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.

1.

2.

3.

PARIMAL K. KAPADIYA(090033119003)

PRASHANT H. BHATT(100033119003)

DHAVAL B. SODHA(080030119024)
 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
 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 (8thSemester) Technological University,
Ahmadabad during the academic year 2013.

Guide By: Prof. Hardik Chauhan

Prof. P. S. Puranik

Head of the Department

 EXAMINER’S CERTIFICATE OF APPROVAL

The project report entitled “SUCKER ROD PUMP” submitted PRASHANT

BHATT (100033119003), DHAVAL SODHA (080030119024), PARIMAL
KAPADIYA(090033119003) 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.
 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
 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
List of Figures:-

Fig. No. Fig. Name Page No.

3.1 Rod Pump Overview 3
3.2 Subsurface Pump 4
4.1 Working of SRP 5
4.2 Component of Sucker Rod Pump 6
4.3 Operational detail of Sucker Rod Pump 7
4.4 Plunger Valve and Balls 8
5.1 Design of Sucker Rod Pump 9
6.1 Rubber Bush 10
6.2 Base Plate of Bush 11
6.3 Base Support Plate 12
6.4 Vertical Pillar 13
6.5 Inclined Rod 14
6.6 Fulcrum Support 15
6.7 Connecting Rod 16

6.8 Back Support 17

6.9 Oscillating Rod 18

6.10 Crank 19

6.11 Staring Cover 20

6.12 Metal Sheet 20

6.13 Gear 21

6.14 Motor 21

6.15 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
 CONTENTS
Sr No. TITLE Page No.
ACKNOLEDGEMENT I
ABSTRACT II
LIST OF FIGURES
III
LIST OF TABLES
III
1 INTRODUCTION 1

2 LITTERATURE REVIEW 2

3 ROD PUMP OVERVIEW 3

3.1 Rod Pump Overview 3

3.2 Subsurface Pump 4

4 DESCRIPTION AND WORKING OF SRP 5

4.1 Working Principle 5

4.2 Basic Figure of SRP 6

4.3 Explanation of How it is Work/It used 7

4.4 Plunger Valve and Balls 8

5 DESIGN OF SUCKER ROD PUMP 9

5.1 Design of Sucker Rod Pump 9

6 DESIGN OF COMPONENT 10
6.1 Component 10
6.1.1 Rubber Bush 10
6.1.2 Base plate of bush 11

6.1.3 Base support plate 12

6.1.4 Vertical pillar 13

6.1.5 Inclined rod 14

6.1.6 Fulcrum support 15

6.1.7 Connecting rod 16

6.1.8 Back support 17

6.1.9 Oscillating rod 18

Sr.No. TITLE Page No.

6.1.10 Crank 19

6.1.11 Staring Cover 20

6.1.12 Metal Sheet 20

6.1.13 Gear 21

6.1.14 Motor 21

6.1.15 Stuffing box 22

7 ESTIMATING AND COSTING 23

7.1 Process Chart 23

7.2 Requirement For MFG 24

7.3 Machine Requirement 25

7.4 Costing Chart 25

7.5 Troubleshooting Notes 26

8 REAL TIME WORKING OF MODEL 28

8.1 Figure 8.1 28

8.2 Figure 8.2 28

9 ADVANTAGES AND DISADVANTAGES 29

9.1 Advantages 29

9.2 Disadvantages 29

10 REFERANCE 30
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
 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 time-
sharing method, are shown, and the independent driving of four actuators is realized by using one of
the control methods with air tubes only.

2
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

 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
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
 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
 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 4.3.

1. 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 4.4.1 and 4.4.2 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
 4.4 Plunger Valve and Balls

Figure 4.4.1 Figure 4.4.2

DOMINANT PHYSICS & DESIGN:

8
CHAPTER – 5. DRAFTING IN CAD SOFTWARE

5.1 Design of SRP

Fig 5.1 Design Of Sucker Rod Pump

9
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

6.1.1 Rubber Bush:-

Fig 6.1 Rubber Bush

10
6.1.2 Base plate of bush:-

Fig 6.2 Base plate of bush

11
6.1.3 Base support plate:-

Fig 6.3 Base support plate

12
6.1.4 Vertical pillar:-

Fig 6.4 Vertical pillar

13
6.1.5 Inclined rod:-

Fig 6.5 Inclined rod

14
6.1.6 Fulcrum support:-

Fig 6.6 Fulcrum support

15
6.1.7 Connecting road:-

Fig 6.7 Connecting road

16
6.1.8 Back support:-

Fig 6.8 Back support

17
6.1.9 Oscillating rod:-

Fig 6.9 Oscillating rod

18
6.1.10 Crank:-

Fig 6.10 Crank

19
6.1.11 Staring cover:-

Fig 6.11 Staring cover

6.1.12 Metal sheet:-

Fig 6.12 Metal sheet

20
6.1.13 Gear:-

Fig 6.13 gear

6.1.14 Motor:-

Fig 6.14 Motor

21
6.1.15 Stuffing box:-

Fig 6.15 Stuffing box

22
CHAPTER-7. ESTIMATING AND COSTING
7.1 Process Chart
SR. NO. PART OPERATION DIMENSION IN MM MEASURING
NAME DETAILS INSTUMENT

1 WOODEN MARKING 155 X 20 X 12 STEEL RULE AND

STRIP OF STRIP MEASURE TAPE
123 X 23X 9
230 X 78 X 15
CUTTING 215 X 20 X 12
77 X 10
DRILLING
78 X 22 X 19
300 X 20 X 5
155 X 18 X 5
210 X 20 X 5

2 AL PLATE MARKING 117 X 92 X 0.5

OF PLATE

CUTTING

DRILING

3 STFFING MARKING D1=ᶲ38 MM

BOX OF PIPE
D2=ᶲ38 MM
CUTTING D3=ᶲ20 MM
L=62 MM
DRILLING D4=ᶲ26 MM
T=17 MM

4 STERING MARKING 120X20X1

COVER OF PLATE

CUTTING

BENDING

TABLE NO.1 PROCESS SHEET

23
7.2 REQUIREMENT FOR MFG

SR NO. NAME RANGE

1 Measure tape 1000 mm

2 Steel Rule 304.8 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
 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 2000

3. Lathe machine:-
Spindle dia.-150mm

7.4 Costing chart

Part name Price Quantity Cost

WOODEN STRIP 20 12 240

WOODEN TABEL 350 1 350

D.C.MOTER 200 1 200

MOTER BELT 5 1 5

ALUMINIUM SHEET 40 1 40

WIRE 80 1 80

MOTER FREE WEEL 60 2 120

OIL TANK 15 1 15

COLOUR 40 4 160

STEEL BOLL 5 1 5

NUT BOLT 3 10 30

SWITCH 15 2 30

TOTAL COST 1245

Table No.3 Costing Chart

25
 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
CHAPTER – 8. REAL TIME WORKING OF MODEL

Figure 8.1

Figure 8.2

27
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
 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
 REFERENCES

1. www.ogbus.com/eng/authors/Takacs/waystodecrease.pdf
2. www.corusconstruction.com
3. infohost.nmt.edu/~petro/faculty/Kelly/424/ROD
4. www.airtec.de/eng/produkte/pdf/Cylinders/GB%20XL/
5. 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