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
Surface Equipment Down hole Equipment
Belts &
Sheaves
Surface Drive Sucker Rods
w/ Couplings
Electric Motor
PC Pump Stator
Flow Tee
Polished Rod PC Pump Rotor
Sucker Rods
Tagbar
No-Turn Tool
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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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Rotor 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
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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
Elastomers for Progressing Cavity Pumps
Water Water
Elastomer code for New Commercial Name Resistance at Resistance at Max Fluid
Elastomer stator labeling (ISO Old and approved Low Temp Elevated Temp H2S Solids CO2 Aromatics Temp.
Family compliance) Name ("nickname") General Description and Application (<50C) (>50C) Resistance ** Resistance Resistance ** Resistance ** (°C) *
Excellent wear and mechanical properties. Lower
hardness compared to regular medium Nitrile.
118 Buna Soft MN-118 (Soft) Fair Poor Fair Excellent Poor Poor 60
Recommended in heavy oil, high sand cut, foreign
Medium
debris concentrations (ex. Iron Pyrite).
Ntirile
Very good wear and mechanical properties.
Buna
116 MN-116 Recommended for heavy oil, coal bed methane Very good Good Fair Very good Fair Fair 80
(59O)
dewatering and water source wells.
Good wear and mechanical properties. Good
HN
309 HN-309 resistance to aromatics. Recommended for medium Good Fair Good Good Fair Very good 80
(68A1)
crudes, many light oils and nonaggressive chemicals.
Good wear and mechanical properties. Good
306 NBRA HN-306 (NBRA) resistance to aromatics. Recommended for medium Good Fair Good Good Good Very good 100
crudes, many light oils and nonaggressive chemicals.
High
Nitrile Excellent wear and mechanical properties. Good
310 NBRHP HN-310 (NBRHP) resistance to aromatics. Recommended for medium Good Good Good Very good Good Very good 100
crudes, many light oils and nonaggressive chemicals.
Good wear and mechanical properties. Excellent
resistance to aromatics, gas and explosive
decompression. Recommended for light oil, many
312 100C HN-312 (Hi-Per) Excellent Excellent Good Fair Excellent Excellent 100
chemicals and applications with high GOR's. Higher
stiffness facilitates higher capacity pressure ratings on
applied pump models
Higher temperature capability than standard nitriles.
Excellent resistance to water and H2S. Recommended
501 HNBR HNBR-501 Excellent Excellent Excellent Very good Good Good 140
for medium crudes, elevated temperature coalbed
methane dewatering and wells with significant H2S.
HNBR
Higher temperature capability than standard nitriles.
Excellent resistance to water, good resistance to H2S
503 N/A HNBR-503 (LS) and very good resistance to aromatics Recommended Excellent Excellent Very good Very good Good Very good 140
for medium crudes, many light oils, coalbed methane
dewatering when at elevated temperatures.
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
Fair
Please contact the WFT PCP Technical Tupport Team for specific recommendations regarding the best elastomer choice for your application 15 Poor
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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 Freq
Low Currect Alarm 10 min 29 Amp Clamp clamp 10 Hz
Trip After 10 min 29 Amp
High Freq
High current Alarm 0.1 min 65 – 70 Amp 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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