Progressing Cavity Pumping Systems Overview …

1 2015 Weatherford. All rights Cavity Pumping Systems Overviewwith a Focus on Coalseam Gas ApplicationsSPE Queensland BrisbanePresented by Lonnie DunnMarch 9 2015 2015 Weatherford. All rights PC Pumping Systems History and Introduction CSG Applications & Differences from Mainstream PCP_____ Pumps Elastomers Geometries Pump Sizing and Testing_____ system Design and Configuration Pump Assemblies Surface Equipment and Monitoring & Control Drive Strings Common Pump Failures and Other Problems Summary 2015 Weatherford. All rights Lift TechnologiesFoamLiftPlungerLiftHydraulic LiftESPGas LiftRodLiftPCP 2015 Weatherford. All rights Lift Market Share by Type(based on dollars spent)ESP54%RRP25%PCP7%GL4%PL3%HL2%Other 5%From Spears Oilfield Market Report, Oct, 2011 2015 Weatherford. All rights system Estimated Well Count 70 to 80K30004000 2015 Weatherford.

2 All rights Cavity Pump History Rene Moineau develops the concept for a series of helical gear pumps one of which is what is now know as the Progressing Cavity (PC) pump Moineau licensed several major manufacturers in the US, UK and Germany; as surface fluid transfer pumps, wide range of displacements but low pressure Downhole motors (power sections) developed for oilfield drilling applications Experimentation with PC pumps for oilfield downhole artificial lift (AL) applications in Russia & California Initial trials of PC pumps in Canadian cold sandy heavy oil applications (CHOPS)Late 1920 s: Late 1920 s: Early 1930 s: Early 1930 s: Late 1950 s: Late 1950 s: 1960 s and 70 s: 1960 s and 70 s: 1979 to 1981: 1979 to 1981: 2015 Weatherford. All rights Canadian PCP Trials Initial Canadian ALS trials were in Lloydminster CHOPS heavy oil wells where other artificial lift methods had all failed due to extreme conditions Initial sand cuts up to 30% declining over time to single digit % s Viscosities between 5,000 and 50,000 cp Shallow directional wells (500 m) with low producing pressures (<200 psi) First Systems were built from short surface transfer pumps welded together 4 and 10 m3/day/100 RPM with 600 m of lift 2 7/8 outside diameter, Cavity portion was only 2 to 4 m long operating torque <100 ft*lbs; axial load <2,000 lbs; power <5 hp The standard for surface pumps was left hand rotation so continuous sucker rod used to avoid connection back-off Surface drive equipment was belt driven direct drive had no recoil control/braking Systems 2015 Weatherford.

3 All rights Canadian PCP Challenges Many pumps failed due to severe component wear or the stator burning up due to running dry (pump off) or excessive P Initial problems with pump quality as there were no inspection or test methods in place Some pumps didn t produce fluid after installed downhole; rudimentary test benches built to allow a simple performance test to verify fluid rates at a range of P @ pump speed Stator elastomer debonding - they even tried square stators in an attempt to hold the elastomer mechanically Manufacturing improvements to increase reliability and safety were gradually implemented Methods to built longer stators to avoid having to weld together many sections Right hand pump versions developed to allow use of sucker rods Hydraulic drive heads with valves to control recoil were developed 2015 Weatherford. All rights Heavy Oil PCP Evolution PC pumps specifically designed for artificial lift began to be developed and the capabilities of the Systems increased and by 1984: Pump displacements of up to 30 m3/day/100 RPM & pressure ratings of up to 1000 m of head; Full operating torques of up to 200 ft*lbs with associated surface power requirements of up to 10 hp In the mid and late 1980 s the use of PC pumps in Canadian heavy oil expanded in terms of different operating companies and equipment suppliers Pump & surface drive technology continued to evolve as did application designs and operating practices resulting in performance improvements By late 1980 s several thousand Systems operating in Canadian heavy oil and use beginning to expand to other regions 2015 Weatherford.

4 All rights Pumps Move Beyond Heavy Oil As PCP technology showed good results in heavy oil and their advantages as an ALS system became established in the late 1980 s they began to be tested in other applications such as medium crude oil and US coalbed methane These applications brought forth new challenges Further increases in volumes and pressure capability as well as different pump geometries to handling varying completions Medium nitrile elastomers showed limited resistance to med/light oils so work began on new oilfield elastomers By early 1990 s pump capacities had increased to 100 m3/day/100 RPM and lifts to 2000 m; operating torques to 1000 ft*lbs & required power to 60 hp Surface drive equipment capabilities grew to keep up with pump but with lower viscosity/deeper wells rod string recoil became a more significant consideration although initially was poorly understood By 1995 the PC pump installed base had grown to 15,000 wells 2015 Weatherford.

5 All rights to 2005 Rapid PCP Expansion By 1995 PC pumps had become recognized as a viable form of artificial lift for a variety of applications and a rapid expansion period began Wide range of products from increasing number of suppliers Design software and technical literature/training courses developed PC pump capability doubled to 200 m3/day/100 RPM and 3000 m lift (not simultaneously) Surface equipment improved in terms of ability tosafely manage rod string recoil Installed PCP system base growing rapidly increasing to approximately 50,000 Systems 2015 Weatherford. All rights to 2015 Diversification, Structure & Growth Growth in size of Systems slowed as they ran up against well completion constraints Advancements came more in terms of fit for purpose application solutions Improvements in elastomers for higher API oil applications ESPCP s, insertable Systems , charge pumps Metallic pumps for high temperature ISO 15136 PCP standards developed in attempt to implement some structure in the industry Large new growth areas including Venezuela Faja high volume heavy oil and Australia coal seam gas (CSG) Installed PCP system base estimated in 2014 at 70,000 to 80,000 2015 Weatherford.

6 All rights Capabilities Now and ThenAttribute19802015 Max Flow Rate (m3/day)20800 Max Lift (m Lift)6003000 Max Temp (Celcius)50150 (300 for metalic)Oil API Gravity<15<45 Sand Cutup to 40%up to 60%CO2n/a10 to 15%Free Gas (%)<30%<50% (<80% w/ charge pump)Max. Surface Power (hp)5250 Drive SystemContinuousContinuous, Sucker Rod, Gearbox ESP, PMM ESPMax Drive String Torque (ft*lbs)7503750 Deployment MethodsTubingTubing, Insertable 2015 Weatherford. All rights EquipmentSurface EquipmentPumping teeStuffing boxPolished rodRod stringRod couplingRod stringPC pumpNo-turn deviceDrivehead 2015 Weatherford. All rights Cavity Pump Positive displacement pump Two key components: Rotor: Typically metal with hard chrome coating Helix of n lobes Only moving part Stator: Generally made with elastomer with an internal shape as an helix of n+1 lobes Stationary housingRotorn = 1 Statorn = 2 2015 Weatherford.

7 All rights Pumping Motion Animations 2015 Weatherford. All rights Pump Theoretical Displacement (Capacity)V:Theoretical DisplacementA:Cross section areae:Eccentricityd:Rotor DiameterP:Stator Pitch Length EffectiveFlowAreaRotor4 x EccentricityStatorRotorDiameterStator PitchRotor PitchFor convenience expressed as a capacity in m3/day/100 RPM or BPD/100 RPM 2015 Weatherford. All rights Pump Flow RateT Actual Flow Rate Theoretical Flow Rate Slippage Fluid leakage (slippage) across the rotor/stator seal lines between cavities results in actual flow rates that are lower then the theoretical Slippage increases with differential pressure and also depends on the rotor/stator fit, pump speed and fluid viscosity PQSLIPV olumetric Efficiency Actual Flow RateTheoretical Flow Rate 2015 Weatherford.

8 All rights Pump Pressure (Lift) Rating PC pump Cavity pressure ratings reflect the maximum recommended differential pressure across the rotor stator/seal Typical value of 65 to 75 psi/pitch but can vary significantly depending on pump geometry and elastomerRated pressure quantity of stator pitches x Cavity pressure rating PCP system designs normally target a 50 to 85% pressure loading066132 198264330396stator pitch 6 66 396 2015 Weatherford. All rights Nomenclature and Standards History PC pumps are not designed or built to an API product specification like sucker rods (11B) and sucker rod pumps (11AX) Suppliers had complete flexibility on design, ratings and nomenclature and published limited information PCP specific processes such as elastomer/fluid compatibility testing, pump testing and sizing were not consistent across the industry Poorly defined quality control standards and documentation Lack of structure impacted the credibility of the products & industry Difficult for users to compare and evaluate products as more supplierscame on stream 2015 Weatherford.

9 All rights ISO & 2 Standards ISO & 2 standards for PC pumps and driveheads developed by joint supplier/user committees Includes requirements for design, design verification and validation, quality, nomenclature, performance ratings, functional verification does not define a product specifically like an API specification Annexes include recommended practices for PCP specific processes like elastomer/fluid compatibility testing and pump testing Enables users to do apples to apples comparisons Users can specify during purchasing validation, quality and functional testing grades that the supplier must comply with Adoption is not required by suppliers and users but in last several years standards are seeing increased use 2015 Weatherford. All rights system Advantages High system energy efficiency (between 55% & 70%) Even when handling highly viscous fluids: Ability to produce highly viscous fluids (up to 100,000 cp) Its geometry can be designed to offer maximum flow area and low fluid velocity minimize emulsion formation No valves or reciprocating parts will not gas lockFluidViscosity(cP)Water1 Motor Oil SAE 40200 Glycerin1,400 Honey 10,000 Ketchup50,000 Viscosities of common fluids 2015 Weatherford.

10 All rights system Advantages Excellent resistance to particulate matter Intermittent Pumping of up to 60% sand in liquid Rotor rolling motion gently presses particle into stator elastomer and then releases particle back into flow. Rotor wiping motion does not trap sand. Wiping motionRolling motion 2015 Weatherford. All rights system Advantages Relative low capital and operating cost High efficiency Smaller components Lower power consumption system simplicity fewer components Steady energy demand (non-cyclic) Low maintenance Simple installation and operation Potential for high turndown ratio (rate flexibility) Deployable in remote locations without power Green: low profile, low footprint, low noise 2015 Weatherford. All rights is just one but for PCP Systems 2015 Weatherford. All rights is just one but for PCP systemsIt is the most difficult to applyand least forgiving artificial lift method!