TEAM MEMBERS (from left) Thomas O’Connor Carter David Jacquelyn Ogle Kenni Bui
Intelligent Rod Rotation Detection System
DESIGN METHOD
PROBLEM
Global Collaboration
OU MENTORS Jackson Autrey Farrokh Mistree COMPANY MENTOR Matt Green
Problem
Our project involved global collaboration to further advance preliminary design work for development, testing, and deployment of an intelligent rod rotation detection system A low-cost prototype was: ● Developed by Weir EnSci in Bangalore, India ● Shipped to Weir Mathena in El Reno, Oklahoma for component analysis ● Sent to Weir Pressure Controls in Edmonton, Canada for testing
Weir produces mechanical parts for pumpjacks of onshore oil wells.
Weir EnSci Engineers designed a preliminary prototype using low-cost, hobby electronic components from which the design would be based.
The company designed a rotational control device to increase the lifespan of the sucker rod string on onshore oil well pumpjacks. The device periodically rotates the rod string for an even distribution of frictional wear.
From this, our team would fulfill these requirements: ● Evaluate the provided prototype for compliance with required safety codes and technical feasibility ● Develop alternative component options and detail specifications ● Seek vendors to satisfy detailed specifications ● Obtain part numbers and quotes from these vendors for comparison ● Detail chosen parts in a Bill of Materials ● Recommend an improved design that adheres to all applicable safety requirements
From this, a need arose to design an intelligent system that could: ● Retrofit existing rod rotator systems ● Measure translational and rotational movement of aboveground polished rod ● Identify malperformance of rotational control system ● Provide real-time predictive maintenance system that sends performance data remotely to end user
Additionally, both company-provided and external vendors would be engaged while developing the Bill of Materials.
Design Method
Prototype Analysis
The overall design process was broken down into four phases.
Specification Development During critical evaluation of the provided prototype, every function to be performed by the final product was outlined.
All system components needed to comply with National Electric Code (NEC) Class 1 Division 2 regulations for a hazardous location where volatile matter could be present under abnormal conditions. Certifications indicating Division 2 compliance include NEMA 4 or 4X, UL698, IP66, IP68, non-incendive, or intrinsically safe.
With the desired functions in mind, working criteria were developed to assess a variety of potential components. Components that did not meet either safety or functional requirements were replaced with Class 1 Division 2 compliant equivalents.
Critical evaluation of safety requirements and technical feasibility eliminated the following prototype components: ● Proximity switches ● Lithium polymer battery ● 3G module
Replacement components included: ● Rotary encoder ● Accelerometer ● Power supply ● Modules for interfacing components
Vendor Qualification ● Vendors were engaged to obtain US deployable specifications and available pricing for all desired components ● Initial communication identified the desired product and described intended use, followed by a request for recommendation ● Engineers would then clarify functionality and request supplementary information to determine feasibility Class 1 Division 2 compliance and component interoperability were the most limiting factors during this search. Other part specifications such as voltage range, output format, termination type, accuracy, frequency, and cost influenced recommendations. Through engaging with vendors, detailed part numbers were acquired.
Recommendations
Cost and Design
OUTCOMES
The project packaged together a Design and Bill of Materials with parts that ensure safety and compliance while meeting affordability and accuracy requirements.
Total cost: $ 6,388.27 KEY REFERENCES 1. 2.
Lamendola, Mark. "NEC Article 501: Class I Hazardous Locations." Electrical Construction and Maintenance, 11 June 2013. Web. 23 Jan. 2017. "The Weir Group Announces Acquisition of Mathena, Inc." PR Newswire: News Distribution, Targeting and Monitoring. The Weir Group PLC, 20 Dec. 2012. Web. 20 Apr. 2017.
LEARNING STATEMENTS
“Through outlining our Specification Development, I realized that each of the tools we have used to justify our component recommendations (re-engineering, reality checks, working criteria) will continue to be useful as I look to start and sustain my engineering career. [POD 5C]” “Through making recommendations and following the proper safety codes, I learned about the responsibility that engineers must have over the projects completed in their career which is a valuable lesson that will apply to any future engineering ventures. [POD 5C]” “By summarizing work to be completed for our project using as few words as possible, I could visualize gaps in its description and anticipate questions that might arise when presenting it, which will serve as a useful predictive tool in industry when presenting concepts in industry. [POD 5B]” “While developing materials for the poster, I realized the importance of concisely articulating the design process and results in order to build customer confidence in the work completed, which will bring continued business opportunities for my team and company. [POD 5A]”
2017 AEROSPACE AND MECHANICAL ENGINEERING CAPSTONE POSTER FAIR