrumentation, their inherent limitations quickly surface when high power
demands in combination with high temperature is needed. High powered battery stacks also become
very lengthy liabilities on the Cat Walk due to the magnitude of their stored energy and therefore
pose a significant threat for explosion and/or fire. Service companies have to implement various fail
safe measures to ensure their battery operated equipment does not accidentally become live at the
Well Head because of this potential danger. Lithium ion batteries can also explode if subjected to
excessive shock, e.g. dropped or subjected to sustained vibration, doubling their hazard at the point
of entry on the rig site. Taking into account their initial cost, length, weight, limited power and down
hole life, high temperature leakage and final disposal costs, Lithium battery stacks become a costly
and inefficient choice of primary power for demanding MWD/LWD applications.
Mud alternators, otherwise known in the industry as mud turbines or mud generators do not suffer
from any of these problems being electrically inert when handled on the rig surface and only
generate significant levels of power when safely disposed down hole. For high power applications
they are more volumetrically efficient than battery stacks and for all practical purposes have an
unlimited energy capacity (Watt.Hours) when compared to batteries. These features make alternators
a more practical power source than batteries for high temperature, high power down hole
applications like EM Telemetry which can deliver a fast and continuous stream of steering and
surveying data regardless of the hydraulic conditions down hole. However, EM Telemetry frequently
fails to live up to this promise due to the limitations imposed by the batteries used to power these
Page 1 of 20
Copyright: Turbine Dynamics Ltd. All rights reserved. This document may not be reproduced either
in whole or in part without prior written permission from the author or the company. 2008
tools. Considering an average bit run is 350+ hours, batteries are simply not a good fit for EMT or
any other high power MWD/LWD application and therefore the only other realistic power source is
a mud alternator.
2.0) Open or Closed Loop
Until Turbine Dynamics successfully designed the Worlds first closed loop alternator, all down hole
mud alternators were by definition, open loop. This meant that the raw rectified output voltage from
the alternator was dependent upon the mud flow rate through the impeller blades. The faster the mud
flow, the faster the impeller turned and the higher the alternators output voltage. In an ideal
instrumentation string, all the tools in that string would be arranged to work with a common and
optimum flow rate. However, this ideal assembly is sometimes not possible and one or more tools
are therefore forced to run with sub optimal flow rate. This can lead to either under performance if
the flow rate is too low or excessive erosion if the flow rate is too high. Optimal flow conditions for
the entire instrumentation string is therefore not always possible and a tool which can automatically
adjust itself to compensate for sub optimal flow would bring commercial benefit to the Service
Companies operating them and practical benefit for their field engineers.
To some extent turbine manufacturers have minimised the problem of sub optimal flow by shipping
several different blade profiles with each mud alternator so that they can be matched to the
prevailing on site flow conditions. Although this tactic has been successful over the years, it carries
with it greater overhead costs in the form of design, inventory, transportation and general
management costs and has therefore been a necessary but inefficient expedient to overcome a
fundamental disadvantage of using conventional open loop mud alternators. This tactic also fails to
overcome the influence of human error which is known the thwart even the best laid drilling plans.
A much more serious operational consequence of using a free running open loop alternator is the
high voltage stress they cause to down hole, down stream electronic instrumentation. Open loop
alternators are post processed by an electronic switch mode power supply to convert the alternators
raw DC to one or more regulated supplies suitable for down hole instrumentation; usually +5V
(+3V3) for processors and other logic and 12V for analogue circuits. Spinning at very high rpm,
some extant open loop alternators generate up to 150V DC which adds significant voltage stress to
the switch mode power supply. This in turn, causes significant internal heating and in a 150C
environment, the heat loss can raise the die temperature of the electronics well above 175C,
reducing conversion efficiency, power transfer and reliability. High voltage stress at high ambient
temperature is therefore the most common cause for switch mode power supply failure, so by
eliminating the high voltage stress at source, the long term reliability and efficiency of all down
stream MWD/LWD electronics is improved.
3.0) The Closed Loop Alternator
The Turbine Dynamics closed loop alternator is the Worlds first machine to solve this problem by
breaking the link between flow rate and output voltage. For the first time, the raw rectified alternator
output is available directly as a high power regulated voltage source enabling much more ambitious
drilling instrumentation to be planned without any loss to the flexibility and convenience of this type
of machine. Although these test results were taken at 30V, the machine is easily programmed for any
output voltage and is therefore a customer configurable variable. The choice of 30V for these tests
was to highlight the fact that this machine could easily replace or complement existing 30V Lithium
Ion battery stacks without affecting the design of the extant drilling steering and/or surveying
Page 2 of 20
instrumentation. The advantages of closed loop control over open loop alternators can be
summarised in the following table:
Statement
Open Loop
Closed Loop
Comments
Yes
No
Open loop cannot protect itself against

changing flow conditions
Mechanical
Flow Rate Dependent
Automatic Flow
Density Compensation
Excessive RPM
Tool Length
Impellers
Optimum Flow Range
No
Yes
Slightly
Shorter
Many
Narrow
Yes
No
Slightly
Longer
Open loop cannot defeat changes in

mud density, e.g. under balanced
drilling fluid.
One
Open loop optimisation means

carrying several impellers to suit each
job. Closed loop = One.
Wide
Closed loop expands the operating

range of any tool. Open loop relies on
specific impellers for each job.
Repeatability
Average
Excellent
Closed loop guarantees repeatability

of machines by minimising the effects
of manufacturing tolerance and
component errors.
Bearing Life
Good
Excellent
Closed loop optimises rotor speed and

minimises bearing losses.
Impeller Life
Good
Excellent
Closed loop optimises rotor speed and

minimises impeller erosion.
Yes
No
Electrical
Excessive output voltage
Output Resistance
100 Watt 175C variant
100 Watt 200C variant
Load Regulation
Medium
Difficult
Very Difficult
Very Low
Easy
Possible
Acceptable
Excellent
Electronic Post Regulation
Yes
Optional
Switchable OL/CL
No
Yes
Open Loop R depends upon the

design of the alternator. Closed loop
significantly reduces output R for any
machine.
Less dependency on electronics
means higher power, higher
temperature machines are easier to
design and manufacture.
Both open and closed loop design
routes limited by 200C silicon, but
closed loop still easier to achieve.
Open loop load regulation is
dependant upon the quality of the
design. Closed loop regulation is
always excellent.
Open loop electronic regulation is a
necessity, not an option. Closed loop
electronic regulation is optional.
If required, closed loop control can be
switched off.
Page 3 of 20
4.0) Tool Dimensions and Flow Loop Conditions.

The 100 Watt closed loop alternator used for these tests was 55mm OD x 1600mm long and fitted
with a 76mm OD impeller, designed for a 3 ID collar. The alternator was flow tested with a low,
medium and high flow impeller at normal temperature and atmospheric pressure using a water glycol
mix from 200GPM 600GPM. A 1000uF, 200V reservoir capacitor was used to smooth the rectified
30V DC regulated output.
5.0) Engineering Drawing of the closed loop alternator used for these tests.
Fig 1: Partial cut away drawing of the closed loop alternator.
Page 4 of 20
6.0) Flow Loop Data.

The spreadsheet plots presented in this report prove that a closed loop mud alternator can maintain a
regulated output within a flow range of 250GPM 600GPM with only one, low flow impeller. This
data proved that the traditional method of shipping two or more sets of flow gear with every tool to
ensure it can match on site flow conditions is redundant, saving equipment and overhead costs for
every tool and every job. The high, medium and low flow impellers used for these tests were cut
with 20 degree, 25 degree and 30 degree blade profiles respectively. To illustrate the dramatic
difference between open and closed loop control, each impeller was also tested open loop and these
plots lead each discussion.
7.0) Open and Closed Loop Flow Data.

7.1) 20 Degree Impeller Open Loop Voltage.
Fig 2 illustrates the performance of the alternator fitted with a 20 degree impeller and configured as
an open loop machine. The open loop rectified output voltage was recorded against flow rate for
various step loads from open circuit to 5R as shown on the graph. This is a typical voltage verses
speed response available from any open loop alternator where the precise voltage to speed
characteristic is primarily determined by the impeller. Note that the rectified output voltage falls
with load as would be expected from any machine of this type.
ALTERNATOR OUTPUT (DC VOLTS)
OPEN LOOP ALTERNATOR RECTIFIED DC OUTPUT VOLTAGE VS FLOW RATE AND LOAD WITH A 20 DEG IMPELLER
60
50
O/C
40
1000R
500R
300R
100R
30
50R
25R
20R
20
10R
5R
10
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Fig 2: Open loop voltage vs flow rate & load with a 20 degree impeller.
Page 5 of 20
7.2) 20 Degree Impeller Open Loop Power.

Fig 3 illustrates the open loop output power of the alternator fitted with a 20 degree impeller.
OPEN LOOP OUTPUT POWER (Watts)
OPEN LOOP ALTERNATOR OUTPUT POWER VS FLOW RATE AND LOAD WITH A 20 DEG IMPELLER.
80
70
60
O/C
1000R
500R
50
300R
100R
40
50R
25R
30
20R
10R
5R
20
10
0
200
250
300
350
400
450
500
550
600
Flow Rate (GPM)
Fig 3: Open loop output power vs flow rate & load with a 20 degree impeller.
Page 6 of 20
7.3) 20 Degree Impeller Closed Loop Voltage.

Fig 4 illustrates the performance of the alternator fitted with the same 20 degree impeller, but this
time configured as a 30V regulated closed loop machine. The rectified output voltage was recorded
against flow rate for various step loads from open circuit to 5R as shown on the graph. This data
showed that the flow rate had to exceed 400GPM before 30V regulation could occur with a 20 deg
impeller. Although suitable for the higher flow ranges, this impeller was not an optimal choice for
the entire flow range of 200GPM 600GPM.
CLOSED LOOP ALTERNATOR OUTPUT VOLTAGE VS FLOW RATE AND LOAD WITH A 20DEG IMPELLER
35
30
O/C
25
1000R
500R
20
300R
100R
50R
15
25R
20R
10R
10
5R
5
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Fig 4: Closed loop voltage vs flow rate & load with a 20 degree impeller.
Page 7 of 20
7.4) 20 Degree Impeller Closed Loop Output Power.

Fig 5 illustrates the relationship between output power and flow rate from the machine. As expected,
alternator power increased with flow rate, but as will become evident from this and later graphs,
closed loop control limits the maximum power available from the alternator making the machine
much more predictable down hole where there is less control over actual flow rate. This can be
interpreted as a useful safety feature for the protection of expensive MWD/LWD instrumentation
systems. Note the flat power characteristic from open circuit to 20R was lost for 10R & 5R loads
because the alternator couldnt generate 30V under these circumstances and therefore represent open
loop power curves.
CLOSED LOOP ALTERNATOR OUTPUT POWER VS FLOW RATE AND LOAD WITH A 20DEG IMPELLER
OUTPUT POWER (WATTS)
80
70
60
O/C
1000R
50
500R
300R
100R
40
50R
25R
30
20R
10R
5R
20
10
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Fig 5: Closed loop output power vs flow rate & load with a 20 degree impeller.
Page 8 of 20
7.5) 20 Degree Impeller Closed Loop Rotor Speed.

Fig 6 illustrates the change in rotor speed with flow rate and load. These plots illustrate how the
machine constantly adjusted its rotor dynamics to maintain closed loop control and a constant output
voltage against changes in flow rate and/or load. Note that with a 20 degree impeller, the machine
behaviour was open loop below 400GPM and closed loop above 400GPM.
ALTERNATOR ROTOR SPEED (RPM)
CLOSED LOOP ALTERNATOR ROTOR SPEED VS FLOW RATE AND LOAD WITH A 20DEG IMPELLER
1600
1400
1200
O/C
1000R
1000
500R
300R
100R
800
50R
25R
600
20R
10R
5R
400
200
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Fig 6: Closed loop rotor speed vs flow rate & load with a 20 deg impeller.
Page 9 of 20

with load as would be expected from any machine of this type.
80
70
60
O/C
1000R
50
500R
300R
100R
40
50R
25R
30
20R
10R
5R
20
10
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Page 10 of 20

OPEN LOOP OUTPUT POWER (WATTS)
OPEN LOOP ALTERNATOR OUTPUT POWER VS FLOW RATE AND LOAD WITH A 25 DEG IMPELLER
140
120
O/C
100
1000R
500R
80
300R
100R
50R
60
25R
20R
10R
40
5R
20
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Page 11 of 20

Fig 9 illustrates the performance of the alternator fitted with the same 25 degree impeller configured
as a 30V regulated closed loop machine. The rectified output voltage was recorded against flow rate
for various step loads from open circuit to 5R as shown on the graph. This data showed that with a
25 deg impeller, the flow rate to achieve 30V regulation fell to only 300GPM compared to 400GPM
for the 20 deg impeller. Although suitable for the medium flow ranges, this impeller was still not an
optimal choice for the entire flow range of 200GPM 600GPM.
35
30
O/C
25
1000R
500R
20
300R
100R
50R
15
25R
20R
10R
10
5R
5
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Fig 9: Closed Loop Voltage vs flow rate & load with a 25 degree impeller.
Page 12 of 20

Fig 10 illustrates the relationship between output power and flow rate from the machine. As
expected, output alternator power increased with flow rate, but this graph also confirmed that closed
loop control limits the maximum power available from the alternator creating a safer power delivery
system for MWD/LWD instrumentation systems.
CLOSED LOOP ALTERNATOR POWER OUTPUT VS FLOW RATE AND LOAD WITH A 25DEG IMPELLER
100
90
80
70
O/C
1000R
500R
60
300R
100R
50
50R
40
25R
30
20
10R
20R
5R
10
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Page 13 of 20

Fig 11 illustrates the change in rotor speed with flow rate and load. By maintaining closed loop
control of rotor above 300GPM, the machine constantly adjusted its rotor dynamics to maintain a
regulated 30V output voltage regardless of changes to flow rate or load.
2000
1800
1600
O/C
1400
1000R
500R
1200
300R
100R
1000
800
50R
25R
20R
10R
600
400
5R
200
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Page 14 of 20

with load as would be expected from any machine of this type. This graph read in combination with
Fig 13 illustrates the disadvantages of open loop mud alternators more than any of the previous
graphs. Fitted with a low flow, 30 degree impeller, the open loop rectified output voltage swings
between 6V and 90V depending upon flow rate and load. A switch mode power supply fitted to this
alternator would therefore have to convert this entire voltage spread into much lower instrumentation
voltages safely and efficiently and at high temperature. Whilst this can be achieved optimally for low
voltage inputs, e.g. 30V 40V, 220GPM 300GPM, the series switch mode power supply becomes
less efficient for higher input voltages caused by higher flow rates. It is unrealistic and impractical to
insist the drilling engineer restricts flow rate to such low levels simply to satisfy the particular
demands of the switch mode power supply, therefore the only other solution is to limit the rectified
output over the entire flow range which is what the closed loop alternator has succeeded in doing.
100
90
80
O/C
70
60
1000R
500R
300R
100R
50
40
50R
25R
20R
10R
30
20
10
0
200
5R
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Page 15 of 20

Whilst this graph illustrates the full open loop potential of the alternator, there is no control over the
power delivered to the load as illustrated by Fig 15. Using the alternator in closed loop not only
controls the output voltage, but indirectly limits the maximum power available to the load.
OPEN LOOP ALTERNATOR OUTPUT POWER VS FLOW RATE AND LOAD WITH A 30 DEG IMPELLER.
250
200
O/C
1000R
500R
150
300R
100R
50R
25R
100
20R
10R
5R
50
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Page 16 of 20

Fig 14 illustrates the performance of the alternator fitted with the same 30 degree impeller
configured as a 30V regulated closed loop machine. The rectified output voltage was recorded
against flow rate for various step loads from open circuit to 5R as shown on the graph. This data
showed that the flow rate only had to exceed 250GPM before 30V regulation could occur with this
impeller. Normally only suitable for the low flow ranges, this graph proved that a closed loop
alternator could work with this impeller over the entire flow range of 200GPM 600GPM obviating
the need for any other impellers to match higher flow rates as is required for conventional open loop
machines.
35
30
O/C
25
1000R
500R
20
300R
100R
50R
15
25R
20R
10R
10
5R
5
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Fig 14: Closed Loop Voltage vs flow rate & load with a 30 degree impeller.
Page 17 of 20

Fig 15 illustrates the relationship between output power and flow rate from the machine. As
expected, output alternator power increased with flow rate, but closed loop control limits the
maximum power available from the alternator creating a safer power delivery system for
MWD/LWD instrumentation systems.
CLOSED LOOP ALTERNATOR POWER OUTPUT VS FLOW RATE AND LOAD WITH A 30DEG IMPELLER
100
90
80
O/C
70
60
1000R
500R
300R
100R
50
40
50R
25R
20R
10R
30
20
5R
10
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Page 18 of 20

Fig 16 illustrates the change in rotor speed with flow rate and load. By maintaining closed loop
control of rotor above 250GPM, the machine constantly adjusted its rotor characteristics to maintain
a regulated 30V output voltage regardless of changes to flow rate or load.
2500
2000
O/C
1000R
500R
1500
300R
100R
50R
25R
1000
20R
10R
5R
500
0
200
250
300
350
400
450
500
550
600
FLOW RATE (GPM)
Page 19 of 20
8.0) Report Conclusions.

All mud alternators develop an output voltage and extract their power from mud flow through the
blades of their impeller. Alternator output voltage and power is therefore inextricably linked to flow
rate; the higher the flow rate, the greater the voltage and power that can be extracted from the mud.
A conventional open loop mud alternator responds directly to flow rate and passes the high voltage
and hence the high thermal stress of a high flow condition to the down stream electronic regulator. In
some cases, the combination of these extremes leads to failure of the down stream electronics and
potential failure of the down hole steering, surveying or other instrumentation service.
It is well known that high down hole temperature affects the resistance of copper based instruments
and changes their characteristics. Local feedback and other forms of temperature compensation in
these instruments minimises the disturbing effects of high temperature and by using the same
principles, feedback wrapped around an alternator minimises the disturbing effect of down hole
temperature, changes in flow rate, mud density, output load and wear and tear to the machine caused
by flow erosion. Although no erosion tests have been conducted to date to prove this assertion, its
truth is implied by the three sets of impeller data presented in this report. In all three cases, the
closed loop alternator was able to automatically compensate for coarse changes in impeller blade
angle and maintain a regulated 30V DC output once there was sufficient flow to maintain regulation
under load.
One objective of the Turbine Dynamics closed loop alternator project was to remove the open loop
relationship between flow rate and output voltage by controlling the alternators rotor speed and
therefore limit and regulate the rectified output voltage to some predetermined level; typically 30V
for compatibility with existing battery stacks and MWD/LWD instrumentation. Another objective
was to demonstrate that under closed loop control, a mud alternator would become a down hole, self
regulating machine capable of automatically compensating for changes in flow rate, output load and
machine characteristics. The data presented by this report proved that both of the first two objectives
were achieved and the third objective is claimed by the use of alternate impellers to simulate worst
case erosion applied to the low flow blade profile. Final proof will be available once the design has
been subjected to flow loop erosion tests and field trials.
Report End: 26th August 2008.
Page 20 of 20

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Performance beyond Expectation

Unit 3, 79 High Street, Pershore, Worcestershire. WR10 1EX. Tel: 05603121643

Turbine alternator flow loop test report.

Open loop cannot protect itself against

Optimum Flow Range

Open loop cannot defeat changes in

Open loop optimisation means

Closed loop expands the operating

Closed loop guarantees repeatability

Closed loop optimises rotor speed and

Closed loop optimises rotor speed and

100 Watt 175C variant

100 Watt 200C variant

Electronic Post Regulation

Open Loop R depends upon the

4.0) Tool Dimensions and Flow Loop Conditions.

Fig 1: Partial cut away drawing of the closed loop alternator.

6.0) Flow Loop Data.

7.0) Open and Closed Loop Flow Data.

ALTERNATOR OUTPUT (DC VOLTS)

FLOW RATE (GPM)

7.2) 20 Degree Impeller Open Loop Power.

OPEN LOOP OUTPUT POWER (Watts)

Flow Rate (GPM)

7.3) 20 Degree Impeller Closed Loop Voltage.

ALTERNATOR OUTPUT (DC VOLTS)

FLOW RATE (GPM)

7.4) 20 Degree Impeller Closed Loop Output Power.

OUTPUT POWER (WATTS)

FLOW RATE (GPM)

7.5) 20 Degree Impeller Closed Loop Rotor Speed.

ALTERNATOR ROTOR SPEED (RPM)

FLOW RATE (GPM)

7.6) 25 Degree Impeller Open Loop Voltage.

ALTERNATOR OUTPUT (DC VOLTS)

FLOW RATE (GPM)

7.7) 25 Degree Impeller Open Loop Power.

OPEN LOOP OUTPUT POWER (WATTS)

FLOW RATE (GPM)

7.8) 25 Degree Impeller Closed Loop Voltage.

ALTERNATOR OUTPUT (DC VOLTS)

FLOW RATE (GPM)

7.9) 25 Degree Impeller Closed Loop Output Power.

OUTPUT POWER (WATTS)

FLOW RATE (GPM)

7.10) 25 Degree Impeller Closed Loop Rotor Speed.

ALTERNATOR ROTOR SPEED (RPM)

FLOW RATE (GPM)

7.11) 30 Degree Impeller Open Loop Voltage.

ALTERNATOR OUTPUT (DC VOLTS)

FLOW RATE (GPM)

7.12) 30 Degree Impeller Open Loop Power.

OUTPUT POWER (WATTS)

FLOW RATE (GPM)

7.13) 30 Degree Impeller Closed Loop Voltage.

ALTERNATOR OUTPUT (DC VOLTS)

FLOW RATE (GPM)

7.14) 30 Degree Impeller Closed Loop Output Power.

OUTPUT POWER (WATTS)

FLOW RATE (GPM)