Introduction to PCP System and Components

Name
Title
 Introduction

Safety Exits and procedure

Sign in sheet

-cell phones

Personal Introductions
-name, location, position
-goals for course

2
 Agenda

Time Day 1 Day 2 Day 3 Day 4 Day 5

Welcome Introduction Quiz and Review Quiz and Review Quiz and Review Quiz and Review
8:00

Metal PCP/Insert PCP

9:00
PCP Components

Rodles PCP PCP Design CFER Design and Discusion CFER Design and Discusion
10:00

PCP Fundamentals Rod String Failures

11:00

Lunch Lunch Lunch Lunch Lunch

12:00

Tubing Failures

13:00
PCP Fundamentals

Pump Failures
14:00
PCP Design and Optimization CFER Design and Discusion CFER Design and Discusion

15:00
Elastomer Selection

Installation
16:00
 What is a PCP?
Video)
It is a rotary positive displacement pump in which the fluid is
carried between screw threads on rotors and displaces axially
as the screws rotate. This type of pump is made of two
elements: rotor and stator.
PCP in the World
PCP by Application
 ADVANTAGES
 Produce high viscosity fluids
 Low internal shear rates
 Continuous power demand
 No valves or reciprocating parts to clog, gas lock or wear
 Tolerates high percentages of free gas
 Low capital and power cost
 Simple installation and operation
 Good abrasion resistance
 Small footprint
 Artificial Lift Efficiency Comparison
Energy Efficiency: Most Typical Range Overall Range Reasons for Inefficiencies:

Slippage through the pump; friction effect in pump; losses in energy

PCP transmission from surface to pump; internal losses of the surface drive
system; handling of multiphase fluids
Slippage through the pump; losses in energy transmission from surface to
Rod pump; extra-energy utilized to overcome peaks in upstrokes; handling of
multiphase fluids
Dynamic pump with maximum mechanic efficiencies not greater than 80%
ESP (60% if radial configuration); Electrical losses in bottomhole motor and
power cable; equipment itself consume about 30% of the energy; handling
of multiphase fluids

Considerable amount of energy utilized to handle power fluid; internal

Jet Hyd. energy losses in the diffuser of the pump; energy losses associated to
surface equipment; handling of multiphase fluids

Most of the energy utilized to compress the gas (over 40%); friction losses
GL Cont.
across pipelines and wellbore annular area; further expansion of gas

Most of the energy utilized to compress the gas (over 40%); friction losses
GL Int.
across pipelines and wellbore annular area; further expansion of gas, the
non-continuous operation of the system

0 10 20 30 40 50 60 70 80 90 100 %
 Artificial Lift Technology Comparison
Well Conditions Unit PCP SRP ESP
ft. 11,000 16,000 15,000
Max Rec. Operating Depth (TVD)
m 3,300 4,080 4,570
bbl./d 5,000 5,000 60,000
Max Rec. Production Rate
m³/d 800 800 9,550
F° 250 * 550 400
Operating Temperature
C° 120 * 288 204
Corrosion Resistance N/A Good & Excellent Good Good
Gas Handling (Free Gas) N/A Good Fair Good
Solid Handling (Sand Cut) N/A Excellent Fair Fair
Oil Gravity °API 5 - 45 10 - 45 >10
System Efficiency % 50 - 75 45 - 60 35 - 60
Foot Print N/A Excellent Poor Excellent
Capital Cost N/A Excellent Good Poor
Fluid Emulsification Resistance N/A Excellent Excellent Poor
Production Operation Range N/A Excellent Good Poor
 PCP Application Range (conventional)
Well Conditions Unit Conventional Range Maximum Value
ft. 1,000 - 6600 8,600
Operating Depth (TVD)
m 330 - 2,000 2,500
bbl./d 5 - 3,800 6,300
Production Rate
m³/d 1 - 600 1,000
F° 75 - 185 250
Operating Temperature
C° 24 - 85 120
°/100ft 0-5 15
Wellbore DLS
°/30m 0-5 15
Corrosion Resistance N/A Excellent
Gas Handling (Free Gas) % 0 - 45 60
Solid Handling (Sand Cut) % 0-3 50
Oil Gravity °API 5 - 40 45
H2S Content % 0-5 15
CO2 Content % 0-7 20
Water Cut % 0 - 100
System Efficiency % 50 - 75
Serviceability N/A Required crane or workover rig
Prime Mover N/A Electric motor or internal combustion engine
 TOTAL FLUID PRODUCED

Avg. Water Cut = 67%

Source: The Welling Report; 2014

 PCP Typical Applications
HEAVY OIL
less than 18 API Gravity:
 500 to 100,000 cps viscosity
 300 to 1100 meters (1000-3500 ft)
 up to 500 m /day (3,150 bls/day)
3
 sand cuts up to 50%
 water cuts up to 100%
 low aromatics, GOR
 H S and CO
2 2 possible
MEDIUM OIL
18 to 30 API Gravity:
 less than 500 cps viscosity
 600 to 1400 meters (2000-4500 ft)
 up to 500 m /day (3150 bls/day)
3
 less than 2% sand cuts
 water cuts up to 100%
 greater possibilities of aromatics,
higher GOR, H2S and CO2
 PCP Typical Applications

LIGHT OIL WATER:

over 30 API Gravity:  Water Source Wells

 Less than 20 cps Viscosity  Gas Water Separation
 Coalbed Methane Extraction
 Over 1000 Meters (3200 ft)
 Up to 800 m3/day (5000 bls/day)
 up to 500 m3/day (3150 bls/day)
 Depth 100 to 500 m (300 to 1500 ft)
 Trace sand
 Negligible Aromatics
 Water cuts up to 100%
 High GLR’s
 High possibility of aromatics, High
GOR’s, H2S and CO2
 H2S and CO2 possible
 PCP footprint

Northern Alberta, Canada

 High Sand Cut (Video)

Akzar, Kazakhstan
 CHOPS Application

Eastern Alberta, Canada

 Slant Well Application

Central Alberta, Canada

 SAGD Application

Northern Alberta, Canada

PCP Animation – PCP System Overview
PCP System Components
Surface Equipment

Subsurface Equipment
 Subsurface Equipment

Tubing string to Sucker rod string

surface to surface

Centralizer
Pup joint/Orbit
Tube
Pony rod
Stator
PR Coupling
Rotor
Torque Anchor

Tag sub
 PCP components
Progressing Cavity Pump (PCP) consists of two components: Rotor, Stator

ROTOR
•Moving (rotating) part
•Machined of high strength steel bar and coated with
chrome (CH) or sprayed with special compound (TC)
•It makes contact with the elastomer along the seal line to
create closed cavities
•The pump efficiency is determined by the diameter of the
rotor, causing more or less interference fit between the
rotor and the stator.

STATOR
•Stationary part
•Tubing with bonded elastomer
 PC Pump Model Description

 ISO 15136-1 governs Progressing Cavity Pump specification

 First number – Pump Rate Capacity (m³/d) at 100 RPM and zero differential pressure
 Second number – Pump Lift Capacity (m of water column)

Example: Pump 16K1200

 16m³/d at 100RPM and 0 Head
 1,200m of lift (rated pressure - 12,000kPa) Stator P/N

Stator S/N

Rotor S/N
Rotor Manufacturing
PCP Geometry Options
Pump Models Distribution
 Chrome Coating Alternative - TOUGH COAT
 Tough Coat is spray metal coating applied to PCP rotors
 Tough Coat rotors have significantly improved resistance to corrosion and
abrasion
 TC rotors have longer rotor life with less degradation of efficiency over time
 PCP Stator

 The stator consists of a steel tube encasing

an injected molded elastomer. The
elastomer is injected around a core, when
the elastomer cools (vulcanizes) the core is
removed.
 The elastomer is held to the steel casing by
special bonding agent

Steel Tube

Injected Elastomer
PCP Torque Anchor

 Designed to prevent rotation of the tubing sting

 Centralizes and stabilizes stator in casing
Options for KUDU CAM-LOC Torque Anchor
Other options for Torque Anchors
 PCP Anti vibration Sub

 Provides support for PCP stator

 Reduces vibrations for high capacity pumps
 PCP Tag Sub Options

 Provides space out reference point

 PC Pump intake
 Types of Tag Subs
− Standard Tag Sub
− Slotted Tag Sub
− Notched Tag Sub
− XL Tag Sub
− XL Slotted Tag Sub
− XL Notched Tag Sub
PCP TOP–TAG SYSTEM

Tag
 PCP Top-Tag Animation

Top-Tag Installation Animation

PCP System Rod String – General Information

 Locates rotor in tubing string

 Acts as a drive shaft to transmit torque to
the rotor from the surface drivehead
 Must handle maximum torque
 Must fit inside tubing
 Not have excessive flow losses
 Main contributing factors to premature
failures due to mishandling, improper
installation, and improper application
PCP System Rod String – Torque Transition
 Most of the torque comes from the
face to face contact between the
shoulder of the rod and the coupling.
 Dirt or over lubrication will result is
reduction in torque below the rating of
the rod body.
PCP System Rod String - Installation

 Make up of the Rod String connections

in the field require the use of a
displacement rod card.

 Effective makeup torque can be

achieved by following the API
recommendations in Section5 of the
RP11BR “ API Recommended Practice
for Care and Handling of Sucker Rods”
PCP System Rod String - Specifications
PCP System Rod String – Continuous Rods

 Benefits:
− Reduced wear on tubing in
deviated/horizontal wells
− Less flow restriction with absence of
couplings
− Faster rod installation and removal
 Challenges:
− Need injector unit and spools of
continuous rods.
− Not available in many areas of the world
 CONTINUOUS ROD vs. CONVENTIONAL ROD

 Larger flow area resulting in lower

pressure losses, lower torque and
lower pump pressure head rating
required.
 Less rod tubing wear.

Continuous Rod Sucker rod couplings

 Hollow Rods

 Benefits:
− Reduced wear on tubing in deviated/horizontal
wells as there is no or minimal upsets at
connections (used in HT applications)
− More rigidity and higher torque rods
− Ability to inject through rods if required
 Challenges:
− Higher material cost
− Unique and large diameter
− Need special tongs to make up connections
− No well control options
PCP System Rod String – Shear Coupling

 Allows to retrieve rod string with stuck

pump
PCP System Rod String - Centralizers

 Rod centralizers stabilize the rod string to reduce or

eliminate rod tubing wear.
 Sucker Rod Centralizers eliminate rod coupling wear
 Reduce torque in deviated wells and lower work over
frequency.
 Radial forces in slant or deviated/horizontally drilled
wells require centralizers.
 Reduce wellbore harmonics
 Reduces effects of rod wrapping
 Reduces required HP in highly deviated applications
Rod String Centralizer Options
 Gas Separator and Horizontal Intake

 Spiral gas separator – fluid flows through center, gas

vents to outside

 Horizontal intake sub – allows inflow when fluid above

mandrel, closes when gas above intake
 Pressure Switch (Presco)
 Allows automatically shutdown the well to prevent
overpressure of downhole or surface equipment
 Prevents accidental activation of drain valve
 Can be automatic or manual reset
 Tubing Drain
 Drain well fluid from tubing when pump is stuck
 Different styles based on customer preference
 Surface Equipment

Polished Rod
PR Coupling Belt guard
Bearing housing
Prime mover
Wellhead frame

Blowout preventer
Pressure switch
 Drivehead Models and Specifications
 Model designations provide the following information:
− Type: V Vertical
H Hollow Shaft
G Gear Driven
− Power: Maximum horsepower
− Load: Maximum thrust load (tons) based upon (L10lifetime) of
25,000 hours at 500 RPM

− Example: VH 60HP - 9.3T

Vertical mounted with Hollow Shaft. Its maximum power is 60 HP and its
maximum load is 9.3T.
 Drivehead Options

VH60
VH100

VHGH VH200
PCP Drive Systems - Functions

 Suspend rod string and carry axial

load (thrust bearing)
 Deliver proper torque to the polished
rod
 Rotate Polished Rod (Rod String,
Rotor) at defined speed
 Provide safe release of stored energy
during backspin
 Prevent well fluid from escaping the
system
 PCP Drivehead Assembly 1
2
3
1 – Polish Rod Clamp
2 – Hollow Shaft
3 – Belt Guard
4 – Backspin Brake
5 – Motor Plate 4
6 – Motor Plate Frame 5
7 – Bearing Housing
6
8 – Surface Seal
7
9 – Wellhead Frame
8
9
 PCP Drivehead Bearing Housing Assembly
1
1 – Hollow Shaft 11-Thrust Bearing
2
2 – Brake Disc 12-Top Seal
3 – Brake Caliper 13-Top Radial Bearing 3
4 – Breather Cap 14-Internal Centrifugal Pump 4
5 – Oil Filling Inlet 15-Oil Drain Outlet
6 – Motor Plate Frame 16-Bottom Radial Bearing 5
7 – Gauge Ports 17-Bottom Seal 6
8 – Oil Filter Connector
9 – Flow Regulator
7
12
10-Internal Manifold 8
13 9
14
10
15
11
16
17
PCP Drivehead – Oryx Seal

 Benefits:
− Low Maintenance
− Lubricated with oil confined in
chamber.
− Maximum static load of 9.0T
− Rated for 500psi operational and
2,000psi static.
− Early warning device that lower
seals are failing.
PCP Drivehead - Regular Stuffing Box

Stuffing Box Assembly:

1 - Frame
2 – Bronze Bushing
3 – Bronze Ring, Packing Retainer
4 – Packing Rings
5 – Bronze Ring, Lantern
6 – Bronze Gland, Packing Retainer
7 – Leap Seal
8 – Stuffing Box Cap
PCP Drivehead – Hollow Shaft
 Enables the polished rod to pass
through the drivehead
 The operation allows the backwash of
the pump from solids
 Supported by the following three large
roller bearings:
− One thrust bearing supporting the
axial load
− Two radial bearings supporting the
radial load
 PCP Drive System – Back Spin

 During operation, energy is stored in the rod string

 When the PCP shuts down, the rods release this energy by
spinning in counterclockwise direction
 If left unchecked, can lead to surface equipment damage,
backed off tubing, and rod strings
 Backspin continues until fluid in tubing and annulus is
equalized

Uncontrolled Back Spin = Danger

PCP Drive System – Brake (Video)

 Liberate the potential energy accumulated

in the system; torque in the rod string and
hydrostatic head.
 Control the backspin speed and to keep it
below maximum rated speed
PCP Drive System – Types

 Transmit the power from the prime

mover to the polished rod

Most common:

− Fixed Belts & Sheaves

− Hydraulic
− Direct Angle
− Mechanical Gears
 Preferred Drive Type

Source: The Welling Report; 2014

 PCP Drive System – Wellhead Equipment (Video)

Flow Tee Composite BOP

RodLoc Composite BOP Hammer Union

PCP Drive System Power Supply Options

 Electrical (genset) and hydraulic power units

 Dual fuel supply: casing (natural) gas,
propane
 Accessible and climate controlled enclosure
with sound attenuated option
 Genset configuration for power output:
50/380 or 60/480
 Cold climate heat trace system for flowline
and wellhead
 Safety and preventive shutdown features
PCP Drive System Automation Options
PCP Drive System Automation Options

 Level 1 – Basic VFD

 Level 2 – VFD and HMI
- Data collection
- Easy to read outputs
- Simple interface
 Level 3 – Level 2 plus
- Advanced production optimization
- Flow and downhole parameters
measurement and control
- Five different control methods