PROGRESSING CAVITY PUMP SYSTEMS

PROGRESSING CAVITY PUMP SYSTEMS

Since 1841, Nati onal Oilwell Varco® has been dedicated to ensuring customers receive the highest quality oilfi eld products and services. NOV® is a worldwide leader in providing major mechanical components for land and off shore drilling rigs, complete land drilling and well servicing rigs, tubular inspecti on and internal tubular coati ngs, drill string equipment, extensive lift ing and handling equipment, and a broad off ering of downhole drilling motors, bits and tools. NOV also provides supply chain services through its network of more than 200 distributi on service centers located near major drilling and producti on acti vity worldwide.

We conti nue to build upon our unlimited, customer-focused soluti ons and are proud to deliver our Arti fi cial Lift Systems through the NOV Monofl o® division.

The NOV Monofl o division is a true partner and worldwide source for complete Arti fi cial Lift equipment and packaged soluti ons. Our Arti fi cial Lift professionals collaborate with you to properly evaluate well conditi ons and determine a customized arti fi cial lift soluti on that will opti mize your producti on.

Arti fi cial Lift Soluti on Packages Include:

• Professional Well Evaluati on• Surface and Subsurface Equipment• Controllers and Producti on Automati on• All Producti on Accessories and Expendables• Global Supply Chain and Service Soluti ons

PRROGRESSING CAVITY PUMP SYSTEMS

Since e 18184141, , NaNati on lal OOililwewellll VVararcoco®® hahass bebeenen ddededicicatateded ttoo enensusuriringng ccusustotomers receiveve tthhehighest quality oilfieldld prodducts andd serviices. NNOVOV®® iis a worldld iwidde lleadder in providing

• Globalal SSupupplplyy ChChaiainn anandd SeServrvicice Soluti ononss

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Progressing Cavity Pump SystemsNOV Monofl o is a leader in the design, manufacture and supply of progressing cavity pumps (PC Pumps) and arti fi cial lift soluti ons worldwide. With over 75 years of experience, 8 internati onal sites and global distributi on network, we provide a range of PC Pump soluti ons that fulfi ll many oilfi eld producti on needs. Our line of downhole PC Pumps are designed for use in both oil producti on and dewatering applicati ons where the economics of producti on demand effi ciency, reliability and low life-cycle cost from the producti on equipment.

Common Applicati ons• Heavy Crude (aggressive geometry)• Medium Crude• Coal Bed Methane – CBM (specialized elastomers)• Shale Oil and Water• High GOR Wells

Features and Benefi ts• Lower Capital Cost

The lack of expensive foundati ons, simple constructi on and the compact surface drive units reduce start-up costs which allow for more pumps to be installed and more oil recovered.

• Lower Running CostTypically, a PC pump has an overall effi ciency rati ng of 70% which is signifi cantly higher than alternati ve lift methods and lowers the cost per barrel of recovered fl uid.

• ReliableThe simple constructi on consists of only one moving part downhole and has no standing or traveling valves to block. The pump handles gas and solids without blocking and is more resistant to abrasive wear.

• Environmentally Acceptable Profi leThe low, unobtrusive profi le of the quiet running surface drivehead makes the PC pump ideal for environmentally sensiti ve areas. Also, state of the art Leak Detecti on Stuffi ng Boxes help protect the environment from spills.

PROGRESSING CAVITY PUMP SYSTEMS

The Pumping PrincipleThe progressing cavity principle is ideally suited to the demands of pumping downhole fl uids. At the heart of the downhole PC pump lay the pumping elements, consisti ng of a hard steel rotor, usually in the form of a single external helix of circular secti on, and a stator with the internal form of a two-start helix. The stator is manufactured from a resilient, abrasion-resistant elastomer bonded inside an alloy steel tube that is selected to be compati ble with the specifi ed well fl uids. When the rotor is placed inside the stator a series of sealed caviti es are formed.

As the rotor turns, these caviti es progress from the sucti on end of the progressing pump up to the discharge end, positi vely transporti ng the well fl uid through the pump and up the tubing string to the surface, without pulsati on. The fl uid fl ow rate is directly proporti onal to the speed of rotati on. Therefore, the pump can be closely matched to the well infl ow rate for opti mum producti on.

The constantly sweeping seal line between the stator and rotor prevents a build-up of solids within the pump. Entrained gas or suspended solids can also pass through the pump without causing gas locking or pump blockage.

Progressing Cavity Pump Specifi cati ons

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Rotors, Stators and Elastomers

Performance by DesignRotors are available in alloy steel (4140) with hard chrome plati ng which provides resistance to abrasion and wear. All pumps have 1:2 rati o lobe geometry and rotor chrome thickness within 0.010 and 0.020 inches.

Through the use of advanced manufacturing technology and modern producti on techniques, fi nite machining and plati ng of the rotor profi le is maintained, ensuring that the design performance is always achieved.

ElastomersA range of stator elastomers is available allowing the pump to be selected for many downhole fl uid conditi ons as described below.

Rotors and Stators

Elastomer Type General Description and Application Temperature Limit Tensile Strength Tear Strength Abrasion Resistance H2S Resistance CO2 Resistance Hardness (IRHD)

QS(Soft Nitrile)

• Very soft medium acrylonitrile content with good oil and solvent resistance and excellent abrasion resistance

• Typically used in very abrasive and high water cut applications with low aromatic content fl uids

80°C Good Good Excellent Good Poor 48-53

OD(Soft Nitrile - Buna L)

• Soft medium acrylonitrile content with good oil and solvent resistance and excellent abrasion resistance

• Typically used in medium abrasive and high water cut applications with low aromatic content fl uids

90°C Good Excellent Excellent Good Fair 60-65

RR(Nitrile)

• Medium acrylonitrile content with good oil and solvent resistance

• Excellent abrasion resistance and mechanical properties

• Typically used in abrasive and high water cut applications with low to medium aromatic content

100°C Good Excellent Excellent Good Good 68-72

OB(High Nitrile)

• High acrylonitrile content with improved oil and solvent resistance and excellent mechanical properties

• Higher acrylonitrile content provides extra resistance to oils with medium to high aromatic content

100°C Excellent Excellent Excellent Good Fair 70-75

OC(Hydrogenated Nitrile)

• High acrylonitrile content with similar properties to OB but with improved resistance to hydrogen sulfi de (H2S) and high temperature capability

150°C Excellent Good Excellent Excellent Fair 69-75

PROGRESSING CAVITY PUMP SYSTEMS

Two Run Insertable PC PumpNOV Monofl o has an innovati ve, new insertable progressing cavity pump design that allows the customer to insert a progressing cavity pump inside the producti on tubing and pressure test the tubing string with one easy to use tool.

Features and Benefi ts• There is no need for a service rig to pull the producti on tubing to change a

downhole pump• Pump changes can be done with a fl ush-by equipped for rod handling• The unit minimizes the need to remove producti on tubing, reducing the cost of

downhole gauge installati ons• Allows for pressure testi ng the producti on tubing as well as the primary seal, while

inserti ng the stator.• The system has the ability to use any progressing cavity pump without performing

any modifi cati ons.• The system can pull the rotor out of the well bore without unseati ng the primary

seal.

Rotor

Operating Position

Insert Position

Insert Tool

Seating Nipple

Tag-Bar

Torque Anchor

Seating Mandrel with Primary Seal

Stator

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NO-GO Tag™ Progressing Cavity PumpsThe NO-GO Tag system is a new advanced generati on tool for rotor placement in progressing cavity pumps. The NO-GO Tag provides all the functi onality of a traditi onal bott om tag bar system with the advantages listed below.

Features and Benefi ts• Tags within the stator, leaving intake free of obstructi on, allowing rotor to

agitate solids• Coilable through the pump by only pulling up polish rod• Protects top end of stator elastomer by guiding coil entry through the pump• Positi ve tag for proper rotor placement by guiding rotor through ti med

helical tag passage into stator elastomer• Unique integrated design eliminates fl ow losses and extra connecti ons• Tags using a conventi onal rod box• Ability to land pump lower in well• Eliminates costly mechanical tools below the pump while maintaining

circulati on clean-out capabiliti es

Applicati on• Medium to heavy oil• Wells producing sand• Wells with history of intake plugging• Wells with minimal cellar

PROGRESSING CAVITY PUMP SYSTEMS

Hydraulic DriveheadsNOV Monofl o’s HTD hydraulic drivehead uti lizes a bent axis motor that is coupled to a hollow shaft bearing box by a belt and pulley system, which transfers torque to the polished rod. Backspin is controlled through the hydraulic system. The motors are available in a variety of displacements to accommodate a wide variety of speeds and torques.

Each model of the NOV Monofl o CG-33 hydraulic drivehead is a beltless top drive using gears to transfer torque to the polished rod. The precision ground gears reduce noise levels by up to fi ve ti mes in comparison to conventi onal belt drives, making the CG-33 drivehead an ideal soluti on for use in populated areas. Each CG-33 drive uti lizes a radial piston motor designed to reduce internal fricti on and run effi ciently. These driveheads are fi tt ed with a hydraulically acti vated stuffi ng box that can withstand any progressing cavity pumping applicati on.

Features and Benefi ts of the HTD Hydraulic Drivehead• Motor is available in various displacements • Standard synchronous belt and sheave system• Fully enclosed hinged belt guard

Features and Benefi ts of the CG-33 Hydraulic Drivehead• Enclosed gear housing eliminates need for belts, thus reducing fi eld

maintenance• Case hardened and precision ground gears drasti cally reduce noise levels.• Gear drive uti lizes a radial piston motor connected to the input gear• Radial piston designed to reduce internal fricti on, providing bett er overall

effi ciencies• Motor is available in various displacements• Motor is easily changed in the fi eld• Pressurized stuffi ng box prevents fl uid from entering the seal chamber extending

the life of the seals• Built in polished rod vise allows stuffi ng box seal change without removal of

drivehead or fl ush-by rig • Gearbox incorporates a fi eld removable main shaft • Main thrust bearing is housed separately eliminati ng contaminates on the gears• Gear drive is compact and easy to handle on verti cal and slant wells

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Technical Specifi cati onsModel HTD CG-33

Max. System Pressure 3600 psi (245 kPa) 3500 psi (24,132 kPa)

Max. System Temperature¹ 175 °F/ 80 °C 176 °F/80 °C

Polish Rod Size 1¼" (32 mm) 1¼" (32 mm)

Wellhead Connection 2d” EUE Pin or 38-3000 psi-R31 Flange

38”-3000 psi-R31 Flange

Thrust Bearing² Ca90-25,000 lbs /ISO-96,300 lbs

Ca90-33,500 lbs /ISO-129,000 lbs

Backspin Control Check valve on pressure side of the motor.

Check valve on pressure side of the motor.

Torque Control Adjustable pressure compensator on pump.

Adjustable pressure compensator on pump.

Model HTD CG-33

Variable Speed Control Adjustment knob on the pump. Adjustment knob on the pump.

Height Integral 31" (787 mm) 31" (787 mm)

Height Retrofi t 47" (1194 mm) N/A

Width 29" (737 mm) 24" (610 mm)

Weight Integral 400 lbs (181 kg) 240 lbs (109 kg)

Weight Retrofi t 450 lbs (204 kg) N/A

Bearing Box Grease Chevron Delo Grease EP NLGi2 1 tube (Chevron Ulti-Plex Synthetic Grease)

¹ Maximum operating temperature may be limited by hydraulic oil. ² Ca90 load rating is for 90 million revolutions at 500 rpm. Reducing load by 50% increases life 10 times. Reducing speed by 50% doubles hours of life.

HTD Hydraulic Drivehead

CG-33 Hydraulic Drivehead

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Electric DriveheadsNOV Monofl o provides a complete line of Electric Driveheads for all your producti on needs.

Features and Benefi ts• Robust frame• Detachable stuffi ng box• Operator-friendly guards and motor adjustments• Easy-to-adjust door for simple belt ti ghtening• Accessible fi ll/drain spouts for easy oil changes• Bearing box is designed with a three-bearing system (Models C-50, C-60, C-80,

and C-33M)• Hollow shaft bearing box (Model N-25)• Hydrodynamic brake (Models C-50, C-60, C-80, and C-33M)• Hydraulically actuated caliper disc braking system (Model N-25)• Brake reservoir for heat dissipati on (Models C-50, C-60, C-80, and C-33M• Service and technical support

Technical Specifi cati onsModel C-50 C-60 C-80 C-33M N-25

Drive Type Direct Direct Direct Direct Direct

Shaft Type Hollow Hollow Hollow Hollow Hollow

Drive Style Bearing Box Bearing Box Bearing Box Bearing Bearing Box

Input Style Vertical Vertical Vertical Vertical Vertical

Drive Ratio 1:1 1:1 1:1 1:1 1:1

Backspin Control Hydrodynamic Hydrodynamic Hydrodynamic Hydrodynamic Caliper Disc

Ratings

Max. Output Torque 2000 ft-lbs (2712 Nm) 2500 ft-lbs (3390 Nm) 3500 ft-lbs (4745 Nm) 1575 ft-lbs (2135 Nm) 600 ft-lbs (813 Nm)

Thrust Bearing 195,000 ISO lbf 227,000 ISO lbf 310,000 ISO lbf 45,100 ISO lbf 96,300 ISO lbf

Thrust Bearing¹ 50,500 Ca90 lbf 59,000 Ca90 lbf 80,400 Ca90 lbf 33,000 Ca90 lbf 25,000 Ca90 lbf

Maximum Speed 600 rpm 600 rpm 600 rpm 600 rpm 500 rpm

Horsepower Rating² 20 - 100 80 - 150 120 - 300 10 - 60 10 - 20

Frame Type Single Motor Dual Motor Dual Motor Single Motor Single

Polish Rod Size 1¼” or 1½”(32mm or 38 mm) 1½” (38 mm) 1¼” or 2”

(38 mm or 51mm) 1¼” (32 mm) 1¼” (32 mm)

Max. Operating Temp. 212°F / 100°C 212°F / 100°C 212°F / 100°C 428°F / 220°C 180°F / 80°C

Dimensions

Height with Retro. Stuffi ng Box 50” (1270mm) 55” (1397mm) 64” (1626mm) 44” (1118mm) 34” (864mm)

Width 35” (889mm) 41” (1041mm) 42” (1067mm) 35” (889mm) 30” (762mm)

Input Shaft Size 3¼” (83 mm) 3¼” (83 mm) 4¼” (108mm) 3¼” (83 mm) 2½” (64 mm)

Weight 1350 lbs (612kg) 1700 lbs (771kg) 2100 lbs (953kg) 1350 lbs (612kg) 600 lbs (272kg)

¹ Ca90 load rating is for 90 million revolutions. Reducing load one half increases life 10 times. Reducing rpm by one half doubles hours of life.² Maximum HP rating based on frame size only. Care must be taken in selecting motor and sheave combinations to ensure input rod torque is not exceeded.

C-50 Electric Drivehead

C-60 Electric Drivehead

C-80 Electric Drivehead

C-33M Electric Drivehead

N-25 Electric Drivehead

PROGRESSING CAVITY PUMP SYSTEMS

Leak Free Stuffi ng BoxThe NOV Monofl o Leak Free (LF) stuffi ng box is a pre-built assembly that has been exclusively designed to simplify monitoring seal wear. It consists of a double mechanical seal supplied in a single sealed cartridge. It comes pre-fi lled with NOV Monofl o approved BP Energrease® LC2 for lubricati on of the bearings and with compati ble Mobil DTE25 mineral oil for fi lling the mechanical seal cavity.

Features and Benefi ts• Designed with a two bearing system consisti ng of seal bearings designed to be in one

cartridge for easy replacement which results in less downti me during maintenance• Can be mounted directly on drivehead with or without a booth• Uti lizes a double mechanical seal supplied as a sealed cartridge, to deliver extended periods of leak free

operati on and contains any leaked fl uid inside the unit• Double sealing mechanism performs an improved sealing functi on.• Easy fi tti ng of the cartridge arrangement with no setti ng requirement normally associated with conventi onal

mechanical seals; seal abuts bearing to set working length• Positi ve drive from the spindle via key through sleeve of the mechanical seal• All sealing faces are made from solid material for increased pressure and thermal stability• Equipped with a leakage detecti on unit which provides a visible indicati on to any breach of the primary seal

and also ensures barrier fl uid lubricati on of the seal faces for maximum durability• The leakage detecti on unit can be reset aft er seal replacement

Hydrodynamic BrakeNOV Monofl o has incorporated the well-proven principle of the Hydrodynamic Brake into the C-Series direct drives to provide safe, reliable and smooth backspin control.

The Hydrodynamic Brake consists of a stati onary half (stator) and a rotary half (rotor). The stator is bolted into the housing and the rotor is coupled to the shaft . During normal operati on the rotor spins freely. When the unit goes into backspin, the rotor begins to rotate in the counter clockwise directi on. The working fl uid is then forced to the outside of the rotor and creates a circular fl ow path inside the brake cavity. As the energized fl uid from the rotor comes into contact with the stati onary fi ns of the stator, the energy is transferred to the stator and then back to the working fl uid as heat. A small amount of working fl uid is conti nually removed from the system and replaced with new fl uid. The working fl uid contained in the drivehead reservoir is used as the braking medium, which allows the energy stored in the fl uid column and rod string to safely dissipate without the drivehead reaching excessive backspin speeds.

Features and Benefi ts• Non-fricti on brake eliminates wear on brake components• Brake capable of 2000 ft -lbs resisti ng torque at 250 hp• Reliable and repeatable braking• Backspin energy is absorbed by the working fl uid• Heat generated by braking is dissipated by the fl uid reservoir• Consistent braking with minimal maintenance throughout the

drivehead’s life

y

Brake Stator

Brake Rotor

Hydrodynamic Brake Curves

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VFD ControllerThe NOV Monofl o Progressing Cavity Pump Controller provides a number of features specifi cally designed for operati on of progressing cavity pumps. The drive combines motor and pump control into a single, compact package that increases producti on, improves energy effi ciency and enhances the reliability of both new and existi ng pumping systems.

Multi ple Constraint Opti mizati onAt any instant during the life of a well, there is a single constraint that limits producti on. Producti on can be maximized without compromising effi ciency or reliability by forcing the system to operate at the constraint limiti ng producti on at each instant of ti me. Determining the applicable limits and moving smoothly between them in real ti me is a key advantage of the Nati onal Oilwell Varco system. Models of all the system elements are run in real ti me at the wellhead to detect appropriate limits and enforce associated control strategies. At diff erent points in ti me, the system may be limited by motor voltage, motor current, motor speed, motor torque, motor thermal capacity, power demand, rod string torque, fl ow line pressure, fl uid level, or well infl ow. Multi ple constraint opti mizati on is parti cularly benefi cial in applicati ons with variable infl ow conditi ons, such as those found in coal-bed methane, high gas/oil rati o, and thermally sti mulated wells.

Sensorless Operati onThe drive uses a number of unique methods for precisely determining performance parameters from models of the pumping system elements without requiring external surface or downhole sensors. Sensorless system variables including rod speed, rod torque, pump speed, pump torque, fl uid fl ow, fl uid level, sucti on pressure, discharge pressure, and diff erenti al pressure can be observed through the drive keypad/display or recorded as circle charts and ti me-based plots. Fluid level, pump fl ow, and total producti on are displayed in selectable engineering units.

Sophisti cated ModelingEmbedded mathemati cal models of the drive, motor, drive head, rod string, pump, fl ow line, tubing, casing, fl uid, and reservoir use component specifi cati ons and well completi on informati on along with fi eld setup parameters to monitor pumping system operati on. Identi fi cati on routi nes automati cally determine installati on-dependent system parameters including those of the motor, rod string, and pump. The models capture the thermal, mechanical, electrical, and hydraulic behavior of the system to control the pumping process with greater precision than ever before.

Pump Speed ControlThe drive provides a number of opti ons for manual, remote, and automati c control of pump speed. Speed commands can be selected from a number of sources including potenti ometer adjustments, keypad presets, serial data communicati ons, and internal opti mizati on controllers. The motor can be operated up to twice base speed at constant power. This allows the overall gear rati o to be increased, thereby providing increased low-speed torque without loss of maximum pump speed. Dual motors can be controlled from a single drive for operati on of large pumps. The system can be confi gured for opti mizati on of fl uid producti on, gas producti on, energy effi ciency, and/or power fl ow.

National Oilwell Varco has produced this brochure for general information only, and it is not intended for design purposes. Although every effort has been made to maintain the accuracy and reliability of its contents, National Oilwell Varco in no way assumes responsibility for liability for any loss, damage or injury resulting from the use of information and data herein. All applications for the material described are at the user’s risk and are the user’s responsibility.All brands listed are trademarks of National Oilwell Varco.

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© 2012 National Oilwell Varco© 2012 National Oilwell VarcoD392004432-MKT-001 Rev. 01D392004432-MKT-001 Rev. 01

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