Transcript
Page 1: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

Progressing Cavity Pumping Systems

Page 2: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

Progressing Cavity Pumping System Advantages

• Low Capital Cost

• Low Surface Profile for Visual and

Height Sensitive Areas

• High System Efficiency

• Simple Installation, Quiet Operation

• Pumps Oils and Waters with Solids

• Low Power Consumption

• Portable Surface Equipment

• Low Maintenance Costs

• Use In Horizontal/Directional Wells

• C-FER, WFT Proprietary

Vertical

Electric Wellhead

Drive

Casing

Production Tubing

Sucker Rod

Sucker Rod Coupling

Tubing Collar

Stator

Rotor

Tubing Collar

Tag Bar Sub

Page 3: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

• Limited Depth Capability

• Temperature

• Sensitivity to Produced Fluids

• Low Volumetric Efficiencies in

High-Gas Environments

• Potential for Tubing and Rod

Coupling Wear

• Requires Constant Fluid Level

Above Pump

Progressing Cavity Pumping System Limitations

Vertical

Electric Wellhead

Drive

Casing

Production Tubing

Sucker Rod

Sucker Rod Coupling

Tubing Collar

Stator

Rotor

Tubing Collar

Tag Bar Sub

Page 4: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

PCP Systems – Basic Operating Principles

• One of the newest forms of artificial lift

(early ’80s)

• Classified as positive-displacement pump

• A single, helical-shaped rotor turns inside a

double-helical, elastomer-lined stator

• In the most common configuration, the energy is

transmitted from surface through a rod string

Page 5: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

PCP System Advantages

• Most efficient ALS, even for

extreme viscosities

• Low capital and operating

cost

• Low profile and small

footprint

Continuous, smooth, and

efficient operation

• Best artificial-lift method for

sand-laden wells

• Will never become

inoperable due to gas lock

No valves to clog or wear

Page 6: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

Evolution and Growth of PCP Systems

1980

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

0

200

400

600

800

1,000

1,200

1,400

1980 1985 1990 1995 2000 2005 2010

Num

ber o

f Ins

talla

tion

s

Pum

p D

ispl

acem

ent

(bpd

/100

rpm

) & L

ift(

ft/1

0) Pump Displacement

Pump Lift

Number of PCP Installations

0

50

100

150

200

250

300

0

500

1,000

1,500

2,000

2,500

3,000

1980 1985 1990 1995 2000 2005 2010

Surf

ace

Pow

er (h

p)

Torq

ue (

ft*l

bs)

Surface Torque

Surface Power

PUMPS

DRIVEHEADS

Pu

mp

Dis

pla

cem

en

t

(B/D

@ 1

00 r

pm

) an

d

Lif

t (f

t/10)

To

rqu

e (

ft-l

bf)

• 50 hp

(37 kW)

• 200 ft-lbf

(270 N•m)

• 50 B/D

(8 m3/d)

• 2,000 ft

(600 m)

• Low rate, shallow wells

• Heavy oil

• Limited elastomer options – Trial-and-error selection process

• No backspin braking control

• Zero monitoring and control

• Rods from RRP applications

Page 7: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

Evolution and Growth of PCP Systems

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

0

200

400

600

800

1,000

1,200

1,400

1980 1985 1990 1995 2000 2005 2010

Num

ber o

f Ins

talla

tion

s

Pum

p D

ispl

acem

ent

(bpd

/100

rpm

) & L

ift(

ft/1

0) Pump Displacement

Pump Lift

Number of PCP Installations

0

50

100

150

200

250

300

0

500

1,000

1,500

2,000

2,500

3,000

1980 1985 1990 1995 2000 2005 2010

Surf

ace

Pow

er (h

p)

Torq

ue (

ft*l

bs)

Surface Torque

Surface Power

PUMPS

DRIVEHEADS

Pu

mp

Dis

pla

cem

en

t

(B/D

@ 1

00 r

pm

) an

d

Lif

t (f

t/10)

To

rqu

e (

ft-l

bf)

• Safe backspin control systems; environmental stuffing boxes

• VSDs; downhole and surface sensors

• High-torque rods and connections; COROD® continuous rod

• Higher rates, deeper wells

• Heavy, medium and light oils;

CBM dewatering

• Local and remote monitoring and control

Today

• 300 hp

(220 kW)

• 2,500 ft-lbf

(3,400 N•m)

• 4,000 B/D

(8 m3/d)

• 10,000 ft

(3,050 m)

More than 60,000 wells

operating with PCP systems

Page 8: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

Engineering a Well-integrated, Fit-for-purpose PCP System

Driveheads and

stuffing boxes

Installation options

Controllers,

automation

and software

Rod string options • Types

• Materials

• Geometries

Downhole

monitoring

Pump options • Rotor geometry

• Elastomer composition

Page 9: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

Elastomers

• The elastomeric stator is the most critical component

of the pump

• Responsible for ~80% of all pump replacements

– Commonly the first to show wear for successful

applications

– Most common failed element for catastrophic

short-life failure

Burned stator

caused by pump off

Extreme swelling due to

fluid incompatibility

Page 10: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

Safe and Reliable Driveheads

• When a PCP system shuts down,

accumulated energy is released and causes

the system to spin backward.

• To protect drive components, backspin

forces must be controlled

• G-Series driveheads feature a wet brake

system that uses centrifugal force, in

conjunction with cams and springs

Page 11: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

DuraSeal™ Environmental Stuffing Box

• Minimal maintenance required

• Redundant sealing ensures continued performance if main

seal is damaged

• Robust bearing system manages misalignment between

wellhead and drivehead

• Internal leak-detection system available

Page 12: Progressing Cavity Pumping Systems - UH SPEuhspe.org/wp-content/uploads/2014/11/Weatherford... ·  · 2014-11-18Progressing Cavity Pumping Systems ... • Low Power Consumption

© 2006 Weatherford. All rights reserved.

Monitoring, Control, Protection, and Optimization

• mPOD™3 multipoint digital gauge delivers accurate

and reliable monitoring of:

– pump vibration

– pressure and temperature at pump intake and

discharge

• Combined with WellPilot® VSD, this system

optimizes production, protects the pump, and

maximizes run life

59 to 257°F

(15 to 125°C)

mPOD3 Multipoint Digital Gauge


Top Related