Bhagyam_PCP_Overview RJ Operations

2013

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PCP (Progressive Cavity Pump)

PCP: A Progressive cavity pump is a type of positive displacement pump and is also known as a progressing cavity pump, eccentric screw pump or cavity pump.

PC Pumping Systems typically consist of the following components: Surface Equipment Drive head assembly VFD (Variable Frequency Drive) Down hole gauge Panel (Geophysical Research Company) BOP (Blow Out Preventer), Flow Tee – Kombi Tree Down hole equipment Stator (Stationary with tubing) Rotor (Internal & Rotary with drive rods)

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PCP System Configuration

Down hole EquipmentBelts &

Sheaves

Surface Drive

Electric Motor

Polished Rod

Sucker Rods

Surface Equipment

PC Pump Stator

PC Pump Rotor

No-Turn ToolTagbar

Sucker Rodsw/ Couplings

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Flow Tee

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General Features

Rotor :Is a high strength steel component externally machined as a helix of “n” lobes and coated with chrome or an alternative hard material.Only moving part.

Stator :Generally made with elastomer (or rubber) with and internal shape as an helix of “n+1” lobes. This rubber body is bonded to the interior of a steel tube. Stationary piece.

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Polish Rod and Clamp arrangement

The entire series of Polish rod, Sucker rod and Rotor is suspended in the downhole through the Polish rod clamp.

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PCP Drive head assembly Belts and Sheaves

The drive head assembly comprises of a Prime mover, Transmission system .

Prime mover is the driver, which in this case is the FLP(flameproof) Electric motor of 75HP.

Transmission system which transfers the power from the Prime mover to the Polished rod, which in this case is the Belt and sheaves.

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The basic functions of a surface PC drive are: Suspend the rod string and carry the axial loads Deliver the torque required at the polished rod Rotate the polished rod at the required speed in a safe manner Provide for safe release of the stored energy during shut-downs Prevent produced fluids from escaping the system

To achieve these functions, drives typically comprise the following components:

Thrust Bearing Transmission System (Fixed Gear or Sheaves & Belts) Braking Mechanism (or recoil control system) Stuffing Box

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Christmas Tree The PCP Christmas tree

assembly comprises of Master valve, BOP, kill wing valve and Drive head on top.

At the bottom we have tubing hanger which has got chemical injection connection and down hole gauge cable running up to the downhole.

The wing XSV is installed for the slam shut of the flow arm in case of trip scenario.

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VFD & GRC Panel VFD panel is an Electrical panel

which houses the VFD(Variable frequency drive) which is an electrical system used to vary the frequency of the input(to the panel) current.

It is important to control the RPM of the motor as per well behavior for which VFD is deployed.

The LCD screen display’s the parameters related to Motor i.e. frequency, current, avg voltage etc.

The Down hole gauge (GRC) panel is installed to monitor the well downhole parameters like Pump intake/discharge temperature & Pressure locally.

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Downhole Gauge Tool

The purpose of downhole gauge is to monitor the PIP(pump intake press), PDP(pump discharge press) and downhole temperature’s respectively.

It is important to closely monitor the PIP, PDP which gives a fair pump operation idea to operated optimally.

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PCP Rotor & Stator The polished rod is

coupled through a series of sucker rod to the Rotor of the pump.

The Rotor is an externally machined rod with helical lobes and is the only moving part downhole.

The Stator is generally made up of Elastomer and has got internal helical lobes. It is stationary part of the pump.

When rotor turns a series of sealed cavities forms and progress from suction to discharge resulting in non pulsating +ve displacement flow

Rotor

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No Turn Tool (NTT) NTT- To avoid backing-off

the tubing string when the system is operating and for easy release in opposite direction when the system stops and back-spins.

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Tag Bar It is the integral part of stator required as a reference to facilitate the installation and space out of rotor and sucker rod string.

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PCP Rotor & Stator

BWP-15, Well-13 well completion drawing

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Stator Elastomer Types

Elastomer Family

Elastomer code for stator labeling (ISO

compliance)Old

Name

New Commercial Name and approved ("nickname") General Description and Application

Water Resistance at

Low Temp (<50C)

Water Resistance at

Elevated Temp (>50C)

H2S Resistance **

Solids Resistance

CO2 Resistance **

Aromatics Resistance **

Max Fluid Temp. (°C) *

118 Buna Soft MN-118 (Soft)

Excellent wear and mechanical properties. Lower hardness compared to regular medium Nitrile. Recommended in heavy oil, high sand cut, foreign debris concentrations (ex. Iron Pyrite).

Fair Poor Fair Excellent Poor Poor 60

116 Buna(59O) MN-116

Very good wear and mechanical properties. Recommended for heavy oil, coal bed methane dewatering and water source wells.

Very good Good Fair Very good Fair Fair 80

309HN

(68A1) HN-309Good wear and mechanical properties. Good resistance to aromatics. Recommended for medium crudes, many light oils and nonaggressive chemicals.

Good Fair Good Good Fair Very good 80

306 NBRA HN-306 (NBRA)Good wear and mechanical properties. Good resistance to aromatics. Recommended for medium crudes, many light oils and nonaggressive chemicals.

Good Fair Good Good Good Very good 100

310 NBRHP HN-310 (NBRHP)Excellent wear and mechanical properties. Good resistance to aromatics. Recommended for medium crudes, many light oils and nonaggressive chemicals.

Good Good Good Very good Good Very good 100

312 100C HN-312 (Hi-Per)

Good wear and mechanical properties. Excellent resistance to aromatics, gas and explosive decompression. Recommended for light oil, many chemicals and applications with high GOR's. Higher stiffness facilitates higher capacity pressure ratings on applied pump models

Excellent Excellent Good Fair Excellent Excellent 100

501 HNBR HNBR-501

Higher temperature capability than standard nitriles. Excellent resistance to water and H2S. Recommended for medium crudes, elevated temperature coalbed methane dewatering and wells with significant H2S.

Excellent Excellent Excellent Very good Good Good 140

503 N/A HNBR-503 (LS)

Higher temperature capability than standard nitriles. Excellent resistance to water, good resistance to H2S and very good resistance to aromatics Recommended for medium crudes, many light oils, coalbed methane dewatering when at elevated temperatures.

Excellent Excellent Very good Very good Good Very good 140

Notes: Excellent* Fluid Temperature rating is for elastomer only. Limitations may occur due to bonding system depending on Fluid Composition. Very good** Limitations may occur at extreme levels under specific operating conditions. Good

FairPlease contact the WFT PCP Technical Tupport Team for specific recommendations regarding the best elastomer choice for your application Poor

Medium Ntirile

HighNitrile

HNBR

Elastomers for Progressing Cavity Pumps

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Advantages & Applications of a PC Pumping System Advantages Pump high volumes (800+ m3/day) Lift capacities of up to 2000 meters Pump a range of Oil Gravity’s from 5 to 35 API. Pump 100 % H2O Pump high density & viscosity fluids. Pump high concentrations of slurries. (70%) No valves to clog or gas lock Applications Sand-laden heavy crude oil and bitumen High-water cuts Various oil gravities with limits on H2S, CO2 and

aromatics Dewatering gas wells, such as coal bed methane projects All well types including horizontal, slant, directional and

vertical Offshore platforms (compatible with foot print restriction)

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PCP Safety system

The PCP protection:

Gas Detector (HI-alarm) : 20% Gas Detector (HI HI-Trip) : 40% High current : 65 - 70A Low current : 29A High discharge pressure : 1000psi Low intake pressure : 205 psi High rod speed : 475 rpm Low rod speed : 80 rpm High frequency clamp : 33 Hz Low frequency clamp : 10 Hz High Tubing head pressure : 31.5 bar

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Operating Parameters

Cause Effect Time Value Cause Effect Value

               

Low Currect Alarm 10 min 29 AmpLow FreqClamp clamp 10 Hz

  Trip After 10 min 29 Amp      

High current Alarm 0.1 min 65 – 70 AmpHigh Freq clamp clamp 33 Hz

  Trip After 0.1 min 65 – 70 Amp      

Low Intake Pr. Alarm NA        

  Trip NA        

High Discharge Pr. Alarm 0.0 min 1000 Psi      

  Trip After 0.0 min 1000 Psi      

High Rod Speed Alarm 0.0 min 475 rpm      

  Trip After 0.0 min 475 rpm      

Low Rod Speed Alarm 1.0 min 80 rpm      

  Trip After 1.0 min 80 rpm      

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PCP Well DCS Graphic page

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Vendors / Suppliers

1. Drive head assembly : Grenco 2. PCP stator / Rotor : Cameron 3. Christmas tree : Cameron 4. Packers : Halliburton 5. Variable Frequency Drives(VFD): Unico 6. Down hole data : Geophysical Research company

(GRC)

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PCP.mp4