gcp presentation web page
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GEARED CENTRIFUGAL PUMPA New High Volume Lift Method
Rod String Drive
Transmission
Upper Seals and Compensator
TransmissionLower Seals and Thrust Bearing
Pump
Rod String Drive
Pay ZoneGas Anchor
Drive Head
Drive Rod String
Receiver SectionUpper Seals and
Compensator
LowerSeals and Thrust Bearing
Transmission
Pump
Intake Stinger
Pay Zone
Drive Head
The Geared Centrifugal Pump
• A mechanically driven centrifugal pumping system.
• Rod string drives an ESP pump via a 7:1 gearbox increasing speed from 500 to 3500 RPM.
• No electrical components down hole.
• ESP capacity with better efficiency.
What is the GCP?
Rod String Drive
Transmission
Upper Seals and Compensator
TransmissionLower Seals and Thrust Bearing
Pump
Rod String Drive
Pay ZoneGas Anchor
Drive Head
Drive Rod String
Receiver SectionUpper Seals and
Compensator
LowerSeals and Thrust Bearing
Transmission
Pump
Intake Stinger
Pay Zone
Drive Head
The Geared Centrifugal Pump
GCP Components from the Bottom up
1
1
2
2
3
3
44
5
5
6
6
7
7
• Pump intake stinger• Centrifugal pump• Lower seal section with
thrust bearing• Transmission• Upper seal, compensator• Receiver• Tubing with a guided rod
string• Drive head8
8
Rod String Drive
Transmission
Upper Seals and Compensator
TransmissionLower Seals and Thrust Bearing
Pump
Rod String Drive
Pay ZoneGas Anchor
Drive Head
Drive Rod String
Receiver SectionUpper Seals and
Compensator
LowerSeals and Thrust Bearing
Transmission
Pump
Intake Stinger
Pay Zone
Drive Head
The Geared Centrifugal Pump
• A bottom intake pump – better gas handling
• Fluid load is carried by the tubing.– Axial rod load is the buoyant rod weight
so side loads are small.– Load on drive head thrust bearing
reduced
• Transmission – Multi-stage parallel shaft transmission– Unique PHG gearing provides high
power in a small diameter.
Unique Traits of the GCP
The Geared Centrifugal Pump Transmission
Before and after load is imposed
Before
After
Paired Helical Gearing - Operation
The Geared Centrifugal Pump Transmission
GCP Single-Stage prototype input spline shaft strain gauge torque – four gear-pair first stage.
.
0
100
200
300
400
500
600
700
800
900
1000
10 11 12 13 14 15 16 17 18 19
Time, seconds
Bridge 2Bridge 3Bridge 4Bridge 5
`
Tor
que,
ft-
lbs
4321
1 Input, 920 ft-lbs
2
3
4 220 ft-lbs
680 ft-lbs
440 ft-lbs
Harrier Technologies, Inc.
Geared Centrifugal PumpTransmission Gear Train Layout
1st Stage (PHG)
3rd Stage5th Stage
4th Stage
2nd Stage
Input
Output
13
The Geared Centrifugal Pump
Transmission - large D-channels for fluid flow
Rod String Drive
Transmission
Upper Seals and Compensator
TransmissionLower Seals and Thrust Bearing
Pump
Rod String Drive
Pay ZoneGas Anchor
Drive Head
Drive Rod String
Receiver SectionUpper Seals and
Compensator
LowerSeals and Thrust Bearing
Transmission
Pump
Intake Stinger
Pay Zone
Drive Head
The Geared Centrifugal Pump
Transmission - large D-channels for fluid flow
Rod String Drive
Transmission
Upper Seals and Compensator
TransmissionLower Seals and Thrust Bearing
Pump
Rod String Drive
Pay ZoneGas Anchor
Drive Head
Drive Rod String
Receiver SectionUpper Seals and
Compensator
LowerSeals and Thrust Bearing
Transmission
Pump
Intake Stinger
Pay Zone
Drive Head
Rod String Drive
Transmission
Upper Seals and Compensator
TransmissionLower Seals and Thrust Bearing
Pump
Rod String Drive
Pay ZoneGas Anchor
Drive Head
Drive Rod String
Receiver SectionUpper Seals and
Compensator
LowerSeals and Thrust Bearing
Transmission
Pump
Intake Stinger
Pay Zone
Drive HeadThe Geared Centrifugal Pump
• D-tube flow channels provide excellent cooling of gears and bearings
• Forced lube oil circulation reduces oil degradation due to stagnation
• Forced oil circulation prevents overheating during gas lock or pump-off.
• Modular construction – allows easy modification of transmission
Other Transmission Features
The Geared Centrifugal Pump
Other GCP Components
• Lower seal section - Contains tandem shaft seals and pump thrust bearing
• Upper seal section – triple shaft seals plus main transmission pressure compensator
• Receiver – accepts rod string drive shaft
•Rod string – equipped with spin-thru stabilizers
Rod String Drive
Transmission
Upper Seals and Compensator
TransmissionLower Seals and Thrust Bearing
Pump
Rod String Drive
Pay ZoneGas Anchor
Drive Head
Drive Rod String
Receiver SectionUpper Seals and
Compensator
LowerSeals and Thrust Bearing
Transmission
Pump
Intake Stinger
Pay Zone
Drive Head
The Geared Centrifugal Pump
GCP Rate Potential
• Same rate potential as an ESP with equal HP rating
• Nominal depth limit is 10,000 feetGeared Centrifugal Pump
Fluid Rate vs. Depth
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
0 1 2 3 4 5 6 7 8 9
Pump Depth, '000 feet
Flu
id R
ate
, B
FP
D
150 HP
100 HP
75 HP
200 HP
Rod String Drive
Transmission
Upper Seals and Compensator
TransmissionLower Seals and Thrust Bearing
Pump
Rod String Drive
Pay ZoneGas Anchor
Drive Head
Drive Rod String
Receiver SectionUpper Seals and
Compensator
LowerSeals and Thrust Bearing
Transmission
Pump
Intake Stinger
Pay Zone
Drive Head
Geared Centrifugal PumpRod String Testing
GCP Rod String Test Apparatus
• Objective: Test the effect of RPM, rod tension, well inclination and stabilizer spacing on rod stability
• Single 25 foot 1” drive rod inside 3-1/2” water-filled tubing
• Hydraulic drive 0 to 1100 RPM, variable tension up to 12,000 lbs
• Rod stability monitored via lasers and multiple view ports in tubing
• Rig inclination variable from 0 deg. (vertical) and 85 deg.
GCP Rod String Test Apparatus
GCP Rod String Test ApparatusRig at 60 deg. inclination
Harrier Technologies, Inc.
• Over 1000 test measurements
• At 0 tension and 500 RPM, rods require three stabilizers per rod for stable rotation
• Only one stabilizer per 25’ rod is required above 650 feet from bottom at 500 RPM
• Rods stable with one stabilizer per rod at 800 RPM above 850 feet from bottom.
• Well inclination has only a minor effect on rod stability
• Stable, smooth rod string drive for the GCP is easily achievable
GCP Rod String Testing Results
High Temperature GCP
• Initial reason for developing the GCP was for Conoco-Phillips’ Alberta, Canada SAGD project.
• SAGD project requires 2500 - 4000 BFPD at 250 deg. C.
• The 575H-100 GCP has transmission, thrust bearings, and pressure compensators specifically designed for high temperature service.
• High temperature spin through rod stabilizers developed for the SAGD application.
• High temperature GCP tested in a full assembly high temperature test loop. First field installation expected in 3rd quarter 2011.
Harrier Technologies, Inc.
• Full GCP assembly testing, including short rod string and stabilizer
• 3000 BFPD rate at 3000 psi and 250º C.
• 125 HP drive motor with VSD
• Monitor input torque, RPM, inlet and discharge pump pressures and temperatures, and flow rate
• All principal controls and data collection remote
High Temperature GCP Test Loop
Harrier Technologies, Inc.
Rod String Drive
Transmission
Upper Seals and Compensator
TransmissionLower Seals and Thrust Bearing
Pump
Rod String Drive
Pay ZoneGas Anchor
Drive Head
Drive Rod String
Receiver SectionUpper Seals and
Compensator
LowerSeals and Thrust Bearing
Transmission
Pump
Intake Stinger
Pay Zone
Drive Head
• Bottom intake pump provides better gas handling than ESP.
• ESP rates at lower cost and better efficiency (especially in 5-1/2” casing).
• Utilizes the best part of an ESP – the pump; eliminates the worst –the down-hole electric motor and cable.
• Surface drive – electric, IC, or hydraulic motor. Simple, inexpensive ‘VSD’ – just change the sheave.
• High temperature application - up to 250º C (482º F).
Advantages of the GCP