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Pumping Unit:

Review
Clarifications
1. Revised design with 24" movement of base unit from the earlier one
2. FEA: summary on different cases
3. Preliminary drawings
1. Drum assy
2. Lift cylinder
4. HPU:
1. schematics & calculations for 50k & 60k unit
2. Schematics for auxiliary unit
5. Civil: concrete pad
6. Review: RAIL
Revised design with 24"
Base Frame
Sliding Frame
Belt integration
Sliding & Rolling
Material weight by units

Item Weight – lb (Kg) Comments


Base Frame 5745 (2611)
Sliding Frame 5000 (2272)
Folding Unit 4200 (1909)
Drum assy 3960 (1800)
Belt 1320 (600)
Belt Integration on well side 572 (260)
Belt Integration on inside 605 (275)
Cylinder rod & piston 3135 (1425)
Material Options by components
Material Options by components….cont’d
FEA Review: FE Meshing

Hybrid Meshing
FE Meshing…..cont’d

Cylinder rod
components

Base unit

Drum
components

Sliding unit
Boundary condition: Fixed Support

Fixed Support

6 locations
Boundary condition: Bearing Load due to belt load

Bearing Load= 60000*1.2=72000lb


two sides 144k lb
Boundary condition: Barrel Pressure
Boundary condition: hinge load in lifted condition
Boundary condition: Wind Load

Case1 : 75mph
Total wind Load= 28477 N

• In extended condition belt would offer more than 50% resistance to wind flow
• As belt would transfer most to drum we have considered 60 % to act on drum
• The above could be worst case scenario approach & the same would be acting on
only one quadrant of the drum
• Other 40 % on cylindrical rod and tube structures
Boundary condition: Wind Load…cont’d

Wind Direction – from inside to well side

Drum Load= 17086 N


Area=1m2
Pressure= 17086 Pa
Boundary condition: Wind Load…..cont’d

Cylindrical road and Tube Load= 11390 N


Area=4.5 m2
Pressure= 2531Pa

Wind Direction
Boundary condition: Lift cylinder FE modeling
B – barrel materials
R – rod material
A – Aluminum 6060
R
B R

R
A contact

Pressure – only in
R contact case-2

Case-1: there is no
internal pressure

Top

2
1
RESULTS: Cases Analyzed in lifted condition
Contact between wear rings on piston to cyl barrel
Contact between wear rings on gland ID to cylinder rod

Wind force-1 Wind force- Rope Hallow Pressure inside Pressure


Strut Solid cyl rod
(75MPH) 2 (50MPH) inside load cyl rod barrel inside Cyl rod
CASE-1a Y Y Y Y Y

CASE-1b Y Y Y Y Y

CASE-1c Y Y Y Y Y

CASE-1d Y Y Y Y Y

CASE-2 Y Y Y Y Y Y

CASE-3 Y Y Y Y Y Y
Summary Case 1a & 1b

Unit wise summary of Induced Stresses\

Folding
CASE STRESS Unit Base unit Sliding unit Unit Cyl Barrel Cyl rod Drum Comments
(plates)
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
PSI 26852 30993 16109 16159 31612 25429
Induced
Case-1a 75 MPH
Stress MPa 185 214 111 111 217.96 175
in 0.02 0.04 0.10 0.11 2.21 2.23
Diflection
mm 0.41 1.08 2.57 2.86 56.20 56.74
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
Induced PSI 25971 30984 13352 16143 19195 25312
Case-1b 50 MPH
Stress MPa 179 214 92 111 132 175
in 0.02 0.04 0.08 0.08 1.01 1.02
Diflection
mm 0.40 1.07 2.00 2.12 25.56 25.91
Summary Case 1c & 1d

Unit wise summary of Indused Stresses


Folding
CASE STRESS Unit Base unit Sliding unit Unit Cyl Barrel Cyl rod Drum Comments
(plates)
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
Induced PSI 26005 31007 15228 16268 23652 25551
Case-1c 75 MPH
Stress MPa 179 214 105 112 163.08 176
in 0.02 0.04 0.10 0.11 1.61 1.63
Diflection
mm 0.41 1.08 2.59 2.87 40.93 41.48
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
Induced PSI 25139 30998 11181 16252 13651 25431
Case-1d 50 MPH
Stress MPa 173 214 77 112 94 175
in 0.02 0.04 0.08 0.08 0.74 0.75
Diflection
mm 0.40 1.08 2.03 2.14 18.75 19.10
Deformation Contours

Maximum displacement is 2.234 inch


von-Misses Stress contours

High Stress region


von-Misses Stress contours-Base unit

• Maximum Stress is 26852 Psi which indicates that stress value is below the
yield stress of the material (50000 Psi)
von-Misses Stress contours-Sliding unit

• Maximum Stress is 30993 Psi which indicates that stress value is below the
yield stress of the material (50000 Psi)
von-Misses Stress contours-Sliding unit

Above 15000 psi is marked as RED


von-Misses Stress contours-Sliding unit
von-Misses Stress contours-Sliding unit
von-Misses Stress contours-Sliding unit
von-Misses Stress contours-Bracing plates

• Maximum Stress is 16109 Psi which indicates that stress value is below the
yield stress of the material (62000 Psi)
von-Misses Stress contours-Piston components

• Maximum Stress is 31612 Psi which indicates that stress value is below the
yield stress of the material (82700 Psi)
von-Misses Stress contours-Cylinder Rod

• Maximum Stress is 16159 Psi which indicates that stress value is below the
yield stress of the material (105000 Psi)
von-Misses Stress contours-Drum Attachments

• Maximum Stress is 25429 Psi which indicates that stress value is below the
yield stress of the material (50000 Psi)
von-Misses Stress contours-Drum

• Maximum Stress is 13120 Psi which indicates that stress value is below the
yield stress of the material (62000 Psi)
von-Misses Stress contours-Drum

• Maximum Stress is 13120 Psi which indicates that stress value is below the
yield stress of the material (62000 Psi)
RESULTS: Cases Analyzed in lifted condition
Contact between wear rings on piston to cyl barrel
Contact between wear rings on gland ID to cylinder rod

Wind force-1 Wind force- Rope Hallow Pressure inside Pressure


Strut Solid cyl rod
(75MPH) 2 (50MPH) inside load cyl rod barrel inside Cyl rod
CASE-1a Y Y Y Y Y

CASE-1b Y Y Y Y Y

CASE-1c Y Y Y Y Y

CASE-1d Y Y Y Y Y

CASE-2 Y Y Y Y Y Y

CASE-3 Y Y Y Y Y Y
Summary

Unit wise summary of Indused Stresses


Folding
CASE STRESS Unit Base unit Sliding unit Unit Cyl Barrel Cyl rod Drum Comments
(plates)
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
Induced PSI 26005 31007 15228 16268 23652 25551
Case-1c 75 MPH
Stress MPa 179 214 105 112 163.08 176
in 0.02 0.04 0.10 0.11 1.61 1.63
Diflection
mm 0.41 1.08 2.59 2.87 40.93 41.48
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
Induced PSI 25139 30998 11181 16252 13651 25431
Case-1d 50 MPH
Stress MPa 173 214 77 112 94 175
in 0.02 0.04 0.08 0.08 0.74 0.75
Diflection
mm 0.40 1.08 2.03 2.14 18.75 19.10
Deformation Contours

Maximum displacement is 2.234 inch


von-Misses Stress contours

High Stress region


von-Misses Stress contours-Base unit

• Maximum Stress is 26005 Psi which indicates that stress value is below the
yield stress of the material (50000 Psi)
von-Misses Stress contours-Sliding unit

• Maximum Stress is 31007 Psi which indicates that stress value is below the
yield stress of the material (50000 Psi)
von-Misses Stress contours-Sliding unit

Above 15000 psi is marked as RED


von-Misses Stress contours-Sliding unit
von-Misses Stress contours-Sliding unit
von-Misses Stress contours-Sliding unit
von-Misses Stress contours-Bracing plates

• Maximum Stress is 15228 Psi which indicates that stress value is below the
yield stress of the material (62000 Psi)
von-Misses Stress contours-Piston components

• Maximum Stress is 23652 Psi which indicates that stress value is below the
yield stress of the material (82700 Psi)
von-Misses Stress contours-Cylinder Rod

• Maximum Stress is 16268 Psi which indicates that stress value is below the
yield stress of the material (105000 Psi)
von-Misses Stress contours-Drum Attachments

• Maximum Stress is 25551 Psi which indicates that stress value is below the
yield stress of the material (50000 Psi)
von-Misses Stress contours-Drum

• Maximum Stress is 13160 Psi which indicates that stress value is below the
yield stress of the material (62000 Psi)
RESULTS: Cases Analyzed in lifted condition
Contact between wear rings on piston to cyl barrel
Contact between wear rings on gland ID to cylinder rod

Wind force-1 Wind force- Rope Hallow Pressure inside Pressure


Strut Solid cyl rod
(75MPH) 2 (50MPH) inside load cyl rod barrel inside Cyl rod
CASE-1a Y Y Y Y Y

CASE-1b Y Y Y Y Y

CASE-1c Y Y Y Y Y

CASE-1d Y Y Y Y Y

CASE-2 Y Y Y Y Y Y

CASE-3 Y Y Y Y Y Y
von-Misses Stress contours-Piston components

• Maximum Stress is 35054 Psi which indicates that stress value is below the
yield stress of the material (82700 Psi)
Summary Case 1a & 1b

Unit wise summary of Induced Stresses\

Folding
CASE STRESS Unit Base unit Sliding unit Unit Cyl Barrel Cyl rod Drum Comments
(plates)
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
PSI 26852 30993 16109 16159 31612 25429
Induced
Case-1a 75 MPH
Stress MPa 185 214 111 111 217.96 175
in 0.02 0.04 0.10 0.11 2.21 2.23
Diflection
mm 0.41 1.08 2.57 2.86 56.20 56.74
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
Induced PSI 25971 30984 13352 16143 19195 25312
Case-1b 50 MPH
Stress MPa 179 214 92 111 132 175
in 0.02 0.04 0.08 0.08 1.01 1.02
Diflection
mm 0.40 1.07 2.00 2.12 25.56 25.91
Summary

Unit wise summary of Indused Stresses


Folding
CASE STRESS Unit Base unit Sliding unit Unit Cyl Barrel Cyl rod Drum Comments
(plates)
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
Induced PSI 26005 31007 15228 16268 23652 25551
Case-1c 75 MPH
Stress MPa 179 214 105 112 163.08 176
in 0.02 0.04 0.10 0.11 1.61 1.63
Diflection
mm 0.41 1.08 2.59 2.87 40.93 41.48
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
Induced PSI 25139 30998 11181 16252 13651 25431
Case-1d 50 MPH
Stress MPa 173 214 77 112 94 175
in 0.02 0.04 0.08 0.08 0.74 0.75
Diflection
mm 0.40 1.08 2.03 2.14 18.75 19.10
Summary

Unit wise summary of Induced Stresses\

Folding
CASE STRESS Unit Base unit Sliding unit Unit Cyl Barrel Cyl rod Drum Comments
(plates)
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
PSI 26852 30993 16109 16159 35054 25429
Induced
Case-2 75 MPH
Stress MPa 185 214 111 111 242 175
in 0.02 0.04 0.10 0.11 2.21 2.23
Diflection
mm 0.41 1.08 2.57 2.86 56.20 56.74
PSI 29700 29700 65000 105000 82700 50000
Yield stress
MPa 205 205 448 724 570 345
Induced PSI 25971 30984 13352 16143 24738 25312
Case-3 50 MPH
Stress MPa 179 214 92 111 171 175
in 0.02 0.04 0.08 0.08 1.01 1.02
Diflection
mm 0.40 1.07 2.00 2.12 25.56 25.91
Hydraulics: Calculations (60k & 50k) & schematics
1. Hydraulics
 Calculations
 Schematics
 Pumps & Valves
2. Motor
Calculations: 60k
INPUTS

Peak Polished Rod Load = 60,000 lbs time per up/dn stroke t 8.57 s
Mast Weight = 5,852 lbs
Piston & Rod Weight 3,135 lbs velocity 21.00 in/s
Minimum Polished Rod Load = 18,000 lbs Flow 1,001.97 in3/s
Strokes Per Minute = 3.5 SPM 60,118.30 in3/min
Stroke Length = 180 in 260.3 gpm
Upstroke Load On Cylinder = 1,28,987 lbs
Downstroke Load On Cylinder = 44,987 lbs 33.40 in3/rev
Rod Diameter = 4.5 in 547.31 cc/rev
3 x Rod Area = 47.7 in Power 456.1 HP
Lift Pressure = 2,703 psi # Lift Pumps - 280 cc 2
Required Flow = 260.3 gpm
Up-Stroke Efficiency = 90% Down-Stroke Pressure 942.9 psi
Down-Stroke Efficiency = 90% Down-Stroke Regen Power 143.2 HP
Up-Stroke HP Required = 456.1 hp EM 312.9 HP
Lift Pump Displacement (1800 RPM) = 37.11 in3
Lift Pump Displacement (1800 RPM) = 608.23 cc Reqd Flow-Regen Pump 92.0 gpm 245.4
Number of 280cc Lift Pumps = 2.17 194 cc/rev 516
Down-Stroke Regen Power = 143.2 hp
Electric Motor Size = 312.9 hp Displ. Regen pump 280 cc/rev
Accumulator Intake Pressure = 900 psi 0.074 gal/rev
Accumulator Discharge Pressure = 2,400 psi 133 gpm
Acc Flow Required At 900 psi = 245.4 gpm
Acc Flow Required At 2400 psi = 92.0 gpm # Regen Pumps - 280 cc 1
Regen Pump Displacement (1800 RPM) = 215 cc Avg. Flow gpm 168.7
Number of 280cc Regen Pumps = 1 Pump Vol. Displ in t sec 24.1 gal
Max Acc Flow = 573.6 cc
Average Accumulator Flow = 168.7 gpm DV ACC 24.1 gal
Oil Volume Required = 24.1 gal Intial Volume ACC 38.6 gal
Accumulator Calculated Size = 38.6 gal
Number of 15 gal Accumulators = 1
Accumulator

Accumulator Inc. A403100


Size 40
Model Bottom Repairable
Pressure 3000 psi
Port NPT
Bladder Buna Nitrile
Service Oil
# Accumulators 1

Gas Bottle A10GB3100


# 1
Calculations: Heat Exchanger
Fluid Entry Temp 175 deg. F
Ambient 75 deg. F
Entry Temp Diff 100 deg. F

Oil SAE 20
Viscosity Correction 1.06
Main Flow 260 gpm

Offline pump 560 cc/rev


2 x 280 266 gpm

Elec. Motor 313 HP

Heat Removal % 35%


Heat Load 110 HP
4645 BTU/min
Corrected Heat Load 4923 BTU/min

Selection OCA 450

DP 10 psi
Correction 1.59
Corrected Pr. Drop 15.9 psi
Calculations: 50k
INPUTS

Peak Polished Rod Load = 50,000 lbs time per up/dn stroke t 8.57 s
Mast Weight = 5,852 lbs
Piston & Rod Weight 3,135 lbs velocity 21.00 in/s
Minimum Polished Rod Load = 15,000 lbs Flow 791.68 in3/s
Strokes Per Minute = 3.5 SPM 47,500.88 in3/min
Stroke Length = 180 in 205.6 gpm
Upstroke Load On Cylinder = 1,08,987 lbs
Downstroke Load On Cylinder = 38,987 lbs 26.39 in3/rev
Rod Diameter = 4.0 in 432.44 cc/rev
3 x Rod Area = 37.7 in Power 385.4 HP
Lift Pressure = 2,891 psi # Lift Pumps - 280 cc 2
Required Flow = 205.6 gpm
Up-Stroke Efficiency = 90% Down-Stroke Pressure 1,034.2 psi
Down-Stroke Efficiency = 90% Down-Stroke Regen Power 124.1 HP
Up-Stroke HP Required = 385.4 hp EM 261.3 HP
Lift Pump Displacement (1800 RPM) = 29.32 in3
Lift Pump Displacement (1800 RPM) = 480.58 cc Reqd Flow-Regen Pump 79.7 gpm 212.7
Number of 280cc Lift Pumps = 1.72 168 cc/rev 447
Down-Stroke Regen Power = 124.1 hp
Electric Motor Size = 261.3 hp Displ. Regen pump 180 cc/rev
Accumulator Intake Pressure = 900 psi 0.048 gal/rev
Accumulator Discharge Pressure = 2,400 psi 86 gpm
Acc Flow Required At 900 psi = 212.7 gpm
Acc Flow Required At 2400 psi = 79.8 gpm # Regen Pumps - 180 cc 1

Regen Pump Displacement (1800 RPM) = 186 cc Avg. Flow gpm 146.2
Number of 180cc Regen Pumps = 1 Pump Vol. Displ in t sec 20.9 gal
Max Acc Flow = 497.1 cc
Average Accumulator Flow = 146.2 gpm DV ACC 20.9 gal
Oil Volume Required = 20.9 gal Intial Volume ACC 33.4 gal
Accumulator Calculated Size = 33.4 gal
Number of 15 gal Accumulators = 1
Accumulator

Accumulator Inc. A403100


Size 40
Model Bottom Repairable
Pressure 3000 psi
Port NPT
Bladder Buna Nitrile
Service Oil
# Accumulators 1

Gas Bottle A10GB3100


# 1
Calculations: Heat Exchanger
Fluid Entry Temp 175 deg. F
Ambient 75 deg. F
Entry Temp Diff 100 deg. F

Oil SAE 20
Viscosity Correction 1.06
Main Flow 260 gpm

Offline pump 560 cc/rev


2 x 280 266 gpm

Elec. Motor 261 HP

Heat Removal % 35%


Heat Load 91 HP
3878 BTU/min
Corrected Heat Load 4111 BTU/min

Selection OCA 450

DP 10 psi
Correction 1.59
Corrected Pr. Drop 15.9 psi
Hyd. Schematic: Auxiliary
Hyd. Schematic: Main
Hyd. Schematic: Main
Main Pumps
 Parker PD series
 Open circuit 100% over-center
 Max displacement 140 cc
Main Pumps
 Parker PD series
 Open circuit 100% over-center
 Max displacement 140 cc
Main Pumps
 Parker PV plus series
 Max displacement 140 cc
 No over center capability
Main Valves
 Required maximum flow: 260.3 gpm

Parker:
• Logic Elements: 132 gpm
• Cartridge Valves: 92 gpm
• DC valve: NG32, D111VW: 529 gpm

Yuken:
• Logic Elements: 554 gpm
Main Motor
Main Motor
Challenges, Risks, Issues
Clarifications / Input
1. Soil data, Reference concrete / foundation drawings
2. RAIL

Challenges
1. Supplier coordination; drum, belt, bearing,
2. Concluding on HPU scope
Risks
1. Belt selection & Integration: not getting good response
2. Rope & sheave
3. Drum assy & size

Issues: None for now


Next week review tasks
1. Design
1. Closing action items from meeting
2. Closing action items from FEA & review
3. Final FEA with few other cases
4. Calculations – all critical components
2. Hydraulic circuit & cylinders review – Closure & Finalization
3. Material & Tolerance review: two sample drawings & closure
4. Supplier Interaction & closure / Standard Parts:
5. Bearing: supplier review & finalization
6. Belt: supplier review & finalization
7. Heavy Duty Ball transfer: supplier review & finalization
8. Hydraulic Cylinder: Make – Lift & Buy – Tilt (Prince), Slide, Short stroke cyl
9. Other STD items
10. Rope & sheave
11. All others
Thank You