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© 2006 Weatherford. All rights reserved.
Progressing Cavity Pumping Systems
© 2006 Weatherford. All rights reserved.
Progressing Cavity Pumping System Advantages
• Low Capital Cost
• Low Surface Profile for Visual and
Height Sensitive Areas
• High System Efficiency
• Simple Installation, Quiet Operation
• Pumps Oils and Waters with Solids
• Low Power Consumption
• Portable Surface Equipment
• Low Maintenance Costs
• Use In Horizontal/Directional Wells
• C-FER, WFT Proprietary
Vertical
Electric Wellhead
Drive
Casing
Production Tubing
Sucker Rod
Sucker Rod Coupling
Tubing Collar
Stator
Rotor
Tubing Collar
Tag Bar Sub
© 2006 Weatherford. All rights reserved.
• Limited Depth Capability
• Temperature
• Sensitivity to Produced Fluids
• Low Volumetric Efficiencies in
High-Gas Environments
• Potential for Tubing and Rod
Coupling Wear
• Requires Constant Fluid Level
Above Pump
Progressing Cavity Pumping System Limitations
Vertical
Electric Wellhead
Drive
Casing
Production Tubing
Sucker Rod
Sucker Rod Coupling
Tubing Collar
Stator
Rotor
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
• Most efficient ALS, even for
extreme viscosities
• Low capital and operating
cost
• Low profile and small
footprint
Continuous, smooth, and
efficient operation
• Best artificial-lift method for
sand-laden wells
• Will never become
inoperable due to gas lock
No valves to clog or wear
© 2006 Weatherford. All rights reserved.
Evolution and Growth of PCP Systems
1980
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
0
200
400
600
800
1,000
1,200
1,400
1980 1985 1990 1995 2000 2005 2010
Num
ber o
f Ins
talla
tion
s
Pum
p D
ispl
acem
ent
(bpd
/100
rpm
) & L
ift(
ft/1
0) Pump Displacement
Pump Lift
Number of PCP Installations
0
50
100
150
200
250
300
0
500
1,000
1,500
2,000
2,500
3,000
1980 1985 1990 1995 2000 2005 2010
Surf
ace
Pow
er (h
p)
Torq
ue (
ft*l
bs)
Surface Torque
Surface Power
PUMPS
DRIVEHEADS
Pu
mp
Dis
pla
cem
en
t
(B/D
@ 1
00 r
pm
) an
d
Lif
t (f
t/10)
To
rqu
e (
ft-l
bf)
• 50 hp
(37 kW)
• 200 ft-lbf
(270 N•m)
• 50 B/D
(8 m3/d)
• 2,000 ft
(600 m)
• Low rate, shallow wells
• Heavy oil
• Limited elastomer options – Trial-and-error selection process
• No backspin braking control
• Zero monitoring and control
• Rods from RRP applications
© 2006 Weatherford. All rights reserved.
Evolution and Growth of PCP Systems
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
0
200
400
600
800
1,000
1,200
1,400
1980 1985 1990 1995 2000 2005 2010
Num
ber o
f Ins
talla
tion
s
Pum
p D
ispl
acem
ent
(bpd
/100
rpm
) & L
ift(
ft/1
0) Pump Displacement
Pump Lift
Number of PCP Installations
0
50
100
150
200
250
300
0
500
1,000
1,500
2,000
2,500
3,000
1980 1985 1990 1995 2000 2005 2010
Surf
ace
Pow
er (h
p)
Torq
ue (
ft*l
bs)
Surface Torque
Surface Power
PUMPS
DRIVEHEADS
Pu
mp
Dis
pla
cem
en
t
(B/D
@ 1
00 r
pm
) an
d
Lif
t (f
t/10)
To
rqu
e (
ft-l
bf)
• Safe backspin control systems; environmental stuffing boxes
• VSDs; downhole and surface sensors
• High-torque rods and connections; COROD® continuous rod
• Higher rates, deeper wells
• Heavy, medium and light oils;
CBM dewatering
• Local and remote monitoring and control
Today
• 300 hp
(220 kW)
• 2,500 ft-lbf
(3,400 N•m)
• 4,000 B/D
(8 m3/d)
• 10,000 ft
(3,050 m)
More than 60,000 wells
operating with PCP systems
© 2006 Weatherford. All rights reserved.
Engineering a Well-integrated, Fit-for-purpose PCP System
Driveheads and
stuffing boxes
Installation options
Controllers,
automation
and software
Rod string options • Types
• Materials
• Geometries
Downhole
monitoring
Pump options • Rotor geometry
• 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
caused by pump off
Extreme swelling due to
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
59 to 257°F
(15 to 125°C)
mPOD3 Multipoint Digital Gauge
Recommended