DECLARATION PARIMAL K. KAPADIYA( ) PRASHANT H. BHATT( ) DHAVAL B. SODHA( )

Transcription

1 DECLARATION We hereby declare that the project entitled SUCKER ROD PUMP submitted in partial fulfillment for the degree of Bachelor of Engineering in Mechanical Engineering to technological university, Ahmedabad, is a bonafied record of the project work carried out at under the supervision of HARDIK CHAUHAN and that no part of the UDP has been represented earlier for any degree, diploma, associate ship, fellowship or other similarity of any other university or institute PARIMAL K. KAPADIYA( ) PRASHANT H. BHATT( ) DHAVAL B. SODHA( )

2 PROJECT REPORT SUCKER ROD PUMP Submitted by PARIMAL KAPADIYA PRASHANT BHATT DHAVAL SODHA Under the guidance of Prof. HARDIK CHAUHAN In fulfillment for the award of the degree Of BACHELOR OF ENGINEERING In Mechanical Engineering Department Atmiya institute of technology & science, Rajkot Gujarat Technological University, Ahmadabad May, 2013

3 Atmiya Institute of Technology & Science Mechanical 2013 CERTIFICATE Date: This is to certify that the dissertation entitled SUCKER ROD PUMP" has been carried out by PRASHANT BHATT, DHAVAL SODHA, PARIMAL KAPADIYA under my guidance in the fulfillment of the degree of Bachelor of Engineering in Mechanical (8 th Semester) Technological University, Ahmadabad during the academic year Guide By: Prof. Hardik Chauhan Prof. P. S. Puranik Head of the Department

4 EXAMINER S CERTIFICATE OF APPROVAL The project report entitled SUCKER ROD PUMP submitted PRASHANT BHATT ( ), DHAVAL SODHA ( ), PARIMAL KAPADIYA( ) in partial fulfillment of the requirement for the award of the degree in Bachelor Of Engineering In Mechanical Engineering of Atmiya inst. of tech & science, Rajkot is here by approved. EXAMINERS: 1. 2.

5 ACKNOWLEDGEMENT We take this opportunity to express our deep sense of gratitude and respect towards our guide Prof. Hardik Chauhan. We are very much indebted to his for the generosity, expertise and guidance. Without his support and timely guidance, the completion of our report would have seemed a farfetched dream. In this respect we find ourselves lucky to have his as our guide. He has guided us not only with the subject matter, but also taught us the proper style and technique of working and presentation. We take very grateful to respected H.O.D. Mr. P.S.Puranik sir and all the staff members of the department of Mechanical Engineering for their constant encouragement and all those who helped us directly or indirectly in our endeavor. I

6 ABSTRACT The impressive agility of living systems seems to stem from modular sensing, actuation and communication capabilities, as well as intelligence embedded in the mechanics in the form of active compliance. As a step towards bridging the gap between man-made machines and their biological counterparts, we developed a class of soft mechanisms that can undergo shape change and locomotion under pneumatic actuation. Sensing, computation, communication and actuation are embedded in the material leading to an amorphous, soft material. Soft mechanisms are harder to control than stiff mechanisms as their kinematics are difficult to model and their degrees of freedom are large. Here we show instances of such mechanisms made from identical cellular elements and demonstrate shape changing, and autonomous, sensor-based locomotion using distributed control. We show that the flexible system is accurately modeled by an equivalent spring-mass model and that shape change of each element is linear with applied pressure. We also derive a distributed feedback control law that lets a belt-shaped robot made of flexible elements locomotive and climb up inclinations. These mechanisms and algorithms may provide a basis for creating a new generation of biometric soft robots that can negotiate openings and manipulate objects with an unprecedented level of compliance and robustness. II

7 List of Figures:- Fig. No. Fig. Name Page No. 3.1 Rod Pump Overview Subsurface Pump Working of SRP Component of Sucker Rod Pump Operational detail of Sucker Rod Pump Plunger Valve and Balls Design of Sucker Rod Pump Rubber Bush Base Plate of Bush Base Support Plate Vertical Pillar Inclined Rod Fulcrum Support Connecting Rod Back Support Oscillating Rod Crank Staring Cover Metal Sheet Gear Motor Stuffing Box 22 List of Tables:- Table No. Name of the table Page No. 1 Process Chart 23 2 Requirement Of MFG 24 3 Costing Chart 25 III

8 Sr No. TITLE ACKNOLEDGEMENT ABSTRACT LIST OF FIGURES LIST OF TABLES CONTENTS Page No. I II III III 1 INTRODUCTION 1 2 LITTERATURE REVIEW 2 3 ROD PUMP OVERVIEW Rod Pump Overview Subsurface Pump 4 4 DESCRIPTION AND WORKING OF SRP Working Principle Basic Figure of SRP Explanation of How it is Work/It used Plunger Valve and Balls 8 5 DESIGN OF SUCKER ROD PUMP Design of Sucker Rod Pump 9 6 DESIGN OF COMPONENT Component Rubber Bush Base plate of bush Base support plate Vertical pillar Inclined rod Fulcrum support Connecting rod Back support Oscillating rod 18

9 Sr.No. TITLE Page No Crank Staring Cover Metal Sheet Gear Motor Stuffing box 22 7 ESTIMATING AND COSTING Process Chart Requirement For MFG Machine Requirement Costing Chart Troubleshooting Notes 26 8 REAL TIME WORKING OF MODEL Figure Figure ADVANTAGES AND DISADVANTAGES Advantages Disadvantages REFERANCE 30

10 CHAPTER-1 INTRODUCTION Pump is generally is used for increase potential energy of fluid. In real life we using pump For suck and supply fluid from lower level to higher level and one place to another place respectively. In petrochemical industry we required to suck crude oil from depth of earth. For above purpose we are using sucker rod pump. which is currently in use by different industries like ONGC, RELIANCE,HP etc A sucker rod pump (nodding donkey, pumping unit, horse head pump, beam pump, sucker rod pump (SRP), grasshopper pump, thirsty bird, jack pump) is the over ground drive for a reciprocating piston pump in an oil well. The Sucker Rod Pump brings underground oil to the earth's surface. It is driven by a motor which turns a flywheel with a crank arm. Attached to the crank arm is a Pitman Arm which in turn, attaches to the Walking Beam. At the other end of the walking beam is the Horsehead.The Hanger Cable hangs off the Horsehead, and is attached with a clamp to a Polished Rod, which goes through a Stuffing Box and is attached to the Rod String. At the bottom of the well a Travelling Valve, often just a ball in a cage, is attached to the Plunger (shown in green) at the end of the Rod String. Below that is another ball in a cage, called a Standing Valve. This pump can lift oil 10,000 feet or more! 1

11 CHAPTER-2 LITERATURE REVIEW 1. Robert P, Cu) Mansur FLUID DYNAMICS IN SUCKER ROD PUMPS tler and A.J. (Chip) measure Sucker rod pumps are installed in approximately 90% of all oil wells in the U.S. Although they have been widely used for decades, there are many issues regarding the fluid dynamics of the pump that have not been fully investigated. A project was conducted at Sandia National Laboratories to develop unimproved understanding of the fluid dynamics inside a sucker rod pump. A mathematical flow model was developed to predict pressures in any pump component or an entire pump under single-phase fluid and pumping conditions. Laboratory flow tests were conducted on instrumented individual pump components and on a complete pump to verify and refine the model. The mathematical model was then converted to a Visual Basic program to allow easy input of fluid, geometry and pump parameters and to generate output plots. Examples of issues affecting pump performance investigated with the model include the effects of viscosity, surface roughness, valve design details, plunger and valve pressure differentials, and pumping rate. 2. Petroleum Engineering Department, Waysto decrease production cost of sucker rod pump Pneumatic actuators have several advantages such as light weight, safety, low cost and high compliance. However, many pneumatic actuators have complicated systems that include a compressor, air tubes, and pneumatic valves with electrical wires. This research proposes a new control method for a multiplex pneumatic transmission constructed with special resonant valves and air tubes with a control system driven by air vibration in air tubes without electrical wires. The control is simplified and effective for pneumatic systems having many degrees of freedom. In this paper, the development of a primitive model of the resonant valve and a prototype valve is described. In addition, two control methods, which are a superimposing method and a timesharing method, are shown, and the independent driving of four actuators is realized by using one of the control methods with air tubes only. 2

12 CHAPTER-3. ROD PUMP OVERVIEW shows the different parts of a sucker rod pumping system, including (from the top down) its five major components: the prime mover, provides power to the system; the gear reducer which reduces the speed of the prime mover to a suitable pumping speed; the pumping unit which translates the rotating motion of the gear reducer and prime mover into a reciprocating motion; the sucker rod string, which is located inside the production tubing, and which transmits the reciprocating motion of the pumping unit to the subsurface pump; and the subsurface pump. Fig. 3.1 Rod Pump Overview 3

13 Figure 2 is a cross-sectional representation of a subsurface pump at two different stages of the pump cycle. Note the location of the standing valve at the bottom of the tubing, and the traveling valve at the bottom of the sucker rods. Note also the changing position of the plunger. Fig. 3.2 Subsurface Pump On the left-hand side of the figure, the plunger is approaching the bottom of its down stroke. The traveling valve is open, and so the standing valve is closed because it is carrying the weight of the fluid above it. At this point in the cycle, the fluid above the standing valve is moving upward through the open traveling valve. On the right-hand side of the figure, the plunger has reached the bottom of the stroke and is just beginning to move upward. The plunger starts to lift the weight of the fluid above it, and the traveling valve closes. As the plunger continues to move upward, the volume in the working barrel between the standing valve and traveling valve increases, while the pressure in the working barrel decreases. As soon as this pressure becomes less than the flowing bottom hole pressure, the standing valve opens and formation fluids flow upward. During each upward movement of the plunger, wellbore fluids are lifted a distance equal to one full stroke length. 4

14 CHAPTER-4. DESCRIPTION AND WORKING OF SRP 4.1 Working principle Fig. 4.1 Working OF SRP A motor supplies power to a gear box. A gearbox reduces the angular velocity and increases the torque relative to this input. As shown in Figure (the crank turns counter clockwise) and lifts the counterweight. Since the crank connected to the walking beam via the pitman arm, the beam pivots and submerges the plunger. Figure B also shows the horsehead at its lowest position. This marks the end of the down stroke. Note that the crank and the pitman arm are in-line at this position. The upstroke raises the horsehead and the plunger, along with the fluid being pumped. The upstroke begins at the point shown in Figure B. At the end of the upstroke, all joints are in-line. This geometric constraint determines the length of the pitman arm. 5

15 When the plunger reaches the top of its stroke, its movement is reversed the traveling valve opens, the standing valve closes and the cycle repeats its reciprocating movement of the rods and the opening and closing of the two valves. With each stroke, fluid is moved up the tubing toward the surface. If the produced fluid contains free gas, there are two points to note regarding the pump cycle 1. The valves will not necessarily open and close at the exact top and bottom of the stroke. in the upstroke at which the standing valve opens will depend on the spacing (the volume that exists at the bottom of the stroke, between the traveling and standing valves), and on the amount of free gas present in this volume. On the down stroke, the traveling valve remains closed until the pressure below the plunger is greater than the pressure above it. The traveling valve then opens and allows fluid to pass through it into the tubing. The exact point in the down stroke at which the traveling valve opens depends on the free gas volume in the fluid below the valve. 2. The greater the volume of free gas, the greater the proportion of the stroke that is taken up in gas expansion and compression, without any true pumping action taking place. For wells producing a reasonable volume of gas, a gas anchor is normally installed on the tubing below the pump. This device allows the separated gas to be produced up the annulus before it would otherwise enter the pump. 4.2 Basic Figure of SRP Figure 4.2 Basic Figure of SRP 6

16 4.3 Explanation of How It Works/ Is Used: Figure 4.3 Operational Detail of Sucker Rod Pump For name and location of parts, see Figure A motor supplies power to a gear box. A gearbox reduces the angular velocity and increases the torque relative to this input. 2. As shown in Figure 4.3, (the crank turns counterclockwise) and lifts the counterweight. Since the crank is connected to the walking beam via the pitman arm, the beam pivots and submerges the plunger. Figure 4.3 also shows the horsehead at its lowest position. This marks the end of the down stroke. Note that the crank and the pitman arm are in-line at this position. 3. The upstroke raises the horsehead and the plunger, along with the fluid being pumped. The upstroke begins at the point shown in Figure B. At the end of the upstroke, all joints are in-line. This geometric constraint determines the length of the pitman arm Figures and show the plunger and ball valves in more detail. These valves are opened by fluid flow alone. On the upstroke, the riding valve is closed and the standing valve is open. Fluid above and within the plunger is lifted out of the casing while more fluid is pumped into the well. On the down stroke, the riding valve is opened and the standing valve is closed. Fluid flows into the plunger and no fluid is allowed to leave the well. 7

17 4.4 Plunger Valve and Balls Figure Figure DOMINANT PHYSICS & DESIGN: 8

18 CHAPTER 5. DRAFTING IN CAD SOFTWARE 5.1 Design of SRP Fig 5.1 Design Of Sucker Rod Pump 9

19 CHAPTER 6. DESIGN OF COMPONENTS 6.1 Components:- 1. Rubber bush 2. Base plate of bush 3. Base support plate 4. Vertical pillar 5. Inclined rod 6. Fulcrum support 7. Connecting rod 8. Back support 9. Oscillating rod 10. Crank 11. Staring cover 12. Metal sheet 13. Gear 14. Motor 15. Stuffing box Rubber Bush:- Fig 6.1 Rubber Bush 10

20 6.1.2 Base plate of bush:- Fig 6.2 Base plate of bush 11

21 6.1.3 Base support plate:- Fig 6.3 Base support plate 12

22 6.1.4 Vertical pillar:- Fig 6.4 Vertical pillar 13

23 6.1.5 Inclined rod:- Fig 6.5 Inclined rod 14

24 6.1.6 Fulcrum support:- Fig 6.6 Fulcrum support 15

25 6.1.7 Connecting road:- Fig 6.7 Connecting road 16

26 6.1.8 Back support:- Fig 6.8 Back support 17

27 6.1.9 Oscillating rod:- Fig 6.9 Oscillating rod 18

28 Crank:- Fig 6.10 Crank 19

29 Staring cover:- Fig 6.11 Staring cover Metal sheet:- Fig 6.12 Metal sheet 20

30 Gear:- Fig 6.13 gear Motor:- Fig 6.14 Motor 21

31 Stuffing box:- Fig 6.15 Stuffing box 22

32 CHAPTER-7. ESTIMATING AND COSTING 7.1 Process Chart SR. NO. PART NAME OPERATION DETAILS DIMENSION IN MM MEASURING INSTUMENT 1 WOODEN STRIP MARKING OF STRIP 155 X 20 X X 23X 9 STEEL RULE AND MEASURE TAPE 230 X 78 X 15 CUTTING 215 X 20 X X 10 DRILLING 78 X 22 X X 20 X X 18 X X 20 X 5 2 AL PLATE MARKING OF PLATE 117 X 92 X 0.5 CUTTING 3 STFFING BOX 4 STERING COVER DRILING MARKING OF PIPE CUTTING DRILLING MARKING OF PLATE CUTTING BENDING D1=ᶲ38 MM D2=ᶲ38 MM D3=ᶲ20 MM L=62 MM D4=ᶲ26 MM T=17 MM 120X20X1 TABLE NO.1 PROCESS SHEET 23

33 7.2 REQUIREMENT FOR MFG SR NO. NAME RANGE 1 Measure tape 1000 mm 2 Steel Rule mm 3 Vanier Caliper 0 to 300 mm 4 Outside Micrometer 0 to 25 mm 5 Heck saw Frame 300 mm 6 Hand Drill 12.5 mm dia. 7 Hammer 2 kg 8 Rough File 300 mm 9 Smooth File 300 mm 10 Vice 150 mm 11 Center Punch 100 mm 12 Jack plane - Table No. 2 Requirement Of MFG 24

34 7.3 MACHINE REQUIREMENT: 1. Hack saw m/c approx cutting range-230mm 2. Drill M/c Max dia. hole- 60mm Max distance-1000mm Spindle dia.- 80mm Spindle R.P.M- min 25 max Lathe machine:- Spindle dia.-150mm 7.4 Costing chart Part name Price Quantity Cost WOODEN STRIP WOODEN TABEL D.C.MOTER MOTER BELT ALUMINIUM SHEET WIRE MOTER FREE WEEL OIL TANK COLOUR STEEL BOLL NUT BOLT SWITCH TOTAL COST 1245 Table No.3 Costing Chart 25

35 7.5 TROUBLESHOOTING NOTES As we know that for achieving something the interruption must come. This interruption is called TROUBLE SHOOTING. Similarly the troubles were also come in our project that our project is related to suction machine our project is based on the O.N.G.C. sucker rod pump. We have also faced a cluster of problem while making of it. The first problem of the gear. We have find the gears for transmit motion but we could not achieved it. So we have deiced to use the wheel of tape recorder instead of gears. This help us for grinding. The second problem was the suction of the water for that we have selected the two washer for it. we placed the rod into the washer hole and made small holes around the small diameter of the washer so when the rod comes backward than the water sucks towards up and when the rod goes down than the door of the washer closed. The third problem of leveling so, to solute this problem we put the plate for the support and also put for the support and also put bushes for same thing. So, by solving some critical and non critical problem made good and efficient working model of sucker rod pump. 26

36 CHAPTER 8. REAL TIME WORKING OF MODEL Figure 8.1 Figure

37 CHAPTER 9. ADVANTAGES AND LIMITATIONS 9.1Advantages:- 1. Since most field and operating personnel are familiar with sucker rod type lift, the installation and operation is not complicated. 2. Sucker rod pumps offer excellent rate range. This is directly influenced by the size and type of unit, tubular size, rod string design and pump size range. In most operating areas different pump and rod sizes are off-the shelf items. Warehousing and stock parts as well as service and repair and availability have historically have associated with this type of lift. 9.2 Limitations:- 1. Volume limitations of sucker rod pumps are due to tubular size and depth. Volumetric efficiency is reduced in wells with high GOR, if solids are produced, if paraffin form or if the fluid is sour or corrosive. 2. A major disadvantages is the rod string operating in a corrosive environment. Rod wear will damage tubing and, upon tubing failure, Amy cause high work over expense. Also, the tubing cannot be internally coated to prevent corrosion due to rod wear. Heavily loaded rod strings, especially in corrosive fluids, may have high failure frequency. 3. Initial capital cost, especially for larger high capacity units is high. The costs of the rod string must be included in the economic analysis. 4. Improper sucker rod handling causes many failures. Common sense handling and make-up techniques can extend rod life and improve operating expense indicators. Also, anchored tubing may improve efficiency and reduce rod wear for high volume pumpers with larger ID tubing. 28

38 CONCLUSION Working on project, right point the selection stage of the project to the testing of the project was a real fun, joy and interesting. The exercise has provided us a lot of insight the various manufacturing processes. The selection of the appropriate materials of different components tool, design and selection of tools. Machine operation and selection of machine for different operations we had applied the knowledge of industrial engineering for different charts and mechanical drafting for drawing. Thus the project work will increase our confidence, skill, planning, co-ordination, team spirit trouble capacity and attitude of inquiry. During our project work of SUCKER ROD PUMP across numerous technical task of manufacturing which enhance our technical knowledge. We also come across planning of work and its organization. It also built spirit among our self. The valuable guidance and suggestions were also available from our professor Prof. N.U.VAGHELA (sir) due to which we could complete the project in time. The opportunity by us in total spirit of learning and accruing related skills which will definitely help us lot in our career years. 29

39 REFERENCES infohost.nmt.edu/~petro/faculty/kelly/424/rod en.wikipedia.org/wiki/sucker rod. 6. Papers. 6.1 Robert P. Fluid Dynamic In SRP 6.2 WAYSTO Decrease Production Cost of SRP 30