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Progressing Cavity Pumping Systems

© 2006 Weatherford. All rights reserved.


Progressing Cavity Pumping
System Advantages
Vertical
Electric Wellhead

• Low Capital Cost


Drive

• Low Surface Profile for Visual and


Casing Height Sensitive Areas
• High System Efficiency
Production Tubing
• Simple Installation, Quiet Operation
Sucker Rod
• Pumps Oils and Waters with Solids
Sucker Rod Coupling

Tubing Collar
• Low Power Consumption
Stator
Rotor
• Portable Surface Equipment
• Low Maintenance Costs
• Use In Horizontal/Directional Wells
Tubing Collar

• C-FER, WFT Proprietary


Tag Bar Sub
© 2006 Weatherford. All rights reserved.
Progressing Cavity Pumping
System Limitations
Vertical
Electric Wellhead
Drive

• Limited Depth Capability


• Temperature
Casing
• Sensitivity to Produced Fluids

Production Tubing
• Low Volumetric Efficiencies in
High-Gas Environments
Sucker Rod

• Potential for Tubing and Rod


Sucker Rod Coupling
Coupling Wear
Tubing Collar

Stator • Requires Constant Fluid Level


Rotor
Above Pump

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

Continuous, smooth, and


No valves to clog or wear
efficient operation

• Most efficient ALS, even for


extreme viscosities
• Low capital and operating • Best artificial-lift method for
cost sand-laden wells
• Low profile and small • Will never become
footprint inoperable due to gas lock

© 2006 Weatherford. All rights reserved.


Evolution and Growth of PCP Systems

1980 1,400 70,000

& Lift (ft/10)


Pump Displacement

Number of Installations
1,200 60,000

(B/D @Displacement
Pump Lift

100 rpm) and


Pump Displacement
1,000 50,000
Number of PCP Installations

(ft/10)
800 40,000

rpm)
600 30,000
(bpd/100Lift
• 50 B/D Pump
400 20,000
(8 m3/d)
200 PUMPS 10,000
• 2,000 ft 0 0
(600 m)
3,0001980 1985 1990 1995 2000 2005 2010 300

2,500 Surface Torque 250

Surface Power (hp)


Torque (ft*lbs)
(ft-lbf)

2,000 Surface Power 200


1,500 150
Torque

• 50 hp 1,000 100
(37 kW) 500 DRIVEHEADS 50
• 200 ft-lbf 0 0
(270 N•m) 1980 1985 1990 1995 2000 2005 2010

• Low rate, shallow wells • No backspin braking control


• Heavy oil • Zero monitoring and control
• Limited elastomer options • Rods from RRP applications
– Trial-and-error selection process

© 2006 Weatherford. All rights reserved.


Evolution and Growth of PCP Systems

1,400 70,000
Today
& Lift (ft/10)

Pump Displacement

Number of Installations
1,200 60,000
(B/D @Displacement

Pump Lift
100 rpm) and
Pump Displacement

1,000 50,000
Number of PCP Installations
(ft/10)

800 40,000
rpm)

600 30,000
(bpd/100Lift

• 4,000 B/D
Pump

400 20,000
(8 m3/d)
200 PUMPS 10,000
0 0
• 10,000 ft
(3,050 m)
3,0001980 1985 1990 1995 2000 2005 2010 300

2,500 Surface Torque 250

Surface Power (hp)


Torque (ft*lbs)
(ft-lbf)

2,000 Surface Power 200


1,500 150
Torque

1,000 100 • 300 hp


500 DRIVEHEADS 50 (220 kW)
0 0 • 2,500 ft-lbf
1980 1985 1990 1995 2000 2005 2010 (3,400 N•m)

• Higher rates, deeper wells • Safe backspin control systems;


• Heavy, medium and light oils; environmental stuffing boxes
More than 60,000 wells
• VSDs; downhole and surface sensors
CBM dewatering
operating with PCP
• Local and remote monitoring and control
systems
• High-torque rods and connections;
COROD® continuous rod

© 2006 Weatherford. All rights reserved.


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

Controllers,
Driveheads and
automation
stuffing boxes
and software

Rod string options


• Types
Installation options
• Materials
• Geometries

Downhole Pump options


• Rotor geometry
monitoring • Elastomer composition

© 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 Extreme swelling due to


caused by pump off 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

• 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

mPOD3 Multipoint Digital Gauge

59 to 257°F
(15 to 125°C)

© 2006 Weatherford. All rights reserved.

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