Progressing cavity pumps : oil well production artificial lift

226 Pages·2013·7.75 MB·English

by  Wittrisch

Christian WITTRISCH
Henri CHOLET
IFP Energies nouvelles
PROGRESSING
CAVITY
PUMPS
Oil Well Production Artificial Lift
Second Edition
Revised and Expanded
2013
Editions TECHNIP 25 rue Ginoux, 75015 PARIS, FRANCE
FROM THE SAME PUBLISHER
Heavy Crude Oils
From Geology to Upgrading. An Overview
A Y. HUC
Multiphase Production
Pipeline Transport, Pumping and Metering
J. FALCIMAIGNE, S. DECARRE
Corrosion and Degradation of Metallic Materials
Understanding of the Phenomena and Applications in Petroleum and Process
Industries
F. ROPITAL
A Geoscientist’s Guide to Petrophysics
B. ZINSZNER, F.M. PERRIN
Physico-Chemical Analysis of Industrial Catalysts
A Practical Guide to Characterisation
J. LYNCH
Petroleum Microbiology (2 vols.)
J.P. VANDECASTEELE
Acido-Basic Catalysis (2 vols.)
Application to Refining and Petrochemistry
C. MARCILLY
CO, Capture
Technologies to Reduce Greenhouse Gas Emissions
J. LECOMTE, P. BROUTIN, E. LEBAS
Chemical Reactors
From Design to Operation
P. TRAMBOUZE, J.P. EUZEN
The Geopolitics of Energy
J.P. FAVENNEC
Marine Oil Spills and Soils Contaminated by Hydrocarbons
Environmental Stakes and Treatment of Pollutions
C. BOCARD
Well Production Practical Handbook
H. CHOLET
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0 Editions Technip, Paris, 20 13.
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ISBN 978-2-7108-0998-2
List of figures
Figure 1 Moineau Deauville competition (source: Musée de l’Air et de l’Espace) page 3
Figure 2 René Moineau’s “Capsulism” pump (source: PCM) page 3
Figure 3 René Moineau’s life 1887-1948 (source: Edition de l’Officine) page 5
Figure 4 Single lobe PCP type 1-2, rotor and stator view (source: National Oil Well) page 10
Figure 5-1 Operating principle diagram of PCP 1-2 (source: PCM) page 11
Figure 5-2 PCP 1-2 operating principle (source: Petrobras) page 12
Figure 6-1 Pump type 3-4: Hypocycloids H and H (source: PCM) page 13
1 2
Figure 6-2 Pump type 3-4 Hypocycloid envelopes (source: PCM) page 13
Figure 6-3 Hypocycloid profile cross sections page 14
Figure 7 Pump 1-2 geometry (source: PCM and IFP Energies nouvelles) page 16
Figure 8-1 Rotor-Stator perspective page 17
Figure 8-2 Mono lobe (1-2) Rotor and stator geometry (source: IFP Energies nouvelles) page 17
Figure 9 Multi lobe pump relationship (source: M.T. Gusman and D.F. Baldenko) page 20
Figure 10 Multi lobe pumps geometry example (source: Netzsch) page 21
Figure 11 PCP typical configuration (source: Protex) page 23
Figure 12 PCP efficiency versus rotor fit and pump life (source: OilLift Technology Inc) page 36
Figure 13-1 Definition Heavy Oil, Extra-Heavy Oil (source: API & Canadian Center page 38
of Energy)
Figure 13-2 Specific gravity/API Conversion page 38
Figure 13-3 Composition of Extra-Heavy Oil and Light Oil page 39
(source: IFP Energies nouvelles)
Figure 14-1 Temperature effect on oil viscosity (source: From Owens and Souler) page 40
Figure 14-2 Heavy oil/kerosene dilution and viscosity reduction page 41
(source: IFP Energies nouvelles)
Figure 15 Flow rate and PCP position in an oil well containing gas page 49
(source: IFP Energies nouvelles)
Figure 16 Recommended limitations of working for wells containing sand page 51
(source: PCM)
Figure 17 Relationship between the rotating speed and the fluid level page 53
(source: IFP Energies nouvelles)
Figure 18 PCP performance curves (source: ISO15136-1) page 58
Figure 19-1 Example of pump manufacturer specification sheet page 64
(source: OilLift Technology Inc)
214 Progressing Cavity Pumps
Figure 19-2 Example of pump manufacturer specification sheet (source: PCM) page 65
Figure 19-3 PCP data sheet well completion and production page 67
(source: IFP Energies nouvelles)
Figure 20-1 Flow pattern in vertical wells (source: A.E. Dukler. University of Houston) page 72
Figure 20-2 Flow pattern in horizontal pipes (source: A.E. Dukler. University of Houston) page 72
Figure 21 Static gas separator (source: IFP Energies nouvelles/Horwell) page 74
Figure 22 Centrifugal gas separators (source: CANAM, Evolution Oil tools) page 75
Figure 23 Gas separator systems for horizontal wells (source: IFP Energies nouvelles) page 76
Figure 24 Non-dimensional gas liberation curve (source: Nabla Corporation) page 78
Figure 25 Relation between fluid level and PCP performance page 80
(source: C.S. Resources/IFP Energies nouvelles)
Figure 26 Solid drive rods (source: Tennaris) page 81
Figure 27 Drive rod and NON rotating centralizers (source: PCM and Canam) page 87
Figure 28 Drive string/Tubing contact geometry (source: IFP Energies nouvelles) page 89
Figure 29 Centralizer location in relation to side force versus well profile (source: PCM) page 90
Figure 30 Hollow PCPRods (source: Tennaris) page 92
Figure 31 Continuous drive rod and transport (source: Weatherford) page 94
Figure 32-1 Tubing anchor catcher fixed to the PCP stator (source: Halliburton) page 96
Figure 32-2 Torque anchor under PCP stator (source: Evolution Oils Tools Inc) page 97
Figure 33 Drive head with solid shaft (source: PCM) page 102
Figure 34 Drive head with hollow shaft and return angle drive (source: Griffin Pumps) page 103
Figure 35-1 Rod twist before pump stars (source: Zenith Oilfield tech) page 104
Figure 35-2 Drive head with back-spin brake rotor (source: KUDU) page 105
Figure 36 Examples of drive systems (source: PCM) page 107
Figure 37-1 Belt drive head (source: Oil Lift Technology) page 111
Figure 37-2 Drive head for slant well Source (source: Kudu) page 112
Figure 37-3 Electric and hydraulic drive head (source: GrenCo) page 112
Figure 37-4 Hydraulic drive head (source: KUDU) page 113
Figure 37-5 Hydraulic vertical drive head (source: Weatherford) page 113
Figure 37-6 Moyno hydraulic Gear Drivehead (source: R&M Energy Systems) page 114
Figure 37-7 Gear drive (source: OilLift Technology Inc) page 114
Figure 38-1 Direct Drive PCP head with permanent magnet motor page 115
(source: Daqing Jinghong Petroleum Equipment Factory)
Figure 38-2 Direct Drive PCP head with permanent magnet motor page 115
(source: Source Shengli Electric limited Company)
Figure 38-3 Direct Drive PCP head with permanent magnet motor page 116
(source: Torquedrive head from Advantages
Figure 39 Rotating seal Stuffing Box
DuraSeal-500 Rotating Stuffing Box (source: Weatherford) page 118
Zero leak stuffing (source: CAN-K) page 118
List of figures 215
Figure 40 Rod Lock BOP (source: OilLift Technology Inc) page 119
Figure 41 RODEC Tubing Rotator Spool (source: RODEC/R&M) page 119
Figure 42 Running in the rotor (source: IFP Energies nouvelles) page 123
Figure 43 Running in rods (source: IFP Energies nouvelles) page 124
Figure 44-1 Basic principle Insert progressing cavity pump page 130
(source: IFP Energies nouvelles)
Figure 44-2 Insert PCP Systems (source: KUDU) page 131
Figure 45 Electrical Submersible PCP Schematic principle (source: Baker Centrilift) page 134
Figure 46-1 RedaMAX ES flat or round power cable (source: Schlumberger) page 137
Figure 46-2 Examples of cable clamp protectors
Composite material cable protector (source: BossCLAMP Artificial page 138
Lift company)
Cast steel cross coupling cable (source: S.U.N. Engineering) page 138
Figure 47 Well head with power feed thru connector (source: ITTCannon/BIW) page 138
Figure 48 Permanent Magnet Electric Motor Principle page 140
Figure 49 Multiphase PCP rotor and stator principle: patent (source: Bratu) page 149
Figure 50-1 PCP pump metal stator and rotor (source: PCM) page 152
Figure 50-2 PCM Vulcain MET Pump characteristics (source: PCM) page 153
Figure 51 Solid metal stator (source: Robbins&Myers Energy Systems) page 154
Figure 52 PCP metal stator principle: patent (source: IFP Energies nouvelles) page 154
Figure 53 Uniform thickness stator elastomer and standard stator page 155
(source: EUROMax PC pumps)
Figure 54 Hollow rotor (source: Kachelle) page 156
Figure 55 Injection through rotor to the horizontal drain hole: patent page 157
(source: IFP Energies nouvelles)
Figure 56-1 Drive head with a lateral injection swivel port (source: KUDU) page 157
Figure 56-2 Hollow drive head injection and coiled tubing drive string page 158
(source: IFP Energies nouvelles)
Figure 57 Hydraulic lines to hydraulic drive PCP (source: CJS) page 161
Figure 58 Steam injection through the PCP hollow rotor principle (source: Kachelle) page 164
Figure 59 Cold production with diluents through injection line page 165
(source: IFP Energies nouvelles)
Figure 60 Downhole sensor on tubing (source: GRC) page 171
Figure 61 Surface pressure safety switch page 172
Figure 62-1 SAM™ PCP Well Manager Automation and algorithm (source: KUDU page 173
Industries and Lufkin Automation)
Figure 62-2 Vector Flux Drive and monitoring read out (source: Weatherford) page 173
Figure 63-1 The crest of the rotor wear (source: C-Fer) page 182
Figure 63-2 High GOR producer elastomer bubbles and rupture (source: Baker) page 183
Figure 63-3 Elastomer damaged by high discharge pressure and heat (source: Baker) page 183
Web Sites and manufacturers (source: IFP Energies nouvelles) page 199-201
Preface
René Moineau was not only a visionary inventor when he filed the patent for a new gear
mechanism in 1930 that could be used as a pump, motor or transmission device. He also set
up a company – “Pompe Compresseur Mécanique” (PCM) – to manufacture and market his
invention. Progressing cavity pumps are now widely used by the industry to transfer many
types of fluids, as well as in artificial oil lifts.
A long story with a happy ending. During the 1980s, the Institut Français du Pétrole
(now IFP Energies nouvelles) based in Rueil Malmaison (France) in partnership with PCM
and associated with french petroleum companies took over leadership of the research, devel-
opment and field testing of progressing cavity pumps applied to downhole artificial lift oil
wells. IFP Energies nouvelles successfully ran the first “Moineau pump”. Now known as
“Progressing Cavity Pumps” or PCPs, they are installed in the bottom of the well and driven
from the surface by solid rods in order to pump fluids. This opened the way for a new artifi-
cial lift method and equipment using a simple, economical and rugged down-hole pump.
Many field tests have been carried out, proving that PCPs are suitable for many environ-
ments and different types of fluids, and can be used with heavy viscous oils containing gas
and sand or light and abrasive oils. They are also suitable for use with today’s high-tempera-
ture fluids from thermal recovery and high flow rates.
This new edition has come about thanks to Henry Cholet and Christian Wittrisch. It
serves as an update to Henri Cholet’s first book – “Progressing Cavity Pumps” – published
by Editions Technip in 1997 and is designed to serve the same purpose: to provide concise
and useful information on the main principles, features, performance and operational condi-
tions. Within this framework, this second edition includes information about new features
related to operating conditions, such as high flow rates, multiphase fluids, high temperature
conditions, heavy oil processes, water flooding, dewatering gas well, monitoring of well
production, etc.
Henri Cholet, who is now retired, was a project manager with a particularly high level of
technical proficiency and a great deal of experience in improving pump technologies.
Christian Wittrisch is an IFP Energies nouvelles research engineer with wide-ranging
experience in down-hole equipment – experience put for the purposes of updating the first
edition of this book.
VI Progressing Cavity Pumps
As Head of the Mechanical Engineering Department within the Applied Mechanics Divi-
sion at IFP Energies nouvelles, I would like to thank Henri Cholet and Christian Wittrisch
for their work in bringing about a better understanding of Progressing Cavity Pumps and for
their help in marketing development, which enhances IFP Energies nouvelles' reputation.
Pascal Longuemare
Head of the Mechanical Engineering Department
within the Applied Mechanics Division at IFP Energies nouvelles
Foreword
Human genius has a tendency to look into apparently unsolvable problems and strive to
develop solutions to them.
This was particularly the case with René Moineau, a famous First World War pilot and
inventor of many advanced technologies, most of which were for use with aeroplanes.
René Moineau was a visionary inventor with a superb intellect and an inventive mind
who would adopt a basic mechanical approach to problem-solving.
He built pump components with sheets of paper in order to manage his mathematical and
geometric intuition and in 1930 filed the patent for a new gear mechanism that could be used
as a pump, motor or transmission device.
In 1932 René Moineau, helped by the Gevelot Company, became the founding chairman
of a new company: “Pompe Compresseur Mécanique”, known today across the world as
PCM.
The Progressing Cavity Pump was a success story from the start. Integrating a new con-
cept and patented invention, it was rapidly adopted throughout the industry for transferring
many types of fluid. During the 1980s, progressing cavity pumps started to be used to lift oil
wells and are used worldwide today.
René Moineau’s PCP invention had been applied and accepted by the market. It became
a great innovation for the whole industry.
The objective of this new edition is to add many improvements to and uses for the PCP
in oil wells. It can now be used in difficult environments, with different types of fluid, in
high temperatures, and in conjunction with recently developed technologies for advanced
materials, on driving heads, monitoring and safety control with data transmission. These
new technologies for materials and data transmission and processing mean that the PCP
operating life can be increased, and well production involves lower operating costs.
Our hope is that this new edition of the Progressing Cavity Pumps book for oil well arti-
ficial lift will help ensure that the Progressing Cavity Pump becomes better known, better
use, more efficiency and ensure it a trustingly development.
Christian Wittrisch & Henri Cholet
Table of Contents
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Chapter 1
WHAT IS A PROGRESSING CAVITY PUMP?
WHAT IS IT USED FOR?
WHAT NEW FEATURES DOES IT HAVE?
1.1 Introduction to the Progressing Cavity Pump . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Moineau: the Pump Success Story for the Oil Industry . . . . . . . . . . . . . . . 5
1.3 PCP Basic Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 2
PROGRESSING CAVITY PUMP: OPERATING PRINCIPLE
2.1 The PCP Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 PCP Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Rotor-Stator Geometries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 Theoretical Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Mono and Multi-Lobes Pump Geometries. . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4.1 Mono-Lobe (1-2 Pump) Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Multi-Lobes Pump Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.3 Multi-Lobe Geometry Pump’s Applications . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Pump Manufacturing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.1 Rotor Manufacturing Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.2 Stator Manufacturing Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6 Pump Rotation Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7 PCP and Oil Well Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
X Progressing Cavity Pumps
Chapter 3
PCP CHARACTERISTICS
3.1 Mono-Lobe Pump Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.1 Pump Kinematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.2 Pump Volume Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.3 Pump Head Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.4 Pump Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1.5 Load on Thrust Bearing Drive Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Multi-Lobe Pump Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.1 Theoretical Rotating Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.2 Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.3 Pump Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Elastomers Stator Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.1 Elastomer Selection versus Pumped Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.2 Measurements Characterising an Elastomer . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.3 Elastomer Characterization and Classification. . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.4 Elastomer Resistance Challenge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3.5 Elastomer Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4 Pump Efficiency Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.1 Calculation of Volumetric Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.2 Evaluation of the Pump’s Actual Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.3 Internal Recirculation Flow or Slippage Under Pressure. . . . . . . . . . . . . . . . . 33
3.4.4 Pump Efficiency and Fluid Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chapter 4
OIL CHARACTERISTICS
4.1 API Oil Gravity Scale. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Oil Viscosity and Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3 Heavy Oil and Dilution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4 Heavy Oil and PCP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter 5
ARTIFICIAL LIFT AND SELECTION OF A PCP
5.1 The Reservoir Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 The Produced Effluent Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3 Well Geometry, Architecture Drainage, Horizontal Well . . . . . . . . . . . . . . 45
5.4 Well Completion and Sand Control Liner Screens. . . . . . . . . . . . . . . . . . . . 45
5.5 PCP Sized to the Well Geometry and Completion . . . . . . . . . . . . . . . . . . . . 46
5.6 PCP’s Operating Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.6.1 Frictional Pressure Drop Generated by Viscosity. . . . . . . . . . . . . . . . . . . . . . 46
5.6.2 Resistant Torque Generated by the Viscosity . . . . . . . . . . . . . . . . . . . . . . . . 47