GCP Presentation

GEARED CENTRIFUGAL PUMP A New High Volume Lift Method

Rod String Drive

Transmission

Upper Seals and Compensator

TransmissionLower Seals and Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver SectionUpper Seals and

Compensator

LowerSeals and Thrust Bearing

Transmission

Pump

Intake StingerPay Zone

Drive Head The Geared Centrifugal Pump

•  A mechanically driven centrifugal pumping system.

•  Rod string drives an ESP pump via a 7:1 gearbox increasing speed from 500 to 3500 RPM.

•  No electrical components down hole.

•  ESP capacity with better efficiency.

What is the GCP?

Rod String Drive

Transmission



Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String


Compensator


Transmission

Pump



GCP Components from the Bottom up

1

1

2

2

3

3

4 4

5

5

6

6

7

7

•  Pump intake stinger •  Centrifugal pump •  Lower seal section with

thrust bearing •  Transmission •  Upper seal, compensator •  Receiver •  Tubing with a guided rod

string •  Drive head 8

8

Rod String Drive

Transmission



Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String


Compensator


Transmission

Pump



•  A bottom intake pump – better gas handling

•  Fluid load is carried by the tubing. –  Axial rod load is the buoyant rod

weight so side loads are small. –  Load on drive head thrust bearing

reduced

•  Transmission –  Multi-stage parallel shaft transmission –  Unique PHG gearing provides high

power in a small diameter.

Unique Traits of the GCP

The Geared Centrifugal Pump Transmission

Before and after load is imposed

Before

After

Paired Helical Gearing - Operation

The Geared Centrifugal Pump Transmission

GCP Single-Stage prototype input spline shaft strain gauge torque – four gear-pair first stage.

.

0 100 200 300 400 500 600 700 800 900

1000

10 11 12 13 14 15 16 17 18 19 Time, seconds

Bridge 2 Bridge 3 Bridge 4 Bridge 5

`

Torq

ue, f

t-lbs

4 3 2 1

1 Input, 920 ft-lbs

2

3

4 220 ft-lbs

680 ft-lbs

440 ft-lbs

Harrier Technologies, Inc.

Geared Centrifugal Pump Transmission Gear Train Layout

1st Stage (PHG)

3rd Stage 5th Stage

4th Stage 2nd Stage

Input

Output

13

The Geared Centrifugal Pump

Transmission - large D-channels for fluid flow

Rod String Drive

Transmission



Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String


Compensator


Transmission

Pump


Drive Head

Rod String Drive

Transmission



Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String


Compensator


Transmission

Pump



•  D-tube flow channels provide excellent cooling of gears and bearings

•  Forced lube oil circulation reduces oil degradation due to stagnation

•  Forced oil circulation prevents overheating during gas lock or pump-off.

•  Modular construction – allows easy modification of transmission

Other Transmission Features


Other GCP Components

•  Lower seal section - Contains tandem shaft seals and pump thrust bearing •  Upper seal section – triple shaft seals plus main transmission pressure compensator •  Receiver – accepts rod string drive shaft

• Rod string – equipped with spin-thru stabilizers

Rod String Drive

Transmission



Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String


Compensator


Transmission

Pump


Drive Head


GCP Rate Potential •  Same rate potential as an ESP with equal HP rating

•  Nominal depth limit is 10,000 feet Geared Centrifugal Pump

Fluid Rate vs. Depth

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

0 1 2 3 4 5 6 7 8 9

Pump Depth, '000 feet

Flu

id R

ate

, B

FP

D

Rod String Drive

Transmission



Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String


Compensator


Transmission

Pump


Drive Head

Geared Centrifugal Pump Rod String Testing

GCP Rod String Test Apparatus

•  Objective: Test the effect of RPM, rod tension, well inclination and stabilizer spacing on rod stability

•  Single 25 foot 1” drive rod inside 3-1/2” water-filled tubing

•  Hydraulic drive 0 to 1100 RPM, variable tension up to 12,000 lbs

•  Rod stability monitored via lasers and

multiple view ports in tubing •  Rig inclination variable from 0 deg.

(vertical) and 85 deg.

GCP Rod String Test Apparatus

GCP Rod String Test Apparatus Rig at 60 deg. inclination


•  Over 1000 test measurements

•  At 0 tension and 500 RPM, rods require three stabilizers per rod for stable rotation

•  Only one stabilizer per 25’ rod is required above 650 feet from bottom at 500 RPM

•  Rods stable with one stabilizer per rod at 800 RPM above 850 feet from bottom.

•  Well inclination has only a minor effect on rod stability

•  Stable, smooth rod string drive for the GCP is easily achievable

GCP Rod String Testing Results

High Temperature GCP

•  Initial reason for developing the GCP was for Conoco-Phillips’ Alberta, Canada SAGD project.

•  SAGD project requires 2500 - 4000 BFPD at 250 deg. C.

•  The 575H-100 GCP has transmission, thrust bearings, and pressure compensators specifically designed for high temperature service.

•  High temperature spin through rod stabilizers developed for the SAGD application.

•  High temperature GCP tested in a full assembly high temperature test loop. First field installation expected in 3rd quarter 2011.


•  Full GCP assembly testing, including short rod string and stabilizer

•  3000 BFPD rate at 3000 psi and 250º C.

•  125 HP drive motor with VSD

•  Monitor input torque, RPM, inlet and discharge pump pressures and temperatures, and flow rate

•  All principal controls and data collection remote

High Temperature GCP Test Loop


High Temperature GCP Test Loop


Rod String Drive

Transmission



Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String


Compensator


Transmission

Pump


Drive Head

•  Bottom intake pump provides better gas handling than ESP.

•  ESP rates at lower cost and better efficiency (especially in 5-1/2” casing).

•  Utilizes the best part of an ESP – the pump; eliminates the worst –the down-hole electric motor and cable.

•  Surface drive – electric, IC, or hydraulic motor. Simple, inexpensive ‘VSD’ – just change the sheave.

•  High temperature application - up to 250º C (482º F).

Advantages of the GCP

GCP Presentation

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