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ABSTRACT
It is amunon knowledge that some of the obstacles
that must be overcome to mce#ully operate
arc
Progmasing cavity Pumping (PCP) systems
attributed to amventional sucker rod couplings
andthcupsctarea aroundthmu
economies
andlor opthnizmion
selectingandutiking
application at hand.
can be realizd w
proper equipxnentfixthe
30275
on the magnitude of flow losses. They can either
be negligible or very significant. If not considered
in heavy oil and high watercutigh volume
designs, flow losses may lead to prematurepump
t%iluredue to over pressuringor readt in much
higher eomected homepowerand subsequent
higher operatingcosts. Thus, properconsideration
must be given to as many parametersas possible,
afterwhich the appropriateequipmentthat will
workmost effectively in the speci6c ckmMamx
shouldbe selected in orderto rninimk operating
costs.
LJ6579
(Sx)
BACKGROUND
Operatingcost reductionas it pertains to PCP
artificiallift systems can be achieved by using the
least amountof horsepowernecessag to produce
the volume of fluid sought and by reducing
maintenancecosts.
Typieslly the total pump horsepowerrequiredto
lift fluid has two components. The first is the
horsepowerrequiredto overcomefriction within
the pump and the second componentis the
horsepowerrequiredto M fluid (@easenote, there
maybe power demandswithin the pump due to
flow characteristicssuch as viscosity and sand eu~
but will be not emsidered in this discussion).
Total pump horsepowerthen is the summationof
these two componentsas follows:
Hptora[= Hpfiction+ Hphyiraulic
where: Hpttir = Total Pump Horsepower
Hp@rim = Pump Friction Horsepower
HpWMUk = Hydraulic Pump Hp
Hpfictim typically represents10?42O%of the total
pumphorsepower. It is largely dependentupon
the interferencefit between rotorand statorand
the numberof continuous seal lines. The pressure
capabilityof a PCP is based on the numberof
eantinuoussealing lines it has. Therefore,
minimizingthe pressurerequirementof the PCP
reducesthe numberof stages which in turn
reducesHpJHctian.
mm)
3027s
virtuallyany operatingcondition. Atypical output
summaryinckks pdkted hydrostaticp~,
flow losses, pump discharge pmssurc, pump
ditxxential pressure, pump intake pressluq pump
Ioad@ polish rod 1- polish rod
P~
torque,wellhead power, prime moverpower, rod
stretch rod rotatioq maxirnunlmdstringleadi.n&
and maximum tubing wear rate.
COMPA3L4TIVE ANALYSIS
30275
1
ACKNOWLEDGMENT
Figure 5 representsthe simulation resultswith
25.4mm (l) GradeD suckerwith slimhole
couplings. The pump differentialpressureis 7,600
kpa (1,097 psi) with total flow losses of 1,900 kpa
(277 psi). The P@ was almost at Ml pressure
loading (96.3% of ratedpressure)and the polish
rodtorqueof 788.1 filbs loadedthe suckerrod
stringto 94.7% of yield and developed 60 hp at the
wellhead. as illustratedin Table 1.
REFERENCES
1. K. J. Saveth, S. T. Kl~ K B. Fisher, Robbin
&Myers Inc.: A Comparative Analysis of
Mlkiency and Horsepower Between Progressing
~vity pllInpSand Plunger pllmpS,SPE 16194.
2. Lonnie D~Cam
Mathews, Todd_:
Progressingcavity Pumping systems:DeSigQ
Operationand PerformanceOptimizadon, CFBR
Progressingcavity Pump tlaining (Sept. 1994).
-.
CONCLUSION
Continuous sucker rod can help lower operating
costs in PcPsyatems. Bccauseofthelackaf
couplings, overall flow losses are dramatically
redwxd in both heavy Od and COIIVCtiOIId(h@
volume) oilwells.This factcreateslower service
.
(1- Grade D #k slimhole couplings)
Simulation
3027~Pagef
Results
Conditions
120.0
85.0
Pump Speed
Pump Efficiency
Flow Rate
RPM
%
10.2 mA31D
15000.O cp
0.0 %
vsCOS&
Sand Cut
Densily
Tubing Head Pressure
Casing Head Preaaure
Fluid Level (from surface):
970
15
15
490
kg/mA3
psi
psi
Vm
Hydrostatic Pressure:
Flow LosS=:
Pump Dscharge Pressure
Pump Differential Pressure:
Pump Intake Pressure
Pump Pressure Loading:
Polish Rod Load:
Polish Rod Torque
147.2
8560.1
316.7
7.24
N/A
12.64
9.28
Wellhead Powm
Prime Mover Powe~
Rod Stretch:
Rod Rotation
Maximum Rod String Loading
Location:
Load (% Ydd):
psi
psi
psi
pi
psi
k Max
Ibf
fflba
hp
hp
cm
turns
O mKB
39.2 %
O mKB
0.0 0/6
Output Warnings
Overpresauring PC Pump ( 147% of rated capacity)
Equipment
Configuration
HighlandlCorod (12-H-1 O)
73.0 mm x 9.67 kglm (EUE)
139.7 mm x 23.07 kglm
Figwe
Highland&orod
S#OOlo7
1994
(1- Corod)
Simulation
Results
7 Corod
Operating Conditions
Pump Speed:
Pump Efficiency
Flow Rate
Vlcosity
Sand Cut
120.0
85.0
10.2
15000.0
0.0
RPM
%
mA3/D
Cp
ah
Density
Tubing Head Pressure
970 kg/mA3
15 psi
15 psi
490 Vm
Hydrostatic Pressure:
Flow Losses:
Pump D~charge Pressure:
Pump Dfierential Pressure:
Pump Intake Pressure:
Pump Pressure Loading
Polish Rod Load:
Polish Rod Torque:
Wellhead Powec
Prime Mover Powec
Rod Stretch:
Rod Rotation:
Maximum Rod String Loading
Location:
Load (AYield):
psi
psi
psi
pai
psi
% Max
Ibf
ftWs
hp
hp
cm
turns
3 mKB
25.8
Y.
O mKS
0.0 %
Output Warnings
No Diagnostic Messages
Equipment
Configuration
Highlan&Corod
Highland/Corod (12-H-1O)
73.0 mm x 9.67 kg/m (EUE)
139.7 mm x 23.07 kdm
Figur)~
SM-OO1O7
C:U%PISPEf.SIM
(f - Grade D du slimholeCouplhtgs)
Simulation
3027&gef
Results
coupiings
Operating Conditions
150.0
Pump Speed:
Pump Efficienqc
Flow Rate
VI
Sand Cut
Density
Tubing Head Pressure:
Casing Head Pressure
Fluid Level (from surface):
RPM
90.0 %
41.9 mA3/D
3000.0 Cp
0.0 %
980
50
50
900
kg/mA3
psi
p
Vm
1380
3017
4448
4258
189
166.3
23335.6
884.3
25.27
WA
75.69
56.57
psi
psi
psi
psi
psi
% Max
Ibf
ftWrs
hp
hp
cm
turns
O mKB
109.1 %
Load (% Yield)
Maximum Tubing Wear Rate
Location:
Wear Rate:
O mKB
0.0 %
Output Warnings
Overpressurirrg PC Pump ( 188% of rated Cape*)
fielding Rod String ( 109% of yield stress et
Equipment
Configuration
Highlen(Xomd
O mKB)
SM401O7
HighlendlCorod (18+-31)
TU9&rn0606:46:4i
i995
Simulation
7 Gmie
Results
D Corod
Operating Condtiions
150.0
Pump Speed:
Pump Eftiaency
Flow Rate
viscosity
Sand Cut
DenW
Tubing Head Pressure
Casing Head Pressure:
Fluid Levef (from surface)
RPM
90.0 %
41.9 mA3/D
3000.0 Cp
0.0 %
980 kg/mA3
50 psi
50 w
900 Vm
Hydrostatic Pressure
Flow Losses
Pump Dkmharge Pressure
Pump Differential Pressure:
Pump Intake Pressure:
Pump Pressure Loading:
Polish Rod Load:
Poliih Rod Torque
Wellhead Powec
Prime Mover Power
Rod Stretch:
Rod RoMon:
Madmum Rod String Loading
Location:
Load (% Ydd):
Mtimum
psi
psi
psi
pai
psi
% Max
Ibf
Wlbe
hp
hp
cm
turns
O mKS
59.2 AI
O mKS
0.0 1%
Output Warnings
High Dtierential PC Pump Pressure ( 87% of reted capacity)
Equipment
Configuration
Highlanct/Corod (18-N-31)
73.0 mm x 9.67 kglm (EUE)
177.8 mm x 34.23 kg/m
Figure
Hl#hlandCorod
sm-oofo7
P.
PGPurnp VeraJon
tf ~ GFER, 9994
TueJun0606:52:46
1896
D CAUallmhole couplings)
Simulation
~~.r
Page f
Results
(=-, cd
couplings
Conditions
400.0
90.0
398.0
RPM
%
mA3/D
3.0 Cp
A
0-0
Pump Speed
Pump Efficiency
Flow Rate
viscosity
Sand Cut
Densily
Tubing Head Pressure:
Casing Head Pressure
Fluid Level (from surface)
980
kg/mA3
50 psi
50 psi
600 Vm
1377 psi
277 psi
1704 psi
1097 psi
608 psi
96.3 % Max
13621.2 Ibf
788.1 Wlbe
60.07 hp
WA hp
32.88 cm
51.24 turns
-1 mKB
94.7
96
0 mKB
0.0 %
Output Warnings
High D~erentiai PC Pump Pressure ( 96% of rated capacity)
High Rod stresses ( 95A of yield stress at
Equipment
Configuration
HlghlandComd
-1 mKf3)
~fo7
HighlancLCorod (6-H-110)
73.0 mm x 9.67 kglm (EUE)
177.8 mm x 34.23 k@m
Figure
30275
TueJun0606:64:26
1995
Page f
Simulation
Results
1 Grade D Corod
Operating Conditions
400.0 RPM
90.0 %
396.0 mA3/D
3.0 Cp
0.0 %
Pump Speed:
Pump Efficiency
Flow Rate
Visity
Sand Cut
Density
Tubing Head Pressure
Casing Head Pressure:
Fluid Level (from surface)
980 kg/mA3
50 psi
50 psi
600 Vm
Hydrostatic %ssure
Flow Losses:
Pump DBcharge Pressure
Pump Dtierential Pressure:
Pump Intake Pressure
Pump Pressure Loading:
Polih Rod Load:
Polish Rod Torqua:
Weflhead Powan
Prime Mover Powec
Rod Stretch:
Rod Rotation:
Mw-mum Rod String Loading
Location
Load (% Ykld)
-1 mKB
78.4 %
O mKB
f)o %
Output Warnings
High Differential PC Pump Pressure ( 87% of rated capacity)
High Rod stresses ( 769A of yield etfSSSet -1 mKS)
Equipment Configuration
Pump Manufacturer (Model)
Tubing Typ&
Casing Tw
Hlghlandtlvod
MLOO1O7
Highlend/Corod (8-H-110)
73.0 mm x 9.67 kglm (EUE)
177.8 mm x 34.23 kglm
Figure
FIGURE
TUBING SIZE
73mm
12-H-1O
PCP MODEL
PCP SPEED
1 120 mm
FLUID VISCOSITY ! 15.000 CD
73mm
12-H-1O
120 mm
15,000 Cp
73mm
18-N-31
150 rpm
3,000 Cp
73mm
18-N-31
150 rpm
3,000 Cp
73mm
73mm
8-H-1 10 8-H-11O
400 rpm 3 Cp
3 cl)
17,300 kpa
8,800 kpa
29,400 kpa
15,300 kpa
PUMP DIFF.
PRESSURE
FLOW LOSSES
PCP PRESSURE
LOADING
POLISH ROD
TORQUE
ROD STRING
LOADING
WELLHEAD HP
I
I 12.700 k~a
147%
I
I
I
I
i
316.7 ft.
lbs.
39.2XO
7.24 hr)
I
4.100 k~a
74.3XO
230.3 ft.
lbs.
25.8XO
5.27 hD
T
884.3 ft.
Ibs.
109.1ZO
25 ht)
521.5 ft.
lbs.
59%
14.9 ht)
1,900 kpa
96.3%
1,200 kpa
87XO
788.1 ft.
lbs.
725.1 ft.
lbs.
78?40
94.7%
&!L
co
o
N
+