WELL HEAD pcp overview1234

MATERIAL OF CAIRN ENERGY BHAGYAM OPERATION RJSTHAN

1. Bhagyam_PCP_Overview RJ Operations 2013

2. PCP (Progressive Cavity Pump) PCP : A Progressive cavity pump is a type of positive displacement pump and is also known as a progressing cavity pump, eccentric screw pump or cavity pump. PC Pumping Systems typically consist of the following components : Surface Equipment Drive head assembly VFD (Variable Frequency Drive) Down hole gauge Panel (Geophysical Research Company) BOP (Blow Out Preventer), Flow Tee – Kombi Tree Down hole equipment Stator (Stationary with tubing) Rotor (Internal & Rotary with drive rods)

3. PCP System Configuration Down hole Equipment Belts & Sheaves Surface Drive Electric Motor Polished Rod Sucker Rods Surface Equipment PC Pump Stator PC Pump Rotor No-Turn Tool Tagbar Sucker Rods w/ Couplings 3 Flow Tee

4. General Features Rotor : Is a high strength steel component externally machined as a helix of “n” lobes and coated with chrome or an alternative hard material. Only moving part. Stator : Generally made with elastomer (or rubber) with and internal shape as an helix of “n+1” lobes. This rubber body is bonded to the interior of a steel tube. Stationary piece.

5. Polish Rod and Clamp arrangement The entire series of Polish rod, Sucker rod and Rotor is suspended in the downhole through the Polish rod clamp.

6. PCP Drive head assembly Belts and Sheaves The drive head assembly comprises of a Prime mover, Transmission system . Prime mover is the driver, which in this case is the FLP(flameproof) Electric motor of 75HP. Transmission system which transfers the power from the Prime mover to the Polished rod, which in this case is the Belt and sheaves.

7. The basic functions of a surface PC drive are : Suspend the rod string and carry the axial loads Deliver the torque required at the polished rod Rotate the polished rod at the required speed in a safe manner Provide for safe release of the stored energy during shut-downs Prevent produced fluids from escaping the system To achieve these functions, drives typically comprise the following components : Thrust Bearing Transmission System (Fixed Gear or Sheaves & Belts) Braking Mechanism (or recoil control system) Stuffing Box

8. Christmas Tree The PCP Christmas tree assembly comprises of Master valve, BOP, kill wing valve and Drive head on top. At the bottom we have tubing hanger which has got chemical injection connection and down hole gauge cable running up to the downhole. The wing XSV is installed for the slam shut of the flow arm in case of trip scenario.

9. VFD & GRC Panel VFD panel is an Electrical p anel which houses the VFD(Variable frequency drive) which is an electrical system used to vary the freq uency of the input(to the panel) current. It is important to control the RPM of the motor as per well behavior for which VFD is deployed . The LCD screen display’s the parameters related to Motor i.e. frequency, current, avg voltage etc. The Down hole gauge (GRC) panel is installed to monitor the well downhole parameters like Pump intake/discharge temperature & Pressure locally.

10. Downhole Gauge Tool The purpose of downhole gauge is to monitor the PIP(pump intake press), PDP(pump discharge press) and downhole temperature’s respectively. It is important to closely monitor the PIP, PDP which gives a fair pump operation idea to operated optimally.

11. PCP Rotor & Stator The polished rod is coupled through a series of sucker rod to the Rotor of the pump. The Rotor is an externally machined rod with helical lobes and is the only moving part downhole. The Stator is generally made up of Elastomer and has got internal helical lobes. It is stationary part of the pump. When rotor turns a series of sealed cavities forms and progress from suction to discharge resulting in non pulsating + ve displacement flow Rotor

12. No Turn Tool (NTT) NTT - To avoid backing-off the tubing string when the system is operating and for easy release in opposite direction when the system stops and back-spins.

13. Tag Bar It is the integral part of stator required as a reference to facilitate the installation and space out of rotor and sucker rod string.

14. PCP Rotor & Stator BWP-15, Well-13 well completion drawing

15. Stator Elastomer Types 15

16. Advantages & Applications of a PC Pumping System Advantages Pump high volumes (800+ m 3 /day) Lift capacities of up to 2000 meters Pump a range of Oil Gravity’s from 5 to 35 API. Pump 100 % H 2 O Pump high density & viscosity fluids. Pump high concentrations of slurries. (70%) No valves to clog or gas lock Applications Sand-laden heavy crude oil and bitumen High-water cuts Various oil gravities with limits on H2S , CO2 and aromatics Dewatering gas wells, such as coal bed methane projects All well types including horizontal, slant , directional and vertical Offshore platforms (compatible with foot print restriction) 16

17. PCP Safety system The PCP protection: Gas Detector (HI-alarm) : 20% Gas Detector (HI HI-Trip) : 40% High current : 65 - 70A Low current : 29A High discharge pressure : 1000psi Low intake pressure : 205 psi High rod speed : 475 rpm Low rod speed : 80 rpm High frequency clamp : 33 Hz Low frequency clamp : 10 Hz High Tubing head pressure : 31.5 bar

18. Operating Parameters Cause Effect Time Value Cause Effect Value                 Low Currect Alarm 10 min 29 Amp Low Freq Clamp clamp 10 Hz   Trip After 10 min 29 Amp       High current Alarm 0.1 min 65 – 70 Amp High Freq clamp clamp 33 Hz   Trip After 0.1 min 65 – 70 Amp       Low Intake Pr. Alarm NA           Trip NA         High Discharge Pr . Alarm 0.0 min 1000 Psi         Trip After 0.0 min 1000 Psi       High Rod Speed Alarm 0.0 min 475 rpm         Trip After 0.0 min 475 rpm       Low Rod Speed Alarm 1.0 min 80 rpm         Trip After 1.0 min 80 rpm      

19. PCP Well DCS Graphic page

20. Vendors / Suppliers 1. Drive head assembly : Grenco 2. PCP stator / Rotor : Cameron 3. Christmas tree : Cameron 4. Packers : Halliburton 5. Variable Frequency Drives(VFD): Unico 6. Down hole data : Geophysical Research company (GRC)