TOM Project Report

PUMP JACK DESIGN FOR OIL EXTRACTION Group Members Jamal Ahmad 2010146 Farhad Jan

2010174

–

Umer Saleem 2010371

Ghulam Ishaq Khan Institute of Engineering and Technology

TABLE OF CONTENTS 1. Abstract

3

2. Introduction

4

2.1 Oil Pump Jack

4

2.2 Structure

5

3. ANALYSIS

6

3.1 Degree of Freedom

6

3.2 Grashof motion Analysis

6

3.3 Position Analysis

7

3.4 Velocity Analysis

8

3.5 Acceleration Analysis

9

3.6 Graphs for Velocity and Position of crank

10

4. CAD Model

12

4.1 Design

12

4.2 Analysis

15

5. Conclusion

19

Appendix A

20

Appendix B

21


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1. ABSTRACT

We are designing a model of oil jack pump in our course project of ME-312 Theory of Machines, as per the requirement of the course. The basic purpose of designing the oil jack pump is the fact that it has a great importance in the petroleum industry. The mechanism is used in extracting the oil from the ground. The report contains the analysis of the mechanism of the oil jack pump. The analysis part contains the position analysis, velocity analysis and the acceleration analysis. The report also includes the CAD models of the mechanism. The graphical solution is also presented in the end. The project has given us the opportunity to completely analyze the work of four bar linkages in the real world problems. The basic purpose of this report and this project is to give an insight of the Oil Pump Jack to the viewer. We are really thankful to our teacher, Dr. Shahid Parvez, who has been so helpful throughout the course. He has also helped us in selecting the topic of our project by giving us the examples of four bar linkage applications as well as helping us throughout till the completion of the project.


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2. INTRODUCTION

2.1 Oil Pump Jack: A pump jack, which has many names like nodding donkey, horsehead pump and sucker rod pump (SRP), is the over ground mechanism for reciprocating motion of the piston pump in oil well. This mechanism is used to take oil out of the ground if there is not enough pressure generated by the vacuum to automatically lift liquid out of the ground. The oil pump jacks have the capability of extracting 5 to 40 liters of oil in a single stroke depending on its size. They are common in areas which are rich in oil. As discussed, the oil pump jacks extract the oil from the ground, after which the oil is taken for the fractional distillation. Thus, oil pump jacks are an important part of the petroleum industry. The pump is worked by a motor which is attached to the crank of the mechanism.

Figure 2.1: An Oil Pump Jack in California (Retrieved from http://en.wikipedia.org/wiki/Pumpjack‎)


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2.2 Structure: Oil pump jack is a four bar mechanism which is mounted on a frame for support. The crank is the shortest link which also has an actuator in the form of a constant speed motor. Usually gears are applied to alter the speed of the stroke from that of the motor. The crank is attached with the coupler which is further attached to the rocker. The crank revolves a complete 360 degrees while the rocker performs oscillatory motion about a pivot point. The rocker is extended further from the pivot point. A complex motion is associated with the coupler link.

Figure 2.2: Structure of oil pump Jack (Retrieved from http://en.wikipedia.org/wiki/Pumpjack‎)

The other links attached are just to support the mechanism and provide the stability to the structure. Different designs are available as per the requirement of the application, where the oil pump jack is to be mounted. To general type of pump jacks are: 1) Above Ground 2) Down Hole We will be designing and analyzing the above ground mechanism.


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3. ANALYSIS (ANALYTICAL APPROACH)

3.1 Degree of Freedom: Firstly we will calculate the degree of freedom of the mechanism. The degree of freedom can be defined as the number of inputs required to completely define the motion of the mechanism. Oil Pump Jack is a four bar mechanism with all full joints. There are no half joints. The mechanism mostly contains the pin joints. The formula used to calculate the mobility or the degree of freedom is given as: M = 3(L – 1) – 2J Where; M = Mobility J = No. of joints L = No. of links In this mechanism, we have 4 links i.e. crank, rocker, coupler and ground and four joints. Thus; J=4 L=4 Putting in the equation above; M = 3(4 – 1) – 2(4) M = 3(3) – 8 = 1 M=1

3.2 Grashof motion Analysis: The link lengths being used can roughly be approximated as: Crank = Shortest link;

Ground = Longest Link

Rocker = Link P

Coupler = link Q

The other two links will be longer than crank but smaller than Ground link. According to the Grashof’s condition; Ghulam Ishaq Khan Institute of Engineering and Technology

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S+L
3.3 Position Analysis: As shown in the graphical analysis of the report, the lower extreme position of the rocker link occurs at an angle of θ2 = 45 degrees. The upper extreme position will occur at θ2 = -135 degrees. Thus the position analysis is being done for the same position as it is of our interest. The link lengths and other required parameters are given below: Crank = a = 5 in Ground = d = 11 in Coupler = b = 8 in Rocker = c = 9 in θ₂ = 45 k₁ = d/a k₂ = d/c k₃ = (a² - b² + c² +d²)/ 2ac A = cosθ₂ - k₁ - k₂ cosθ₂ + k₃ B = -2sinθ₂ C = k₁ + k₃ - (k₂ + 1) cosθ₂ Angle θ₄ can be calculated by the following relations: √

k₄ = d/b k₅ = (c² - d² - a² - b²)/ 2ab Ghulam Ishaq Khan Institute of Engineering and Technology

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D = cos θ₂ - k₁ + k₄cos θ₂ +k₅ E = -2sin θ₂ F = k₁ + (k₄ - 1)cos θ₂ + k₅ Angle θ₃ can be calculated by the following relation: √

After putting the values in the above given formulas, the following results are deduced for a specific value of Ө₂=45°. Table 3.1 k₁ 2.2

k₂ 1.22

k₃ 1.81

k₄ 1.375

k₅ -1.612

A -0.54

B -1.41

C 2.44

D -2.133

E -1.41

F 0.85

Ө₃ 42

This has also been shown in the graphical analysis of the mechanism.

3.4 Velocity Analysis: As we have done the position analysis, we can now shift to the velocity analysis of the mechanism. The velocity analysis includes the angular velocity of the links as well as the linear velocity of the point of the interest. As our crank is mounted with the motor, the angular velocity of the crank ω₂ is known by using tachometer. We can place the values of the other parameters in the following relations to get the angular velocities; The value of ω₂ as calculated from the tachometer is 102rev/min so, ω₂ = 1.7 rev/sec

The velocity of the link four is approximately equal to 0 rev/sec, which is in accordance with our graphical analysis that it will be minimum at a crank angle of almost 45°. The linear velocity of the end point can be measured by the following formula;


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Ө₄ 99

Table 3.2 ω₃

ω₄

rev/sec -1.022

rev/sec 0.063

v₄ in/sec 2.37

3.5 Acceleration Analysis: The acceleration analysis can be performed as we have completed the velocity analysis. As the angular velocity of the motor is constant so the angular acceleration of the crank will be 0 rev/sec². The acceleration of different links, at the extreme position, can be calculated by using the following relations: α₂ = 0rev/sec² A = c sin Ө₄ B = b sin Ө₃ C = aα₂sin Ө₂ + aω₂² cos Ө₂ + bω₃² cos Ө₃ - cω₄² cos Ө₄ D =c cos Ө₄ E = b cos Ө₃ F = aα₂ cos Ө₂ - aω₂² sin Ө₂ - bω₃² sin Ө₃ + cω₄² sin Ө₄ The following values are calculated from the above formulas; Table 3.3 α₂ 0

A 8.58

B 5.35

C 16.6

D -2.7

E 5.94

F -15.93

And from the values in the table and the formulas given as under, the values of α₃ and α₄ are calculated.

α₃ = 1.40 rev/sec²

α₄ = 2.81 rev/sec²


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So, these values show the angular acceleration of the link 3 and 4 respectively, when the link 4 is in its lower position.

3.6 Graphs for Velocity and Position of crank: The graphs for the complete revolution of the crank can be drawn by using the same above formulas. The chart shows the values of Ө₃, Ө₄, ω₃ and ω₄ for different values of the crank angle Ө₂. Table 3.4 Ө₂(deg) 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360

Ө₂(rad) 0 0.34906585 0.698131701 1.047197551 1.396263402 1.745329252 2.094395102 2.443460953 2.792526803 3.141592654 3.490658504 3.839724354 4.188790205 4.537856055 4.886921906 5.235987756 5.585053606 5.934119457 6.283185307

A -0.61 -0.596732 -0.55853 -0.5 -0.428203 -0.351797 -0.28 -0.22147 -0.183268 -0.17 -0.183268 -0.22147 -0.28 -0.351797 -0.428203 -0.5 -0.55853 -0.596732 -0.61

B

C

0 -0.68404 -1.28558 -1.73205 -1.96962 -1.96962 -1.73205 -1.28558 -0.68404 -2.5E-16 0.68404 1.285575 1.732051 1.969616 1.969616 1.732051 1.285575 0.68404 4.9E-16

1.79 1.923882 2.309381 2.9 3.624501 4.395499 5.12 5.710619 6.096118 6.23 6.096118 5.710619 5.12 4.395499 3.624501 2.9 2.309381 1.923882 1.79

D -1.4375 -1.58073 -1.99314 -2.625 -3.40009 -4.22491 -5 -5.63186 -6.04427 -6.1875 -6.04427 -5.63186 -5 -4.22491 -3.40009 -2.625 -1.99314 -1.58073 -1.4375

E 0 -0.68404 -1.28558 -1.73205 -1.96962 -1.96962 -1.73205 -1.28558 -0.68404 -2.5E-16 0.68404 1.285575 1.732051 1.969616 1.969616 1.732051 1.285575 0.68404 4.9E-16

F 0.9625 0.939885 0.874767 0.775 0.652618 0.522382 0.4 0.300233 0.235115 0.2125 0.235115 0.300233 0.4 0.522382 0.652618 0.775 0.874767 0.939885 0.9625

Ө₃ 78.58484 60.61332 45.00981 34.00304 26.5096 21.38069 18.00816 16.3239 16.90449 20.99787 29.33841 40.77949 53.57546 66.44704 78.34913 87.99406 93.29956 90.97964 78.58484

Ө₄ 119.4502 105.3568 99.70973 101.9787 109.262 119.3508 130.8073 142.5066 153.1882 161.2402 165.6221 166.9622 166.3746 164.4172 161.1016 155.9697 147.9995 135.7231 119.4502


ω₃ -1.41551 -1.50491 -1.12394 -0.76602 -0.52268 -0.35438 -0.21471 -0.05587 0.18419 0.535736 0.868872 1.052139 1.105815 1.067492 0.937036 0.672077 0.179546 -0.62247 -1.41551

ω₄ -1.41531 -0.87316 -0.10063 0.446942 0.765419 0.934823 1.001673 0.97286 0.819423 0.528123 0.221123 0.015484 -0.11507 -0.224 -0.3519 -0.54077 -0.84313 -1.25361 -1.41531

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The graph from the above data is plotted between crank angle Ө₂ and the angular velocity of the link 4 i.e. ω₄. The graph shows that the velocity of the desired point becomes 0 rev/sec instantaneously at two specific points which are approximately Ө₂ = 42° and 220°. 1.5 1 0.5 0 0

50

100

150

200

250

300

350

400

-0.5 -1 -1.5 -2

Figure 3.1


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4. CAD MODEL (Design and Analysis) 4.1 Design Following are the steps that lead to the design of the oil pump jack model. The images were extracted from Creo 1.0. Both Engineering drawings and Extruded models are shown below. The first image belongs to the coupler.

Figure 4.1: Coupler’s Engineering Drawing

Figure 4.2: Coupler’s Extruded Model Ghulam Ishaq Khan Institute of Engineering and Technology

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Similarly, the engineering design and extruded model of the Crank are as follows:

Figure 4.3: Engineering Drawing of Crank

Figure 4.4: Extruded Model of Crank


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The drawing and model of the Rocker is given below:

Figure 4.5: Engineering Drawing of Rocker

Figure 4.6: Rocker’s Extruded Model Ghulam Ishaq Khan Institute of Engineering and Technology

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And finally the assembly’s engineering drawing and model is given below:

Figure 4.7: Engineering Drawing of the combined Assembly

Figure 4.8: Assembly View


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4.2 Analysis The following three images were taken from the motion analysis of the software. It shows the progression and working mechanism of the pump jack.

Figure 4.9: Oil Pump Jack initial position

Figure 4.10: Oil Pump Jack after completing quarter of revolution


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Figure 4.10: Oil Pump Jack after completing half a revolution Further, the motion analysis was done for the rocker. The graph of the position as a function of time is shown below:

Figure 4.11: Position Analysis of Rocker


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The graph of the rocker’s velocity analysis is given below:

Figure 4.12: Velocity Analysis of Rocker And finally the acceleration graph of the rocker is as follows:

Figure 4.13: Acceleration Analysis of Rocker


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5. Conclusion The report contains all the position, velocity and acceleration analysis. The CAD models are attached with the email and the soft copy. Moreover the report also contains the graphical analysis for position and instant centers. The physical model is made to give an idea to the viewer that how a pump jack really works. The motion of the mechanism is visible in the CAD model and the physical model as well. The analysis clearly shows that the rocker and the desired point have 0 in/sec velocity at the extreme positions for which the crank angle is 42° and 99°.


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Appendix A References http://aoghs.org/technology/all-pumped-up-oil-production-technology/ http://en.wikipedia.org/wiki/Pumpjack

http://www.sjvgeology.org/old_stuff/pumpjacks.html https://www.youtube.com/watch?v=5uJ_8lemzoo http://weburbanist.com/2010/03/21/10-pimped-pump-jacks-give-the-nod-to-urban-oil-art/


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Appendix B Index Acceleration 3, 9, 10, 18 Analysis 3, 6, 7, 8, 9, 12, 16, 17, 18 Coupler 5, 6, 7, 12 Crank 4, 5, 6, 7, 8, 10, 11, 13 Design 3, 5, 7, 12, 13 Grashof 6 Links 6, 8, 9 Position 3, 7, 8, 10, 17 Pump 3, 4, 5, 6, 12, 16, 17, 20 Rocker 5, 6, 7, 11, 14, 17, 18 Velocity 3, 8, 9, 11, 13, 18


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TOM Project Report

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