progressing cavity pumping systems - uh cavity pumping systems ... • low power consumption ......

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  • 2006 Weatherford. All rights reserved.

    Progressing Cavity Pumping Systems

  • 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

  • 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

  • 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

  • 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

  • 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 Nm)

    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

  • 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 Nm)

    4,000 B/D

    (8 m3/d)

    10,000 ft

    (3,050 m)

    More than 60,000 wells

    operating with PCP systems

  • 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

    Section 29 Weatherford Corporate Differentiators.pptxSection 29 Weatherford Corporate Differentiators.pptxSection 29 Weatherford Corporate Differentiators.pptxSection 29 Weatherford Corporate Differentiators.pptxSection 29 Weatherford Corporate Differentiators.pptxSection 29 Weatherford Corporate Differentiators.pptx

  • 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

  • 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

  • 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

  • 2006 Weatherford. All rights reserved.

    Monitoring, Control, Protection, and Optimization

    mPOD3 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 257F

    (15 to 125C)

    mPOD3 Multipoint Digital Gauge

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