Weatherford Pcp

PC PUMP PRODUCTS & SERVICES TURNING IDEAS INTO RESULTS

Progressing Cavity Pumping Systems Information for Progressing Cavity Pumping Equipment

Multimedia & Extras Innovation for your Workspace

Bulletins & Published Articles

Additional Information & Reviews About our Line of PC Pumping Equipment

Technical Data Handbook

Information for Standard Oilfield Equipment

www.Weatherford.com

See Everything Weatherford Has to Offer (Internet Connection Required)

Navigation

A Couple Quick Tips to Help Navigate this CD

What’s New

Everything New or Updated from the Previous CD Version

January 2004 Click on the Bookmarks to the Left or Click on the Red Fonts on the Page to View the Related Information.


Progressing Cavity Pumping Systems Information for Progressing Cavity Pumping Equipment

Progressing Cavity Pumping System Locations Quality Certification PC Pump Information PC Drive Information System Design Equipment Operation Technical Literature Related Products

Click on the Bookmarks to the Left or Click on the Red Fonts on the Page to View the Related Information.


Progressing Cavity Pumping System The Basics of a Progressing Cavity Pumping System

Progressing Cavity Pumping System Overview Progressing Cavity Pumping System Animation


n integral part of Weatherford's complete suite of artificial list systems for production enhancement and ultimate A reservoir recovery, Progressing Cavity Pumping (PCP) Systems include a comprehensive portfolio of value-added products, services and systems solutions for a variety of lifting applications and well conditions. PCP Systems typically consist of a surface drive and a downhole PC pump comprised of a single helical-shaped rotor that turns inside a double helical elastomer-lined stator. The stator is attached to the bottom of a production tubing string and, in most cases, the rotor is attached to a drive string that is suspended and rotated by the surface drive. The operation of the pump is quite simple. As the rotor turns eccentrically in the stator, a series of sealed cavities form between the stator and rotor surfaces to move fluid from the intake to the discharge end of the pump. The differential pressure between the pump intake and discharge provides the lift necessary to move produced fluid to the surface. The result is a non-pulsating positive displacement flow with a discharge rate proportional to the rotational speed of the rotor and the differential pressure across the pump.

PROGRESSING CAVITY PUMPING SYSTEMS Another Production Enhancement Solution from Weatherford

Applications S Sand-laden heavy crude oil and bitumen S Medium crude oil with limits on H2S and CO2 S Light sweet crude oil with limits on aromatic content S High water cuts S Dewatering gas wells such as coal bed methane projects S Mature waterfloods S Visual and/or height sensitive areas S All type wells, including horizontal, slant, directional and vertical reservoirs Surface Drives Weatherford PCP surface drives are relatively small, lightweight, and feature a low profile requiring minimal vertical space and easy installation. The basic function of the surface drive unit is to supply the necessary speed and torque to the downhole progressing cavity pump by suspending and rotating a drive string. The drive string is typically made up of conventional rods or Corod® continuous sucker rods.

Individual parameters vary with well conditions and system components, and should be evaluated case by case. Maximum characteristics typically require special analysis.

515 Post Oak Blvd. S Houston, Texas 77027 www.weatherford.com

Surface drives are available in direct electric motor drives as well as direct gearbox drives that may be coupled to an electric motor or a gas engine. A wide range of hydraulic drives systems for both gas and electric applications are also available. Subsurface PC Pumps There are two basic components that make up the downhole PC pump — a single helical alloy-steel rotor connected to a rod string and a double helical elastomer-lined stator attached to the tubing string. Using the latest manufacturing technology, rotors are kept to tight tolerances and treated with chemical and abrasion-resistant coating, typically hard chrome. Stators are comprised of a steel tube with an elastomer molded inside to provide the internal geometry. Each combination of rotor/stator is matched to downhole conditions to provide highly efficient operation and optimum production enhancement.

PCP Selection Programs Weatherford PCP specialists assist operators with well design and pump selection using their wide network of experience and special PC Pump Selection Program. This program offers the ability to predict differential pressure, estimated pump speed, polished rod drive torque and total input power required for a given set of well parameters. From this information the most efficient and effective bottomhole pump is recommended based on volume and lift capabilities, sucker rod diameter and grade, prime mover horsepower and surface drive type most suitable for the application.

Weatherford products and services are subject to Weatherford’s standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford.

© Copyright 1999 Weatherford • All rights reserved • ALS3013 • 0599/7000 • Printed in U.S.A.


Locations

Find Your Nearest Weatherford BMW Products & Services Location

Weatherford BMW Products & Services Locations Lloydminster Weatherford Artificial Lift Systems Locations For All Other Location Information Visit www.Weatherford.com


City of Lloydminster

CITY OF

S A S K AT C H E W A N

1 Hwy. 17

A L B E R T A

leisure and cultural facilities for both the young and the young at heart. And naturally, it’s the ideal location for hosting conventions and tournaments.

Facilities Parks

A

2 MILES WEST 67 ST.

Lloydminster, a unique Canadian city straddling the Alberta/Saskatchewan border, offers excellent recreational,

Legend

67 ST.

67 ST.

The restaurants, stores, accommodations, attractions, major events and friendly people of Lloydminster are ready to serve you. Discover why the skyline of Canada’s only Border City is fast becoming the most welcome sight on the Yellowhead!

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

65 ST.

E. AV 53

62 ST.

62 ST.

. AVE 52

59 AVE.

62 AVE.

PC Pump Products & Services 4604-62nd Avenue 780/875-0103

49 AVE.

. AVE 53

Weatherford ALS Locations

BMW Products & Services 4206-59th Avenue 780/875-2730

(MERIDIAN) 50 AVE.

51 AVE.

63 ST.

59 ST.

57 ST. 57 ST.

Alberta Tourism Information Centre Archie Miller Arena Barr Colony Heritage Cultural Centre/OTS Heavy Oil Science Centre Bud Miller All Seasons Park Canada Post Office Centennial Civic Centre Communiplex Golf & Winter Club Greyhound Bus Depot Jaycee Park Kinsmen Participark Lakeland College Legacy Centre Legion Ball Park / VLA Soccer Pitches Lloydminster Chamber of Commerce Lloydminster City Hall Lloydminster Exhibition Grounds Lloydminster Fire Department Lloydminster Hospital Lloydminster Leisure Centre (indoor wave pool) Lloydminster Public Library Lloydminster Tourism & Convention Authority Royal Canadian Mounted Police Russ Robertson Arena Saskatchewan Tourist Information Centre Outdoor Pool Weaver Park Campground

No matter what your destination, treat yourself to a wonderful surprise at Bud Miller All Seasons Park. This year-round outdoor recreational facility, offering everything from lawn bowling to family barbecues, is bound to captivate the entire family. A 200 acre green space, Bud Miller All Seasons Park offers a complete range of activities and facilities. Head for the water and enjoy paddleboating or fishing in the idyllic 10 acre recreational lake. Or improve your tennis game on one of the four competition quality tennis courts. Perhaps you would rather stroll through the formal gardens or the Arboretum, or explore the nature and hiking trails through aspen forest and marshland.

Cemetery

56B ST. 56 ST.

Bud Miller All Seasons Park

40 AVE.

52 AVE.

Facilities

56A ST.

51 AVE.

63 AVE.

52 AVE.

56 ST.

Golf Course

55 ST.

P

54 ST.

54 ST.

F 52 ST.

G

Lloydminster Leisure Centre

53 ST.

52 ST.

H50 ST. 1

37 ST.

46A AVE. CL.

46 AVE.

. ST

43

AV E.

R

38 ST. CL.

32

31 ST.

ST .

51 AVE.

33

33 ST.

ST.

32

45 AVE.

CRESCENT

34 ST.

W

ST.

ST. 35 ST.

46 A VE.

BARR 35

48 AVE.

52 AVE.

55 AVE.

54 AVE.

57 AVE.

35 ST. 34 ST.

T.

33 S

32 S

T.

. ST

1 2

37 ST. CL.

40 AVE.

Barr Colony Heritage Cultural Centre Stop into Weaver Park, home of the Barr Colony Heritage Cultural Centre. Here you’ll find the OTS Heavy Oil Science Centre, Imhoff Art Gallery, Richard Larsen Museum, travelling exhibits, and the taxidermy display of Fuchs’ Wildlife Collection. For more information call (306) 825-5655.

31 S

J

30 ST.

I

29 ST.

29 ST.

29 ST.

45 A VE.

48 AVE.

31 ST.

47A AVE.

30 ST.

49 AVE.

31 ST.

52 AVE.

55 AVE.

57A AVE.

30 ST.

30 ST .

46 AVE.

T.

ST .

29 ST.

29 ST.

E. AV

49 AVE.

(MERIDIAN) 50 AVE.

HWY. 17

52B AVE.

54 AVE.

53 AVE. 23 ST.

24 ST. 23

ST .

22 ST.

21 ST.

42 AVE. CL.

26 ST.

43 AVE. CL.

T.

26 S

27 ST .

. ST

46 AVE.

51 AVE.

27

47 AVE.

26 ST.

27 ST.

49 AVE.

54 AVE.

.

26A ST

E. AV 47

57B

58 AVE.

. ST

25 ST.

24 ST. 55 AVE. CL.

57A AVE.

E. AV

58A AVE.

27

25 ST.

56 AVE.

58

59 AVE.

27A ST.

57 AVE.

E. AV

56 AVE.

B 57

K

23 ST.

28 ST.

28 ST.

28 ST.

E. AV 59

S

35 ST.

55A AVE.

58 AVE.

59 AVE.

62 AVE.

64 AVE.

63 AVE. CL.

61 AVE.

31 30

45 AVE.

52 AVE. . ST

46B AVE. CL.

56 AVE.

56B AVE.

38

51 AVE.

59 AVE. CL.

58 AVE.

38 ST.

38 ST.

39

36 ST.

35 ST.

Bud Miller All Seasons Park D

39 ST.

36 ST.

33 ST.

Z

40 ST.

E. AV

37 ST.

Yellowhead Hwy. 16 East

V

39 ST.

39 ST.

. AVE 64 CL.

39 S T.

53

40 ST.

3

.

42 ST. 41 ST.

Located within Bud Miller All Seasons Park, the Lloydminster Leisure Centre offers an aquatic experience for the entire family. Ride the waves and 50-metre water slide. Relax your weary muscles in the whirlpool, sauna or steam room. Avid swimmers and exercisers, too, will appreciate the 25metre competition pool and fitness room. For an hour or a day, Bud Miller All Seasons Park and the Lloydminster Leisure Centre combine to make the perfect travel break. For information on activities and special events, call (780) 875-4497.

A

CX

E. AV

T. 9S

M

44 ST.

52

AV E

. AVE 60

AVE. 63A

E. AV B . 63 CL

65

VE. 63 A

41 ST.

46 ST.

42 ST. 56 AVE.

BMW P & S

42 ST.

40 ST.

43 ST. 57 AVE.

43 ST.

54 AVE.

59 AVE.

63 AVE.

66 AVE.

2

65 AVE.

70 AVE.

44 ST.

Yellowhead Hwy. 16 West

48 AVE.

52 AVE.

N

L U O

46 AVE.

45 ST.

48 ST.

E 49 AVE.

56 AVE.

46 ST.

E.

62 AVE.

AV 56A

CRES. 47 ST.

PC Pump P & S

52 ST.

50 ST.

5

48 ST.

B

Y

Q

T

49 ST.

54 AVE.

CENTENNIAL DR.

47 ST.

1

(MERIDIAN) 50 AVE.

MILLER DR.

51 ST.

57 AVE.

ALBERTA

58 AVE.

59 AVE.

48 ST.

49A AVE.

51 ST.

42 AVE.

52 ST.

LLOYDMINSTER MAKE A BREAK FOR THE BORDER

This publication was produced in May 2001 by Lloydminster Tourism. Efforts have been made to ensure accuracy, but information is subject to change without notice. For additional publications and information such as the complete Lloydminster Vacation Guide contact our office weekdays from 8:00 a.m. - 12:00 p.m. and 1:00 p.m. - 5:00 p.m. 4420 - 50 Avenue Lloydminster, AB T9V 0W2 Toll Free: 1-800-825-6180 Phone: (780) 871-8333 Fax: (780) 871-8347 E-mail: [email protected] Website: www.lloydminsterinfo.com


Quality Certification

ISO 9002 Certified for a Quality Product Every Time

Quality Certification Registration Quality Certification Certificate



PC Pump Information

Products for your Downhole Needs

Uniform Thickness PC Pumps Weatherford PC Pumps BMW PC Pumps Insertable PC Pumps Horizontal Gas Separator Open / Close Tagbar ~ OCT


PROGRESSING CAVITY PUMPING SYSTEMS Uniform Thickness PC Pumps

Weatherford’s Uniform Thickness Stators are manufactured with an external profile that matches the internal geometry, as illustrated on the left. The result is a stator that has a uniform thickness of elastomer throughout, which can lead to numerous operating advantages including:

Using Weatherford’s Uniform Thickness technology, operators should find PC pumps more reliable and better suited for more applications, than ever before.

Improved Heat Dissipation As a result of the innovative design, the elastomer runs cooler leading to improved mechanical properties. Extensive pump inspections from various heavy oil customers document that the majority of failures were due to stress or wear of the stator elastomer minors. By eliminating this portion of the stator, failures should be drastically reduced. Uniform Elastomer Swell / Uniform Thermal Expansion Having a uniform elastomer thickness means the elastomer also swells or expands in a uniform fashion. Properly sizing the rotor for aggressive applications is therefore much simpler. Wider Applicability Applications that once pushed the envelope for PC pumps may now be within reach. These include wells with higher concentrations of aromatics, or wells with higher downhole temperatures. Higher Pressure Rating Uniform Thickness Stators allow for a more consistent rotor/stator fit, with less interference. This enables the pump to handle higher differential pressures, resulting in a very compact pump design.

Uniform Thickness Pump with Rotor

Conventional Pump with Rotor

UNIFORM THICKNESS PC PUMPS Another Production Enhancement Solution from Weatherford

Added Benefits Less pump for easier rotor removal during flush-bys Ability to land in deviated areas where longer pumps would be more difficult Less start-up torque, less frictional torque = less energy consumption ~30% savings on rotor re-chroming

PC Pump Metric

Imperial

10-1200 U 10-2400 U 15-1400 U 15-2800 U 50-500 U 50-1000 U 50-1500 U 70-500 U 70-1000 U 70-1500 U 105-400 U 105-800 U 105-1200 U

60-4100 U 60-8000 U 95-4600 U 95-9200 U 310-1600 U 310-3200 U 310-5100 U 440-1600 U 440-3200 U 440-5100 U 660-1400 U 660-2800 U 660-4100 U

Displacement

Lift Capacity

Style m3/day/100 rpm bbl/day/100 rpm Meters 1:2

10

60

1:2

15

95

1:2

50

310

1:2

70

440

1:2

105

660

1200 2400 1400 2800 500 1000 1500 500 1000 1500 400 800 1200

Feet 4100 8000 4600 9200 1600 3200 5100 1600 3200 5100 1400 2800 4100

Rotor Drift Diameter

Stator OD

mm

inches

mm

inches

48.64

1.915

90.0

3.543

48.64

1.915

90.0

3.543

51.99

2.047

104.9

4.130

55.75

2.195

104.9

4.130

55.50

2.185

110.0

4.331

*Additional Models Pending

Uniform Thickness Pump with Rotor

Worldwide Customer Service 515 Post Oak Blvd. Houston, Texas 77027 Phone: (713) 693-4000 [email protected]

WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Phone: (403) 269-7788

Europe / W. Africa Phone: (44) 1224 331 331

Latin America North - El Tigre, Venezuela Phone: 58 283 231 0555 South - Buenos Aires, Argentina Phone: 54 (11) 5077 0077

ME / CIS / N. Africa Phone: (43) 2630-339771 Asia Pacific Phone: 65-543-2133

Weatherford products and services are subject to Weatherford's standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford. © Copyright 2001 Weatherford • All rights reserved • ALS3032P.01 • 0402/3000 • Printed in Canada

PROGRESSING CAVITY PUMPING SYSTEMS Weatherford PC Pumps PC Pump Metric 22-200 22-600 22-900 22-1200 22-1500 22-1800 32-200 32-600 32-900 32-1200 32-1600 32-1800 80-600 80-800 80-1000 80-1200 80-1400 80-1600 98-800 98-1200 98-1600 130-800 130-1200 130-1600 160-200 160-400 160-600 160-800 160-1000 160-1200 161-900 161-1200 161-1500 161-1800 175-800 175-1200

Imperial 140-700 140-2100 140-3100 140-4100 140-5100 140-6000 200-700 200-2100 200-3100 200-4100 200-5200 200-6000 500-2100 500-2800 500-3200 500-4100 500-4600 500-5200 615-2800 615-4100 615-5200 820-2800 820-4100 820-5200 1000-700 1000-1400 1000-2100 1000-2800 1000-3200 1000-4100 1010-3100 1010-4100 1010-5100 1010-6000 1100-2800 1100-4100

Displacement

Lift Capacity

Style m3/day/100 rpm bbl/day/100 rpm Meters

1:2

22

140

1:2

32

200

1:2

80

500

1:2

98

615

1:2

130

820

1:2

160

1000

1:2

161

1010

1:2

175

1100


200 600 900 1200 1500 1800 200 600 900 1200 1600 1800 600 800 1000 1200 1400 1600 800 1200 1600 800 1200 1600 200 400 600 800 1000 1200 900 1200 1500 1800 800 1200

Feet 700 2100 3100 4100 5100 6000 700 2100 3100 4100 5200 6000 2100 2800 3200 4100 4600 5200 2800 4100 5200 2800 4100 5200 700 1400 2100 2800 3200 4100 3100 4100 5100 6000 2800 4100


Stator OD

mm

inches

mm

inches

47.63

1.875

90.0

3.543

47.83

1.883

90.0

3.543

64.29

2.531

114.3

4.500

73.63

2.899

139.7

5.500

81.03

3.190

139.7

5.500

64.29

2.531

114.3

4.500

90.50

3.563

152.4

6.000

90.50

3.563

152.4

6.000

WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Phone: (403) 269-7788




Weatherford products and services are subject to Weatherford's standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford. © Copyright 2001 Weatherford • All rights reserved • ALS3036 • 0402/3000 • Printed in Canada

PROGRESSING CAVITY PUMPING SYSTEMS BMW ™ PC Pumps

Displacement & Lift Capacities PC Pump Metric

Imperial

4-600 4-900 4-1200 4-1600 4-1800 7-600 7-1000 7-1400 7-1600 7-2000 10-600 10-900 10-1200 10-1600 10-1800 15-1400 15-1800 15-2000 16-200 16-600 16-900 16-1200 16-1600 16-1800 28-600 28-900 28-1200 28-1600 28-1800 42-600 42-900 42-1400 42-1600 42-1800

25-2100 25-3100 25-4100 25-5200 25-6000 45-2100 45-3200 45-4600 45-5200 45-6500 60-2100 60-3100 60-4100 60-5200 60-6000 95-4600 95-6000 95-6500 100-700 100-2100 100-3100 100-4100 100 5200 100-6000 175-2100 175-3100 175-4100 175-5200 175-6000 265-2100 265-3100 265-4600 265-5200 265-6000

Displacement

Lift Capacity

Style m3/day/100 rpm bbl/day/100 rpm Metres Feet

1:2

4

25

1:2

7

45

1:2

10

60

1:2

15

95

1:2

16

100

1:2

28

175

1:2

42

265

600 900 1200 1600 1800 600 1000 1400 1600 2000 600 900 1200 1600 1800 1400 1800 2000 200 600 900 1200 1600 1800 600 900 1200 1600 1800 600 900 1400 1600 1800

2100 3100 4100 5200 6000 2100 3200 4600 5200 6500 2100 3100 4100 5200 6000 4600 6000 6500 700 2100 3100 4100 5200 6000 2100 3100 4100 5200 6000 2100 3100 4600 5200 6000


Stator OD

mm

inches

mm

inches

36.58

1.440

75.0

2.953

41.15

1.620

88.9

3.500

48.90

1.925

90.0

3.543

48.64

1.915

90.0

3.543

48.90

1.925

90.0

3.543

57.66

2.270

Standard 104.9 Standard 4.130 Slim Hole 96.5 Slim Hole 3.800

59.94

2.360


Chart continued on back

BMW ™ PROGRESSING CAVITY PUMPS Another Production Enhancement Solution from Weatherford

Displacement & Lift Capacities PC Pump Metric

Imperial

56-200 56-500 56-800 56-1000 56-1200 56-1500 56-1800* 64-600 64-900 64-1200 64-1400 64-1500 S 64-1800 S 83-200 83-400 83-600 83-800 83-1050 83-1200 83-1600 S 88-600 88-900 88-1350 120-200 120-300 120-600 120-775 120-900* 120-1075 S 120-1200 S 180-350 180-500 180-700 180-1050

350-700 350-1600 350-2800 350-3200 350-4100 350-5100 350-6000 400-2100 400-3100 400-4100 400-4600 400-5100 S 400-6000 S 520-700 520-1400 520-2100 520-2800 520-3500 520-4100 520-5200 S 550-2100 550-3100 550-4400 750-700 750-1000 750-2100 750-2750 750-3100 750 3550 S 750-4100 S 1150-1150 1150-1600 1150-2300 1150-3500

Displacement

Lift Capacity

Style m3/day/100 rpm bbl/day/100 rpm Metres

1:2

56

350

1:2

64

400

1:2

83

520

1:2

88

550

1:2

120

750

1:2

180

1150

200 500 800 1000 1200 1500 1800 600 900 1200 1400 1500 1800 200 400 600 800 1050 1200 1600 600 900 1350 200 300 600 775 900 1075 1200 350 500 700 1050

Feet 700 1600 2800 3200 4100 5100 6000 2100 3100 4100 4600 5100 6000 700 1400 2100 2800 3500 4100 5200 2100 3100 4400 700 1000 2100 2750 3100 3550 4100 1150 1600 2300 3500


Stator OD

mm

inches

mm

57.66

2.270


56.77

2.235


57.66

2.270


71.37

2.810

55.50

2.185

71.25

2.805

127.0

inches

5.000


127.0

5.000

*- Sectional or One-Piece pump assembly. S - Sectional pump assembly. Standard, XL, 2XL or 3XL Rotor lengths available for all pump models.


WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Phone: (403) 269-7788

Europe Phone: (44) 1224 331 331


CIS & Middle East Phone: (43) 2630-339771

Weatherford products and services are subject to Weatherford's standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford. © Copyright 2001 Weatherford • All rights reserved • ALS3006.02 • 0702/3000 • Printed in Canada

PROGRESSING CAVITY PUMPS Insertable PC Pumps Corod or Sucker Rod String Production Tubing

Seating Rings

Key Features Patent Pending Arrowhead design

Pump Seating Nipple

Seating Mandrel

Reduce the down time and cost related to pulling or replacing a tubing PC Pump The only special piece of equipment in the tubing string is the Pump Seating Nipple (PSN) Extension Tube

PSN and Seating rings are located at the top of the assembly, eliminating the chance of sand packing in the annular space between the pump and the tubing Very similar to Insertable Rod Pumps, using only a PSN downhole Allows for special intake screens (snivees) and/or other equipment to be used below the pump

Stator

Allows for pump volume/lift changes without having to pull tubing All pumps utilize a No-turn tool on the bottom of the insert assembly

Optional Tagbar Slotting Tagbar

Optional Tubing Perforations

Tubing

No-Turn Tool

Attach Additonal Equipment

The main objective of an Insertable PC Pump is to help reduce down time related to pulling tubing when changing or replacing a tubing installed PC Pump. The Insertable PC Pump is installed down hole by first installing the tubing string with a corresponding Pump Seating Nipple (PSN) and the correct amount of tubing below the PSN at the desired pump landing depth. Once the tubing Is installed, the Insertable PC Pump assembly is ran down hole on the bottom of sucker rod or continuous rod until it seats in the PSN, sealing the production fluid away from the pump in-take.

Cloverleaf Design Corod or Sucker Rod String

Insertable PC Pumps "Cloverleaf Design" • Intended for 2 7/8" tubing • This design is similar to other conventional Insertable PC Pumps that are available • The assembly is removed by a rod coupling on the top of the rotor, and a "Cloverleaf" pick-up acting like a no-go at the top of the assembly • When the rod coupling and the "Cloverleaf" meet, the pump can be pulled from the seating nipple and brought to surface

Production Tubing

CLOVERLEAF SUCKER-ROD ROD COUPLING

ROTOR

Seating Rings Seating Mandrel Pump Seating Nipple

Cloverleaf

• The pump has a flush tube between the top of the stator and the "Cloverleaf" to allow the pump to be flushed and maintained. • The flush tube is approximately the length of the rotor to allow fluid to pass around the rotor and through the stator during a flush-by

Pull Rod

Insertable PC Pumps "Arrowhead Design"

Extension Tube

Pick-Up Coupling

•Utilizes patent pending "Arrowhead" technology to make Insertable PC Pumps more practical and compact • Intended for 3 1/2" & 4 1/2" tubing • Rotor features a special shaped Arrowhead structure on the bottom of the rotor designed to mate with a floating ring acting as a no-go at the top of the insert assembly • When these two parts come into contact the entire assembly can be removed from the well

Tubing Rotor ROTOR

Stator


Optional Tagbar Slotting

No-Turn Tool Attach Additonal Equipment

FLOATING RING ARROWHEAD

• The ability to pick up from the bottom of the rotor reduces the length of the flush tube between the stator and the floating ring Tagbar Pin • When a flush is required, the Arrowhead structure is positioned between the stator and the floating ring in a 4’ tube, extending the rest of the rotor into the production tubing Tagbar • Once the rotor is positioned fluid can be flushed around the rotor and through the stator Available in XL and longer lengths only Note: Additional rotor length reduces the chance of having the Arrowhead operate in the stator

Applications & Considerations

Arrowhead Design

Tubing & Equipment • New or like new tubing is recommended • Tubing should be cleaned and drifted during tubing installation • Tubing weight is not an option, heavier tubing weights than stated may prevent insert from being properly installed • Recommended to have tubing below the PSN drilled with holes near the pump intake to increase flow • Tubing below the PSN should be long enough to allow for different length of pumps to be installed • Consider possible future pump sizes in order to get the maximum payback from the insert concept without having to pull tubing

Corod or Sucker Rod String

Production Tubing

Well & Well Bore • Applications with extremely high sand content may not be good candidates • Wells with deviations near the PSN landing location may prevent the insert from being seated properly

Seating Rings

Insert Components

Seating Mandrel Pump Seating Nipple

• Nearly all components in the insert assembly are reusable • Allowing only stators and/or rotors to be purchased, once the initial components are purchased • A back up assembly is recommended to reduce turn around time • Insert tagbars are similar to conventional tagbars therefore slotting can be requested to allow for greater inflow

Floating Ring

Pull Rod

Operation • Proper rotor landing is critical with the patent pending "Arrowhead" style insert pump - rotor only needs to be 8"-12" off of the tagbar • If the "Arrowhead" is landed in the stator it may cause a restriction and cause slight damage to the stator Note: The pump will still operate normally if the arrowhead is landed with in the stator

Extension Tube

Maintenance • Regular flushing can extend the life of an insert pump assembly • Make sure flush-by or service rig crews are aware that it is an insert pump, and the know the proper procedures Note: Drive head can be tagged or marked, advising an Insertable PC Pump is down hole

Rotor

Stator Optional Tubing Perforations

Arrowhead Tagbar


Tubing

No-Turn Tool


Tagbar Pin

INSERTABLE PC PUMPS Another Production Enhancement Solution from Weatherford

Available Sizes Insertable Inside of 2 7/8" EUE x 6.50 lbs/ft or 9.67 kg/m & lighter Tubing

PC Pump Series Metric 1-1200 Y 7-1000 Y

Imperial

PSN I.D. ~ 2.325"

Lift Capacity

Displacement m3/day/ 100rpm

bbl/day/ 100rpm

(m)

(ft)

1 7

6 44

1200 1000

4100 3200

6-4100 Y 44-3200 Y

Length

Stator Top Bottom Connection Connection 1 1/4" NPT Pin

(m)

(in)

5.00 7.29

197 287

Rod Connection 3/4" API Pin

Max Operating Torque 3/4" Sucker-Rod 460 ft*lbs

Lengths Specified for Standard Length Tagbars Only Insertable Inside of 3 1/2" EUE x 9.30 lbs/ft or 13.84 kg/m & lighter Tubing

PC Pump Series

Displacement 3

Metric 7-1000 AY 7-1400 AY 7-1600 AY 10-1200 AY 10-1600 AY 14-1200 AY 14-1800 AY 17-1000 AY 17-1500 AY

Imperial 45-3200 AY 45-4600 AY 45-5200 AY 60-4100 AY 60-5200 AY 88-4100 AY 88-6000 AY 110-3200 AY 110-5100 AY

m /day/ 100rpm

bbl/day/ 100rpm

7

45

10

60

14

88

17

110

PSN I.D. ~ 2.830"

Lift Capacity (m)

(ft)

1000 1400 1600 1200 1600 1200 1800 1000 1500

3200 4600 5200 4100 5200 4100 6000 3200 5100

Length

Stator Top Bottom Connection Connection

2 3/8" EUE Box

1.900 EUE Pin

(m)

(in)

5.00 5.89 6.76 5.13 6.05 6.05 7.92 6.05 7.92

197 232 266 202 238 238 312 238 312

XL Minimum Rotor Lenght

Rod Connection

1" API Box

Metric 10-900 AY 10-1200 AY 10-1600 AY 10-1200 AYU 15-1400 AY 15-1800 AY 15-1400 AYU 22-900 AY 22-1200 AY 22-1500 AY 32-900 AY 32-1200 AY 32-1600 AY

Imperial 60-310 AY 60-4100 AY 60-5200 AY 60-4100 AYU 95-41600 AY 95-6000 AY 95-4600 AYU 140-3100 AY 140-4100 AY 140-1500 AY 200-3100 AY 200-4100 AY 200-5200 AY

1" Sucker-Rod 1100 ft*lbs

Lengths Specified for XL Length Tagbars Only

Insertable Inside of 4 1/2" EUE x 12.75 lbs/ft or 18.97 kg/m & lighter Tubing

PC Pump Series

Max Operating Torque

Displacement m3/day/ 100rpm

bbl/day/ 100rpm

10

60

10

60

15

95

15

95

22

140

32

200

PSN I.D. ~ 3.810"

Lift Capacity (m)

(ft)

900 1200 1600 1200 1400 1800 1400 900 1200 1500 900 1200 1600

3100 4100 5200 4100 4600 6000 4600 3100 4100 5100 3100 4100 5200

Top Bottom Connection Connection

2 7/8" EUE Box

2 3/8" EUE Pin

XL Minimum Rotor Length Y~Clover Leaf Insert AY~Arrowhead Insert Other Lifts Available Upon Request

Length

Stator

(m)

(in)

4.74 6.32 7.09 4.67 7.19 8.56 5.33 6.15 7.21 8.28 8.08 9.78 11.48

226 249 279 184 283 337 210 242 284 326 318 385 452

Rod Connection

1" API Pin


1" Sucker-Rod 1100 ft*lbs

Lengths Specified for XL Length Tagbars Only AYU~Arrowhead Insert Uniform

Rod Connection Length

Top Connection

Bottom Connection


WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Phone: (403) 269-7788





Horizontal Downhole Gas Separator

Figure A

Free Gas/ Gaseous Oil

Pump Intake

The Horizontal Downhole Gas Separator automatically orients a V-Slot intake towards the bottom of the horizontal wellbore (Figure B). Oil enters the gas separator through slots cut around the outer shell, flowing inside the shell down toward the V-Slot. The location of the V-Slot intake orients itself so that the pump always draws fluid from the bottom of the wellbore. The fluid at the bottom of the wellbore, which should be less gaseous, will be drawn into the gas separator's inner tube and then into the pump intake. The lighter, gaseous oil will then stay at the top of the wellbore away from the pump intake.

PUMP

One of the inherent problems of producing horizontal wells is the inability to minimize any gas that may be present in the wellbore from entering the pump. Although free gas and gaseous oil will migrate to the top of the wellbore in the horizontal section, the gas can still be drawn into the pump intake (Figure A), negatively effecting pump performance by reducing the pump volumetric efficiency. Conventional gas handling equipment that has been designed for use in vertical well applications is typically ineffective in horizontal applications.

PUMP

OIL

Free Gas/Gaseous Oil Gas Separator V-Slot Intake

Figure B

OIL

HORIZONTAL DOWNHOLE GAS SEPARATOR Another Production Enhancement Solution from Weatherford

Configurations The Horizontal Downhole Gas Separator is available in different flows and outside diameters to suit most PC Pump and Reciprocating Pump applications.

Style

O.D. (A) Length (B)

3 1/2' x 3" O.D. 4' x 3 3/4" O.D. 4' x 4 1/2" O.D. 7' x 6" O.D.

3" 3 3/4" 4 1/2" 6"

42" 48 1/4" 49 3/4" 80"

Connection (C) 2 3/8" EUE PIN 2 7/8" EUE BOX 3 1/2" EUE PIN 4 1/2" EUE PIN

Min. Flow Area 1.7 SQ. IN 3.1 SQ. IN 3.1 SQ. IN 9.6 SQ. IN

B A

Developed and constructed exclusively under license by Weatherford.

C

515 Post Oak Blvd. Houston, Texas 77027 www.weatherford.com

Worldwide Customer Service Phone: (713) 693-4000 Fax: (713) 693-4323 [email protected] Canada Phone: (403) 263-3125 Fax: (403) 266-1837

Weatherford products and services are subject to Weatherford's standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford. © Copyright 2000 Weatherford • All rights reserved • ALS 3022 • 0900/1000 • Printed in Canada

PROGRESSING CAVITY PUMPING SYSTEMS Open/Close Tagbar (OCT) The design of the Weatherford Open/Close Tagbar (OCT) will provide the producer with all the benefits of a non-slotted and a slotted tagbar in one piece of equipment. The OCT gives the producer the ability to: circulate the well through the tubing, reduce the shock loading and costs of sand bailing problem wells during work-overs, and allow fluid to enter the pump through slots directly at the intake when the well is in production.

PUMP INSTALLATION PUMP OPERATION

PC Pump

The OCT features top and bottom threaded connections that can simply thread on and replace your existing XL or 3XL threaded tagbar. The simplicity of the OCT makes cleaning quick and easy, allowing for multiple reuse if your PC Pump should ever need to be pulled and changed.

After the OCT feature is attached to the bottom of the Weatherford PC Pump of choice, the tagbar will sit in the open position during installation due to the weighted bottom end. During installation when the bottom of the tagbar comes in contact with loose or packed well bore debris, the bottom of the tagbar will be pushed to the closed position. Once in the closed position the OCT offers the producer the ability to pump fluid down the tubing string and through a concentrated area at the bottom. As the pumped fluid dispenses the well bore debris the pump can be continually lowered. Repeatedly lowering and circulating fluid allows the producer the ability to optimally locate the PC Pump intake within the well bore.

Once the PC Pump intake has been optimally landed within the well bore, the OCT can be fully opened by means of the following: allowing the weighted bottom end to slide open, the resistance to fluid pressure during circulation pushing the bottom open, and / or by resting the weight of the rotor and rod string on the tagbar pin and thus opening the assembly.

Perforations

PC Pump

OCT

Intake

Circulating Fluid Perforations OCT Well Bore Debris

Well Bore Debris

OPEN/CLOSE TAGBAR (OCT) Another Production Enhancement Solution from Weatherford

Available Sizes & General Dimensions OCT Description 2 7/8 " XL 2 7/8 " 3XL 3 1/2 " XL 3 1/2 " 3XL 3 1/2 " XL Welded* 3 1/2 " 3XL Welded*

Rotor Length Outside Open Closed Standard Top Standard Bottom Diameter Length Length Connection Connection Required XL 3XL XL 3XL XL 3XL

3 1 /2 " 3 1 /2 " 4 1 /2 " 4 1 /2 " 4 1 /2 " 4 1 /2 "

40 1/2 " 55 3/4 " 36 " 52 " 38 " 54 "

33 1/2 " 49 " 28 " 44 " 30 " 46 "

2 7/8 " EUE Pin 2 7/8 " EUE Pin 3 1/2 " EUE Pin 3 1/2 " EUE Pin Welded Welded

2 7/8 " 2 7/8 " 3 1/2 " 3 1/2 " 3 1/2 " 3 1/2 "

EUE Pin EUE Pin EUE Pin EUE Pin EUE Pin EUE Pin

*A weld on version is also available for new or replacement of current weld on tagbar assemblies within the Weatherford PC Pump product line.

2 7/8 " 3XL OCT Shown Performance and operation

Top Connection

Open Length Closed Length

of the OCT is based on use with the Weatherford PC Pump Product Line.

Tagbar Pin Outside Diameter

Bottom Connection



PC Drive Information

Products for your Surface Needs

MG Surface Drives M4 Surface Drives Hydraulic Surface Drives Stealth Shack & Stealth Wrap Polished Rod Support Clamp


BLK YELL MAG CYAN BLK

PROGRESSING CAVITY PUMPING SYSTEMS

YELL

BLK

CYAN

MAG

YELL

BLK

CYAN

MAG

YELL

MG Surface Drives

Key Features Patented Centrifugal Wet Braking System - Braking resistance does not occur until the polished rod speed reaches ~250 RPM or greater - Centrifugal force created during backspin engages large brake shoes against a stationary housing - Once the polished rod speed slows to ~250 RPM or less, the brake shoes retract for a quick, controlled & complete fluid dump - Braking system is immersed in synthetic oil to control fluctuating temperatures & to ensure a long service life Proven, compact & robust design

MG-I Direct Drive

MAG

Single or dual electric motor designs Hinged belt guards with balanced lifting points Low maintenance

CYAN

MAG

YELL

BLK

CYAN

MAG

YELL

BLK

CYAN

Optional removable pin plate

MG Direct Drive Shown with optional retrofit rotating stuffing box

CYAN

MAG

YELL

BLK

CYAN

MAG

YELL

BLK

CYAN

MAG

YELL

BLK

CYAN

MAG

PROGRESSING CAVITY PUMPING SURFACE DRIVES Another Production Enhancement Solution from Weatherford

Drive Name/ Model Drive Type Drive Ratio Drive Style Input Shaft

Options Driven Sheave Maximum Diameter Drive Sheave Maximum Diameter Drive Sheave Minimum Diameter Drive Belt Type - Integral

Rotating Stuffing Box

Maximum Number of Belts Minimum Center Distance (in)

Polished Rod Support Clamp

Height Weight 2

Polished Rod Guards

Polished Rod Speed Indicator CSA Approved-Class I, Div II


2000 ft-lbs 600 rpm 194,000 lbs 50,300 lbs 125 hp 75 hp x 2 NA 1 1/4" 1 1/4" or 1 1/2" 2 3/4" Centrifugal Wet 3 1/8" 3000#, R-31 Flange Housing - 140°C Electric or Hydraulic

Prime Mover

- Retrofit

MG-I MG MG-I MG

48" 64" 1600 lbs 1780 lbs

Upgradeable to 310,000 Ib (ISO), 80,400 Ib (Ca90) Thrust Bearing

2

Excluding Motor

EASTERN HEMISPHERE

Canada Phone: (403) 269-7788

Europe Phone: (44) 1224 331 331



Electric

30" 14" 4.9" V-Belts or synchronous Belts/Sprockets 6 8 16 1/2" + D 16" + D

1

WESTERN HEMISPHERE

MG Dual

Direct 1:1 Bearing Box Hollow Shaft

Maximum Input Polished Rod Torque Maximum Polished Rod Speed Thrust Bearing - ISO Rating1 Thrust Bearing - Ca90 Rating1 Maximum Motor Size, Single Motor Polished Rod Size MG-I MG Input Shaft Size Backspin Control Wellhead Connection Maximum Suggested Temperature

MG Dual Direct Drive - Shown with optional retrofit rotating stuffing box

MG

NA

60" NA

1850 lbs


YELL

PROGRESSING CAVITY PUMPING SYSTEMS M4 Surface Drives Drive Name/ Model MC4 MC4-I M4 Drive Type Drive Ratio Drive Style Input Shaft Shaft Type

Direct 1:1 Bearing Box Vertical Hollow Shaft

Ratings Max Input Polished Rod Torque (ft-lbs) Thrust Bearing - ISO Rating (lbs) Thrust Bearing - Ca90 Rating (lbs) Max. Polished Rod Speed (rpm) Max. Motor Size (hp) (Single Motor) 1 Polished Rod Size (in) Max. Suggested Temperature Backspin Control Input Shaft Size (in) Wellhead Connection

1500

2000

M4 Drive

129000 33,500 600

Shown with optional retrofit rotating stuffing box

60 HP, 365T

60 HP, 404T 1 1/ 4 Disc - 215°C Automatic External Caliper and Disc Brake 2 3/ 4 2 7/8" Pin or 3 1/8" 3 1/8" 3000 psi 2 7/8" Pin or 3 1/8" 3 1/8" 3000 psi 3000 psi Flange Flange 3000 psi Flange Flange Electric or Hydraulic

Prime Mover Driven Sheave Maximum Diameter (in) Drive Sheave Maximum Diameter (in) 2 Drive Sheave Minimum Diameter (in) Drive Belt Type Max. Number of Belts Center Distances

M4-I

30 11.5

14 4.9 V-Belts or Synchronous Belts/Sprockets

M4-I Drive

4 Each Type C V-Belts or Synchronous Belts to 120mm wide 284T & 286T : 19 1/2" - 22 1/2" 284T & 286T : 22 1/2" - 25 1/2" 324T & 326T : 20 1/2" - 23 1/2" 324T & 326T : 23 1/2" - 26 1/2" 364T & 365T : 21 1/2" - 24 1/2" 364T & 365T : 24 " - 27" 404T : 3 25 " - 27 3/4"

Dimensions & Weights Height (in) Weight (lbs)

53 850

39 800

53 1120

39 1090

1 Maximum HP is based upon frame size only. Care must be taken in selecting motor and sheave combinations to ensure input rod torque is never exceeded. 2 Maximum drive sheave diameter depends on the motor size. Smaller motors can accommodate larger drive sheaves. 3 60 Hp Maximum.

MC4 Drive

Note: An electric motor can produce 250% of it's rated torque without a proper torque limiting device. Note: Maximum ratings are individual specs. Maximum torque, hp and speed cannot occur at the same time.

MC4-I Drive

PROGRESSING CAVITY PUMPING M4 SURFACE DRIVES Another Production Enhancement Solution from Weatherford

Key Features Proven External Caliper Braking System Optional removable Pin Plate Hinged Belt Guards

Braking System The MC4/M4 braking system developed by Weatherford provides tremendous flexibility and control leading to safer operating systems. The brake automatically engages when the drive begins to recoil but it is also possible to manually engage the brake if required. The M4 braking system features an Adjustable Recoil Control Manifold (shown below). This manifold incorporates the ability to test the braking system before the wellhead drive is shut down (Test on the Fly) and the ability to adjust the brake to accommodate a range of downhole conditions (Recoil Speed Adjustment). *The Recoil Control Manifold is not available on the MC4/MC4-I

Options


Polished Rod Support Clamp - Retrofit

Polished Rod Guards

- Integral

Polished Rod Speed Indicator

Recoil Control Manifold

Test On The Fly

Recoil Speed Adjustment


PROGRESSING CAVITY PUMPING SYSTEMS HYDRAULIC DRIVES Another Production Enhancement Solution from Weatherford


Weatherford Engine Specifications Industrial Engine Displacement Compression Ratio Bore and Stroke Torque At Dimensions Length Width Height Weight

Industrial Engine Model 4.3 G.M. Industrial Engine

Model 5.7 G.M. Industrial Engine

4.3

5.7

4294.18 cc (262 cid) 9.2:1 101.60 x 88.39mm (4.00 x 3.48in) 2400 R.P.M. - 200 lb.-ft.


114 cm (45 in.) 68 cm (27 in.) 96 cm (38 in.) 970 lbs (441 kgs)


RPM

HP

1200 1400 1600 1800 2000 1200 1400 1600 1800 2000

35 40 46 52 58 48 55 63 71 79

Hydraulic Drives

All Horsepower figures are at 2,000' elevation with propane fuel.

HTD Drive Shown with optional retrofit rotating stuffing box

In-line-I Drive

4.3L G.M. Industrial Engine mounted on a Weatherford VSH2 Pumping unit

In-line Drive


HTD-I Drive

Weatherford Hydraulic Drive Specifications Hydraulic Drive Braking System Standard Stuffing Box Wellhead Connection Drive Ratio Approx. Drive Frame Weight Sheave/Belt Type Max Polished Rod Speed Thrust Bearing Rating Oil Polished Rod Size

HTD

Inline HTD

HTD-I

Inline HTD-I

Hydraulic Fixed Orifice Restriction Retrofit Rotating Flanged N/A 2 7/8" EUE Pin or 3 1/8" 3000 psi Flange 3 1/8" 3000 psi Flange 1:1 704 lbs 672 lbs 524 lbs 492 lbs Synchronous N/A Synchronous N/A 600 rpm 25, 900 lbs Ca 90 Elliot Petroleum Hydra-Blue MG36 or equivalent 1 1/4"

Hydraulic Drive Combinations

Maximum Speed (rpm)

Ratio



Inline Inline Inline Inline Inline

Maximum Speed (rpm)

3:1

F60/L38 F60/V74 F60/P74 F60/P98 F60/K80 F80/L38 F80/V74 F80/P74 F80/P98 F80/K80 F110/L38 F110/V74 F110/P74 F110/P98 F110/K80

378 743 740 986 802 281 552 550 733 596 199 392 390 520 423

Maximum Torque (ft-lbs)

Maximum Speed (rpm)

4:1 436 581 526 526 581 586 781 708 708 781 826 1101 998 998 1101

284 557 555 740 602 211 414 412 550 447 150 294 293 390 317


5.14:1 581 775 702 702 775 781 1042 944 944 1042 1101 1468 1331 1331 1468

221 434 432 576 468 164 322 321 428 348 116 229 228 304 247

746 995 902 902 995 1004 1339 1213 1213 1339 1415 1887 1710 1710 1887

1:1

Ratio

Options


HTD/L38 HTD/V74 HTD/P74 HTD/P98 HTD/K80

141 278 276 369 300

1166 1554 1409 1409 1554

Ratios not applicable to this drive

Note: Maximum speeds and torques are calculated based upon 100% efficiencies. - Retrofit

- Integral

Polished Rod Guards


Pump Model

Maximum Continuous Pressure (psi)

Sunstrand L38 Sunstrand V45 - 74cc Vickers PVH74 Vickers PVH98 Kawasaki K3VL80

3000 4060* 3625 3625 4600*

* Weatherford hydraulic systems are rated to 4000 psi, to use these pumps beyond rated pressure the system must be upgraded.

Hydraulic Skid

Electric/Gas Prime Mover

Reservoir Capacity Hose Size/Type Filter System

Standard 260 L (65gal) up to 360 L (80gal) 1" 4 Wire hose, 1" FD45 Series Quick Couplers Dual 3 Micron Filtering System with built-in 25 psi bypass

Dimensions Weight (w/o Prime Mover)

5' x 8' approx. 56" high Approx. 1350 lbs. (615 kg)

Hydraulic Power Transmission Available with gas or electric prime movers

Weatherford Hydraulic Drive Specifications Hydraulic Drive Braking System Standard Stuffing Box Wellhead Connection Drive Ratio Approx. Drive Frame Weight Sheave/Belt Type Max Polished Rod Speed Thrust Bearing Rating Oil Polished Rod Size

HTD

Inline HTD

HTD-I

Inline HTD-I

Hydraulic Fixed Orifice Restriction Retrofit Rotating Flanged N/A 2 7/8" EUE Pin or 3 1/8" 3000 psi Flange 3 1/8" 3000 psi Flange 1:1 704 lbs 672 lbs 524 lbs 492 lbs Synchronous N/A Synchronous N/A 600 rpm 25, 900 lbs Ca 90 Elliot Petroleum Hydra-Blue MG36 or equivalent 1 1/4"

Hydraulic Drive Combinations

Maximum Speed (rpm)

Ratio



Inline Inline Inline Inline Inline

Maximum Speed (rpm)

3:1

F60/L38 F60/V74 F60/P74 F60/P98 F60/K80 F80/L38 F80/V74 F80/P74 F80/P98 F80/K80 F110/L38 F110/V74 F110/P74 F110/P98 F110/K80

378 743 740 986 802 281 552 550 733 596 199 392 390 520 423


Maximum Speed (rpm)

4:1 436 581 526 526 581 586 781 708 708 781 826 1101 998 998 1101

284 557 555 740 602 211 414 412 550 447 150 294 293 390 317


5.14:1 581 775 702 702 775 781 1042 944 944 1042 1101 1468 1331 1331 1468

221 434 432 576 468 164 322 321 428 348 116 229 228 304 247

746 995 902 902 995 1004 1339 1213 1213 1339 1415 1887 1710 1710 1887

1:1

Ratio

Options


HTD/L38 HTD/V74 HTD/P74 HTD/P98 HTD/K80

141 278 276 369 300

1166 1554 1409 1409 1554

Ratios not applicable to this drive

Note: Maximum speeds and torques are calculated based upon 100% efficiencies. - Retrofit

- Integral

Polished Rod Guards


Pump Model

Maximum Continuous Pressure (psi)

Sunstrand L38 Sunstrand V45 - 74cc Vickers PVH74 Vickers PVH98 Kawasaki K3VL80

3000 4060* 3625 3625 4600*

* Weatherford hydraulic systems are rated to 4000 psi, to use these pumps beyond rated pressure the system must be upgraded.

Hydraulic Skid

Electric/Gas Prime Mover

Reservoir Capacity Hose Size/Type Filter System

Standard 260 L (65gal) up to 360 L (80gal) 1" 4 Wire hose, 1" FD45 Series Quick Couplers Dual 3 Micron Filtering System with built-in 25 psi bypass

Dimensions Weight (w/o Prime Mover)

5' x 8' approx. 56" high Approx. 1350 lbs. (615 kg)

Hydraulic Power Transmission Available with gas or electric prime movers

PROGRESSING CAVITY PUMPING SYSTEMS HYDRAULIC DRIVES Another Production Enhancement Solution from Weatherford


Weatherford Engine Specifications Industrial Engine Displacement Compression Ratio Bore and Stroke Torque At Dimensions Length Width Height Weight

Industrial Engine Model 4.3 G.M. Industrial Engine

Model 5.7 G.M. Industrial Engine

4.3

5.7





RPM

HP

1200 1400 1600 1800 2000 1200 1400 1600 1800 2000

35 40 46 52 58 48 55 63 71 79

Hydraulic Drives

All Horsepower figures are at 2,000' elevation with propane fuel.

HTD Drive Shown with optional retrofit rotating stuffing box

In-line-I Drive

4.3L G.M. Industrial Engine mounted on a Weatherford VSH2 Pumping unit

In-line Drive


HTD-I Drive

STEALTH SHACK & STEALTH WRAP

Weatherford has Engineered two products to meet today's stringent Oil Field Noise Level Requirements by reducing noise from Gas Powered Hydraulic Skid Units and Hydraulic Driveheads: The Stealth Shack and Stealth Wrap. The Stealth Shack can be operated independently or the overall noise suppression can be reduced by combining the Stealth Wrap.

Double Door Accessibility

Stealth Shack

Stealth Wrap

STEALTH SHACK & STEALTH WRAP Another Production Enhancement Solution from Weatherford

Sound Suppression Solution - For Noise Sensitive Areas Stealth Shack Steel clad building 8 feet long, 6 feet wide & 7 feet high Interior walls lined with acoustical absorbing material Engineered air intake & discharge All doors equipped with panic hardware & locks for personnel and equipment safety Designed to fit prime movers of any size Maintenance on prime mover & / or hydraulics can be done comfortably inside the shack Environmental base

Stealth Shack Optional Equipment Several muffler options available • Metal floor grating for added safety • Portable 12 volt lighting system

Stealth Wrap Stealth Wrap shown with Optional P.R. Guard Noise Cover

Intended for new and existing hydraulic driveheads Durable, weatherproof, lightweight Reduction in drivehead operating noise Very versatile Easy handling & installation Provides easy access to the Stuffing Box Top opening is large enough to fit around a Polished Rod Guard

Stealth Wrap Optional Equipment Polished Rod Guard Noise Cover


WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Phone: (403) 269-7788





PROGRESSING CAVITY PUMPING SYSTEMS Polished Rod Support Clamp

Advantages Compact simple design. Enhances field serviceability. Easily adaptable to existing equipment. Minimizes repair & maintenance costs. Minimal training required.

The Weatherford Support Clamp is a device that is capable of supporting axial rod weight during maintenance shutdowns. Once the detachable Support Clamp is installed between the stuffing box and the flow tee, it utilizes a series of rams machined to a specific tolerance to grip the polished rod. Once engaged service personnel can easily perform service work to any component of the surface equipment including the stuffing box.

POLISHED ROD SUPPORT CLAMP Another Production Enhancement Solution from Weatherford

Installation Procedures: 1. Position clamp between stuffing box and flow-tee. 2. Install surface drive. NOTE: Stud length may need to be lengthened to ensure that there is sufficient thread exposed to screw on the nut. (Approximately 7" x 7/8" for composite flow-tee - 8 1/2" x 7/8" regular flange connection) 3. Tighten stud bolts in star pattern as normal.

Running Position

Engaged Position

To Engage Support Clamp:

To Disengage Support Clamp:

1. Shutdown the drivehead. (see note 1 below) 2. Tighten the four bolts on the Support Clamp in a star pattern until the gauge threads are equal. Torque each bolt to 250 ft/lbs. 3. Recheck each bolt for 250 ft/lbs. torque in a circular pattern. 4. Slowly release the weight of the rods on to the Support Clamp checking for any slippage of the polished rod. 5. If any slippage is detected, support the rod weight using the surface drive clamp at the top of the drive. Do not attempt to use the Support Clamp after slippage. (See note 3 below)

1. Support weight of the rods either with the surface drive clamp at the top of the drivehead, flushby truck or a service rig. 2. Slowly release torque on the Support Clamp bolts watching for remaining energy in the system. 3. Back the Support Clamp bolts out a minimum of two turns each or until the gauge thread is exposed on all bolts. 4. Clamp is now disengaged. NOTES: 1. Shutdown wellhead drive prior to using the Support Clamp ensuring that ALL energy has been released from the well. Refer to the Wellhead Drive Manufacturers Operation Manual for proper shutdown and energy release procedures. 2. The Support Clamp relies on an o-ring seal to prevent leakage past the bolts on the clamp. When bolts are being turned in or out, it should be done slowly to prevent damage to the o-ring seals. 3. The Support Clamp relies on jaws grabbing on to the polished rod. If the polished rod slips while the Support Clamp is engaged it may damage the jaws of the clamp, making it less effective. If any slippage is noted the Support Clamp should be returned for Inspection/Rebuild.



System Design

Knowledgeable Help When You Need it

PC Pump Design Form ~ Adobe PC Pump Design Form ~ Excel Weatherford Drive Head Belt Sizing


PC Pump Design Form Weatherford offers the ability to analyze and recommend the most efficient and effective PC Pumping system for each application. Please ensure that all production and well data information is completed as accurately as possible. The quality of the information is critical to the well modeling from which the equipment and technical recommendations are proposed. Company Name: Well Name: Location: Country:

Contact: Phone: e-mail: Date:

WELL DATA

Units Circle One

Vertical:

Horizontal:

Slant:

Total Depth:

mkb-ftkb

Perforations:

PRODUCTION & FLUID DATA

Current Production:

m3pd-bfpd

Projected Production:

m3pd-bfpd

Water Cut:

% %

Top:

mkb-ftkb

Abrasive Cut:

Bottom:

mkb-ftkb

Gas Oil Ratio (G.O.R.):

mkb-ftkb

Total Fluid Viscosity:

Pump Landing Depth:

Fax:

m3/m3-bbls/scf

Producing Fluid Level from Surface Current:

mkb-ftkb

Projected:

mkb-ftkb

Flowline Pressure:

kpa-psi

Casing Pressure:

Viscosity Correlation:

C-F

cp

C-F

cp

C-F

kpa-psi

ppm

Water S.G.:

ppm

Water Salinity:

Degrees

Tubing Size:

mm-in

Casing Size:

mm-in

Aromatics (Benzene, Toluene, Xylene):

Rod Size:

mm-in

Bottomhole Temperature:

Rod Grade: Rod Type:

Conventional Rod

Continuous Rod

Rod Couplings:

Full Size

Slimhole

ppm vol% C-F

Temperature Gradient: Treating Chemicals

IPR DATA

C/m-F/ft

SURFACE EQUIPMENT

Static Reservoir Pressure:

kpa-psi

Bubble Point Pressure:

kpa-psi Test Point #1

Producing Pressure(s) Productivity Index:

C-F

API Oil Gravity: H2S: CO2:

Fluid Rate(s)

cp cp

Test Point #2

Electric Prime Mover:

rpm Brand

Gas Prime Mover: Surface Drive:

hp

Direct

Size Hydraulic

kpa-psi

Belt & Sheave Ratio:

Gear Box Ratio:

m3pd-bfpd

Operating Frequency:

Line Voltage:

(m3/kpa-bbls/psi)

Hydraulic Pump & Motor:

Please attach the following if available:

Flow-Tee to Drivehead Connection:

Directional Survey: Pertinent Information:

Flow Tee Style & Size:

Fluid Analysis:

PC Pump Design and Technical Support e-mail: [email protected] International

North America

Canada

780/417-4800 Office 780/464-5198 Fax

888/522-0252 Toll Free

780/875-0103 Office 780/875-0963 Fax

Reivsed: January 2004


Equipment Operation

Correct Operation Means Maximum Performance & Longer Life

Progressing Cavity Pump Manual Weatherford Progressing Cavity Pump Specifications & Capacities Insertable PC Pump Manual Progressing Cavity Drive Manual Direct Drive Operators Manual Hydraulic Drive Operators Manual GM 4.3, 5.7 & 8.1L Engine Operators Manual Stuffing Box Manual


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Progressing Cavity Pump Manual

General Information Version 1.2

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Preface Profile This manual is intended as a guide for the selection, operation and routine maintenance of Weatherford Artificial Lift Systems progressing cavity pumps. The information, specifications and illustrations in this publication are up to date at time of printing. Our policy is one of continued development and therefore we reserve the right to amend any of the information contained in this manual or binder without prior notice. For more information about Weatherford progressing cavity pumping equipment, or technical assistance in evaluating your requirements, contact your nearest Weatherford representative.

PC Pump Manual

Table of Contents Progressing Cavity Pump Generic Information

Introduction

Pg. 1

PC Pump Configuration

Pg. 2

Selection Considerations

Pg. 3

Input Data Sheet

Pg. 4

Elastomer Swell Test Parameters

Pg. 5

Tagbar Considerations and Selections

Pg. 5

Troubleshooting Problems

Pg. 6

Installation Guidelines

Pg. 7-9

Data Base System

Pg. 10

PC Pump Evaluation

Pg. 10-11

Identification of the Most Common Sator and Rotor Failures

Pg. 12-15

Downhole Accessories

Pg. 16

Suggested Make-up Torque for Tubing

Pg. 17

Rod Specifications

Pg. 18

Tensile Rod Stretch

Pg.19-22

Tubing Fill Times

Pg. 23

Useful Formulas

Pg. 24

Weatherford Canada Partnership Warranty

Pg. 25

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Introduction rogressing Cavity (PC) Pumps are a widely accepted means of artificial lift; with high production, lift capacity, and system efficiency being a few of the major benefits over other oil and water pumping systems. The ability for PC pumps to handle sand and viscous fluids make them the best solution for heavy oil production and the high gas oil ratio tolerance is beneficial in pumping mixtures of sand, oil, gas and water.

P

PC pumps are comprised of two parts - a helical shaped steel rotor and a stator. The rotor, which is the rotating internal component of the pump, is normally driven by a rod string. It is precision machined from high strength steel and coated with a wear resistance layer, such as chrome. The stator is attached to the production tubing string and remains stationary during normal operation. It consists of a molded elastomer permanently bonded to the inside of a steel tube. As the PC pump operates, cavities formed between the stator and rotor move fluid upward in a non-pulsating action from the intake to the discharge of the pump. Pressure builds linearly from the inlet to the discharge of the pump providing the necessary lift to produce fluid to surface.

Rotor Major Diameter

PUMP DISPLACEMENT

Rotor Minor Diameter

Displacement of any PC pump is a function of the rotor diameter, eccentricity, and the pitch length.

STAGE AND PRESSURE CONVENTIONAL DEFINITION Pump pressure rating = 100 psi/pump stage

Rotor Stator Pump Pitch Pitch Stage Length Length Length

Pump Discharge

Pump stage = 3 rotor pitches = 1.5 stator pitches

Stator

Tag Bar

Rotor

1

Inlet Sub

PC Pump Configuration Typical Progressing Cavity Pump Set-up Driven Sheave

26

5

Drive Sheave

3 25

27 28

EQUIPMENT LIST

23

1. Stator (includes Tagbar sub) 1a. Tagbar Sub 2. Rotor 3. MG Direct Drive 4. Stuffing Box Wellhead Connection 5. Belt Guard 6. Flow-Tee (Composite Pumping Tree (CPT) Illustrated) 7. Rod BOP (Composite Pumping Tree (CPT) Illustrated) 8. Polished Rod 9. Polished Rod/Sucker Rod Change-Over Coupling 10. Sucker Rods 11. Sucker Rod Coupling 12. Shear Coupling 13. Rod Guides 14. Pony Rods 15. Sucker Rod/Rotor Change-Over Coupling 16. Tubing Drain 17. Pump Seating Nipple (PSN) 18. Tubing/Stator Swedge Adapter 19. Pup Joint 20. Torque Anchor/No-Turn Tool 21. Downhole Check Valve 22. Gas Separator/Tail Joints 23. Prime Mover 24. ePac VFD or Starter Box 25. Belts & Sheaves 26. Polished Rod Guard 27. Remote Tachometer 28. Booth Guard

4 6&7

8 9 16 11 14 18 19

13 10 12 17 15

1 Production Zone 20 22

2

2

1a 21

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Selection Considerations PC pump selection is dependent on the following conditions: •Production requirements. •Pump landed depth. •Tubing and casing pressures. •Fluid conditions. -Density, viscosity, fluid level, sand and water content, aromatic content, CO2 & H2S presence, temperature, and gas oil ratio. •Well equipment configuration. •Tubing specifications. •Casing specifications. •Rod specifications. •Drive capabilities. An important factor to consider when selecting a PC pump is the experience gained from other wells in the area. Weatherford personnel are available to assist with well design and pump selection using our wide network of experience and a very powerful design program developed at C-FER. In order to complete a C-FER PC pump run, the following input sheet must be filled out completely. This program can predict all elements of a Downhole Progressing Cavity Pumping System including: •Pump differential pressure. •Pump speed. •Total input power required. •Polished rod drive torque. •Rod axial and sidewall loading. •Surface equipment loading. •Tubing life and location of high tubing wear. The program can then help determine the following: •Pump size (volume and lift). •Rod & tubing size. •Drive system. •Suggested rotor space out. •Total system efficiency.

Note: Please ensure that all production and well data information is completed. This information is critical to the surface equipment design, PCP and elastomer selection. If key information is missing, designs cannot be completed accurately and delays will result. Please circle unit of measure where applicable. To receive a CFER design, return a completed input data sheet to one of the following: For inquiries for Canada Fax: 780/875-0963 For United States or International Fax: 780/464-5198

3

Input Data Sheet We offer the ability to predict all elements of a Downhole Progressing Cavity Pumping System including differential pressure, estimated pump speed, polished rod drive torque and total input power required for any given set of well parameters. From this information it is possible to correctly select the bottom hole pump based on volume and lift capabilities, sucker rod diameter and grade, prime mover horsepower and surface drive type most suitable for your application. ®

Company Name:

Country:

Date:

Contact:

E-mail:

Phone:

Well Name:

Fax:

Location:

WELL DATA

Circle Unit of measurement

PRODUCTION AND FLUID DATA

Total Depth:

Ft - m

Current Production:

Bfpd - M3pd

Midpoint of Perforations:

Ft - m

Desired Production:

Bfpd - M3pd

Pump Landing Depth (TVD):

Ft - m

Water Cut:

%

TMD:

Ft - m

Abrasive Cut:

%

Producing Fluid Level From Surface (TVD)

Scf/Bbl - M3/M3

Gas/Oil Ratio:

Current:

Ft - m

Projected:

Ft - m


Cp@

˚F - ˚C

Cp@

˚F - ˚C

Aromatic Content Mole% Benzene, Toluene, Xylene:

Flowline Pressure:

Psi - Kpa

Oil Gravity:

Casing Pressure:

Psi - Kpa

Water Gravity:

Water Salinity:

Casing size:

Psi - Kpa

C02:

Ppm%

Tubing Size:

Inches -mm

Temperature at Pump:

˚F - ˚C

Rod Size & Grade:

Inches -mm

Bottom Hole Temperature:

˚F - ˚C

Coupling

❏

Slimhole

❏

Standard

❏

˚API

H2S:

Ppm%

Treating Chemicals (list type and application):

IPR DATA Static Reservoir Pressure: Bubble Point Pressure: Test Point #1

Psi - Kpa

SURFACE EQUIPMENT

Psi - Kpa

Primer Mover Type:

Gas

Surface Drive:

Direct

Test Point #2

Producing Pressure:


Fluid Rate (Bfpd-m3pd): Productivity Index:

❏ ❏

Hydraulic

Hz Line Voltage:

Specify Flow-Tee to Drive Head Connection: Bbl/Psi - M3/Kpa

Pertinent Information:

To Receive this Data Information Sheet please contact your local Weatherford Distributor. For an electronic copy please contact us at www.weatherford.com

4

Electric

❏ ❏

Volts

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Elastomer Swell Test Parameters Elastomer swell tests and gas/fluid compositional analysis are completed to assist in determining gas and fluid affects on PC stator elastomers prior to running the pump. This testing can be conducted on any well or area but is predominantly completed on higher API oils and in areas with no previous PC pump experience. The following are general instructions for elastomer testing: 1. Contact your Weatherford representative for information on elastomer testing labs in your area. 2. Contact the lab to discuss your objectives and to determine which tests will be completed (72 hour/240 hour tests). 3. Determine who will obtain the sample. (The customer or the lab). 4. Obtain a pressurized fluid sample at the well. 5. Complete a swell test request form. (Forms available from Weatherford PC Pump). 6. Fax the completed request form to the lab. 7. Discuss the results of the test with a Weatherford representative.

Tagbar Considerations & Selections

XL Tagbar

Tagbar Pin

The tagbar is a bar or rod that is welded in high strength mechanical tubing and screwed or welded into the pump intake. The tagbar has 2 primary purposes: 1. 2.

Used as a reference point for landing the rotor. Used as a safety stop to prevent the loss of the rotor and rods in the event of a failure to the drive string. It is not designed to support the rod string during continuous operation.

Tagbar Pin

There are a few different styles of tagbars available: 1. 2.

3.

4.

5.

Slotted Tagbar

Standard Tagbar • Used where pump inflow is not a problem (i.e. high H20 cut fluid, high API fluid). XL Tagbar • Used with an XL rotor to allow operator more flexibility during landing and the ability to adjust wear locations on the tubing caused by rod couplings. • Used in applications where optimum inflow is anticipated. Slotted Tagbar • Used primarily in heavy oil applications where pump inflow is sometimes problematic. • Consists of two slots approximately 1" x 10". Slotted XL Tagbar • Used primarily in heavy oil applications where pump inflow is sometimes problematic. • Allowing the rotor to stick out the bottom of the stator keeps the pump intake free of sludge. Custom Tagbars • Custom tagbars can be built to suit specific applications as required.

5

Slotted XL Tagbar

Tagbar Pin

Trouble Shooting Problems There are many variables in any producing environment. These are a few of the more common problems that occur and possible actions that could be taken. C O N D I T I O N

C O N S I D E R A,B,D,E,F,G,H,I F,I,J,K,O,P,Q, F,K,L,N,O,P,Q,R,S,T R,S,T F,J,K,L,O,P,Q,R,S,T A,B,C,D,E,F,I,K,P,Q,S Possible Action

Low or no production > Normal torque Low efficiency > High torque Polish rod will not turn > High torque RPM increases not possible > Low torque RPM increases not possible > High torque Uneven production Possible Cause of Problem A

Well pumped off

• Slow down PC pump RPM. • Lower casing gas pressure. • Down size PC pump.

B

Wellbore inflow problem

• Lift rotor out of stator and flush stator and tubing string cleaning the sand and sludge away from the perforations. • Lower casing gas pressure.

C

Wellbore inflow fluctuating

• Lower casing gas pressure. • Lift rotor out of stator and flush stator and tubing string cleaning the sand and sludge away from the perforations.

D

Pump intake partially plugged

• Lift rotor out of stator and flush stator and tubing string cleaning the sand and sludge away from the pump intake. • Use XL rotor and XL slotted tagbar to keep intake clean.

E

High fluid GOR (Gas oil ratio)

• Lower pump intake below perforations. • Use a gas separator on pump intake or charge pump configuration.

F

Rotor landed incorrectly

• Refer to rotor landing procedure to ensure rotor is correctly landed. Note: landing procedures are only guidelines and changes may be required for certain applications.

G

Hole in tubing or stator

• Pressure test tubing ( if possible) to see if a hole exists. • Pull equipment and repair as required. If problems occur at the same location, coated rod boxes, Corod or hardened tubing may be an option.

H

Tubing drain blown

• Pressure test tubing (if possible). • Use a drain with more pins.

I

Pump worn out

• Pressure test tubing (if possible). • Have pump test bench tested.

J

Pump operating at maximum lift

• Complete C-FER design module to confirm. • Replace with a pump with more lift. • Lower pump discharge pressure by: 1. Increasing tubing size or install Corod. 2. Continuously loading casing with a less viscous fluid. 3. Decreasing flowline pressure.

K

Stator / rotor interference fit increased due to elastomer swelling or hardening

• Insure proper elastomer has been used. • Use a looser fit pump to allow for swelling. • Complete fluid analysis.

L

High fluid viscosity

• Continuously load casing with a less viscous fluid. • Use viscosity reducing agents.

M

Broken rod or polished rod

N O

Tubing string has backed off Debris has settled out above the stator A large slug of wellbore debris has entered the pump intake Stator elastomer failed

P Q R S T

Drive head improperly sized Drive head or drive skid problems VFD improperly sized or programmed

• Insure proper sized rods are being used for torque velocities. • Insure torque setting limit is set correctly on drive unit. • Install no-turn tool. • Use smaller tubing to increase fluid velocities. • Lift rotor out of stator and flush tubing. • Lift rotor out of stator and flush tubing and stator. • Insure proper elastomer has been used. • Complete C-FER design module to confirm pump is correctly sized for application. • Inspect pump to determine failure mode. • Recalculate drive requirements. • Repair as required or consult your local Weatherford service center. • Confirm all parameters are correct.

6

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Installation Guidelines The procedures listed below are intended to form a basic framework for a typical installation of a Weatherford Progressing Cavity Pumping System. Special applications or equipment may necessitate changes to these procedures. A Weatherford Artificial Lift representative can provide assistance in formulating modified installation procedures.

1-Stator Installation

2-Rotor Installation

1

3-Graphs & Charts

Stator Installation 1-1

PRE-INSTALLATION

• Well cleanout procedures should be considered before running any progressing cavity pumping system. The removal of any solids (i.e. sand, coal fines) from the bottom of the wellbore is recommended with a minimum of two meters below the well perforations or two meters below the pump inlet sub. • The rotor and stator are matched for optimum pump efficiency. Ensure the rotor serial number located on the rotor head (top) corresponds with the last set of numbers on the stator. • Tighten all pump connections between optimum and maximum torque (According to API specifications outlined on page 17).

ROTOR LANDING: Zero Rod Weight Mark

Zero Weight Mark Full Rod Weight Mark

• If the inside diameter of the production string is less than the stator discharge connection diameter a tubing pup joint equivalent to the stator discharge connection diameter should be installed above the stator. DO NOT SWAGE DOWN AT PUMP DISCHARGE. Swage to smaller tubing size at least one full joint (if possible) above the stator (minimum of four feet acceptable).

• If additional equipment is required for operation (i.e. PSN, no turn tools, tail joints) contact a Weatherford Artificial Lift Systems representative for additional landing procedures.

STATOR INSTALLATION

• The stator is run into the well on the end of the tubing string with the tagbar or inlet sub on the bottom of the stator. • Run the stator and tubing into the well and tighten all connections between optimal and maximum torque (according to the API specifications outlined on page 17). • Run the stator down to the recommended landing depth and set the tubing. The inlet sub of the pump is usually landed in or below the level of the perforations.

7

Pull Back 12" Plus Applicable Rod Stretch Operating Point

• Consideration should be given to using a torque anchor in high speed and/or high torque applications or when production tubing cannot be made up to optimum makeup torque.

1-2

Full Rod Weight Mark

Rotor Landed on Tagbar

1-3

SECTIONAL PUMP INSTALLATION

Stator and Tubing String: Tighten all connections between optimal and maximum API specified torques. • Run all equipment below the PC pump (i.e. gas separator, tail joints, no-turn tool, etc.) into the well, if required. Hang the last connection on the wellhead using tubing elevators or a dog collar. • Note: The stator is properly oriented when the serial numbers are towards the top or in the up-hole position. • Make sure the tagbar is properly installed (if threaded tagbar) on the bottom stator section. Install the required sectional stator pup joint onto the top of the bottom stator section. Thread a tubing collar onto the other end of the sectional stator pup joint to prevent tubing elevators from slipping off. • Tighten all connections and raise the assembly into rig's derrick, tagbar down. Connect the bottom of the tagbar onto the last connection if equipment is being used below the PC pump. • Lower assembly into well and hang sectional stator pup joint on wellhead using a dog collar, remove the tubing collar leaving the pin end up. • Connect a handling pup joint onto the top of the top stator section, add a tubing collar on the other end of the handling pup joint to prevent the tubing elevators from slipping off. • Tighten all connections and raise the assembly into the rig's derrick, stator down. Connect bottom of top stator onto the top of the sectional stator pup joint. Lower the assembly into the well, hanging the handling pup joint on the wellhead with the tubing elevators. • Connect the next joint of tubing onto the handling pup joint. Then continually add joints of tubing and other equipment (drain, burst joint, etc.) as normal until the sectional stator assembly reaches the required landing depth.

STATOR

Tubing Collar

ROTOR

Handling Pony Rod

Handling Pup Joint

Top Stator Section

Top Rotor Section

Sectional Stator Pup Joint

2

Rotor Installation 2-1

Sectional Rotor Pony Rod

ROTOR LANDING

• The rotor is run into the well on the end of the sucker rod or continuous rod string. • Care should be taken while handling the rotor on surface to avoid damaging the pin threads or the finished surface. The rotor should be supported in a manner as to prevent excessive bending that may cause permanent damage. • Check the rods and couplings for excessive wear or other defects. • Tighten all sucker rod couplings to API specifications as recommended by rod supplier. • Prior to entering the stator with the rotor record the rod string weight. • To prevent damage to the stator elastomer, SLOWLY lower the rotor into the stator. The rotor usually rotates to the right (clockwise). • Lower the rods until the rotor rests on the tagbar (indicated when the rod string weight reaches zero). • Mark the rod string and lift the rods ten to fifteen feet then lower to zero string weight again to ensure rotor is resting on the tagbar. • Slowly pick the rods up until rod string weight is achieved. • Pick up an additional 12". • Pick up the rod string an additional amount for rod stretch. Please refer to Tensile Rod Stretch charts on pages 19 to 22.

8

Bottom Stator Section

Tagbar

Bottom Rotor Section

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2-1

WARNING: Additional couplings at the stator discharge will restrict the fluid flow, also the orbiting motion of the rotor can cause increased tubing wear and/or possible rotor failure. Therefore whenever possible connect the first sucker rod directly to the rotor or the longest pony rod as possible.

ROTOR LANDING (CONTINUED)

• If a tubing anchor catcher is used, difference in thermal expansion between the tubing and rod string may need to be considered.

*THIS IS ONLY A GUIDELINE. EACH FIELD HAS INDIVIDUAL AND UNIQUE CHARACTERISTICS THAT NEED TO BE MONITORED AND ANALYZED TO ESTABLISH THE PROPER ROTOR LANDING. THE CFER PC PUMP PROGRAM CALCULATES ROD STRETCH BASED ON ALL OPERATING PARAMETERS.

• The rotor should now be in the operating position. Do not lift the rotor from this position. Landing with least amount of rotor sticking out of the top of the stator minimizes downhole vibration. • Measure the height of the wellhead drive. • Add the length of the well head drive assembly to the operating position. This becomes the clamping point. Allow an additional 6" to 12" for polished rod to stick up above the clamping point. • DO NOT leave wrench marks on the polished rod. • Install a polished rod clamp to support the polished rod on the well head drive. A second rod clamp may be installed above the first clamp to prevent polished rod slippage. 2-2

3

Polished Rod Measurement For Drive Installation:

ROTOR AND ROD STRING

Tighten all connections between optimal and maximum API specified torques. • Connect the required sectional rotor pony rod onto the top of the bottom rotor section (typically the API box end). • Tighten the connection and raise the assembly into the rig's derrick, rotor down. Lower assembly into tubing, hanging the sectional rotor pony rod on the wellhead with the rod elevator. • Connect a hanging pony rod onto the top of the top rotor section (typically the API pin end). • Tighten the connection and raise the assembly into the rig's derrick, rotor down. Connect the bottom of the top rotor section onto the top of the sectional rotor pony rod. • Lower assembly into the well, hanging the handling pony rod on the wellhead with the rod elevators. • Connect the next rod onto the top of the handling pony. Continually add rods and other equipment (rod shear, etc.) as normal until the rotor tags out on the tagbar pin. • Once the rotor tags out on the tag bar pin use conventional landing procedures to land the rotor. Note: Sectional Pup Joint and Pony Rod are generally specific length combinations, but lengths can be adjusted for customer requests. 2-3

Zero Rod Weight mark

Coupling Clamp 6" Preferred (24" Max.)

"B"

Clamping Point

Polished Rod

Full Rod Weight Mark

Operating Point

Operating point

"C" Remove One or Two RODS from Wellbore

"A" End of POLISHED ROD to be BELOW B.O.P. Makeup PONY RODS (as required)

TO SUMMARIZE

• Record string weight before the rotor enters the stator. • Land the rotor on the tagbar. • Pull up string weight. • Pull up an additional 12". • Pull up to allow for rod stretch-operating position. • Measure and allow for wellhead height-clamping position. • Remove sucker rod(s) and replace with the polished rod and pony rods. • Run the polish rod into the well and clamp off.

LENGTH

9

DESCRIPTION

"B"

Length from operating mark to top of Coupling (relative to the Polished Rod). Overall length of Drivehead

"C"

Length from operating string = Length of polished rod + pony rods. (C = A + B + 6" {24" Max})

"A"

Data Base System The PC Solution Data Base was designed specifically for use with PC pumps. The system provides pump test and inspection results, inventory listings and pump life analysis reports. Every pump manufactured by Weatherford PC Pump is tested in-house and the results are recorded in the system.

Test Reports

Inspection Reports

• Test results for all new and used pumps. • Documentation of pump serial numbers, elastomer type, rotor dimensions and performance parameters.

• Inspection summary for every pump returning from the field. • Detailed analysis of rotor, stator and tagbar condition. • Includes pump run time and the reason the pump was pulled.

Installation Summary

Inspection Summary

• Summary of all PC pumps installed. • Report can be be summarized for each company and/or field for a specified date range. • Sorted by installation date or location in each field. • Includes a summary of the pump test report.

• Summary of all PC pumps inspected. • Report can be summarized for each company and/or field for a specified date range. • Sorted by location and the date the pump was pulled for each field. • Includes a summary of the pump type, condition, run time, and reason for being pulled.

PC Pump Evaluation 1

Test Temp: shows the temperature of the fluid the PC pump is being tested with.

5

Test Time: Time in seconds recorded to determine time to fill a volumetric weight at specific test point throughout the test.

2

Test Speed: Rotor speed during test.

6

Hyd. Press: Actual hydraulic or VFD torque reading taken at each specific test point.

3

Eff. (100 psi/stage): Volumetric efficiency of the pump calculated based on the nominal pump displacement measured fluid rate and pump speed.

7

Pump Eff. (%): Pump efficiency determined by taking the test time and dividing by 60 seconds.

8

Torque (ft-lbs): Total torque required to turn the pump. This includes both the friction and hydraulic components.

4

Diff Press: Shows the simulated lift in psi at specific test points throughout the test.

10

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Weatherford PC Pump Test Report Weatherford PC Pump Inc., Lloydminster, Alberta, Canada Placed In Stock:

Company: ABC Company Pulled From:

Pump ID: 12 W.O.# : 31113 1 Test Temp (C): 30.0 Stator Run #: 35339 Date Tested: 04-Sep-99 Date Installed: 01-Jan-00

Installed Into:

Field:

ABC Field One

Location:

01-01-01-03 W3

UWI:

Well # 1

PC PUMP: 28

XL

1200

Stator Condition: New

Top #

Rotor Coating: Chrome

Bott. #

5

PC PUMP TEST DATA: Tested By:

Type: Standard

32372

Elastomer Type: N080

Rotor Condition: New

Distributor:

6481

4 Diff. Press. (psi) 0

BMW Lloyd

6

7

8

Test Time Hyd. Press. Pump Eff. (%) (sec) (psi) 61 47 98.4

Torque (ft-lbs) 47.0

JJ

300

63

60

95.2

60.0

Rotor Major Diameter:

2.265

600

65

70

92.3

70.0

Rotor Minor Diameter:

1.715

900

66

80

90.9

80.0

2 Test Speed RPM: 150

1100

68

92

88.2

92.0

120

1400

72

105

83.3

105.0

3 Eff. (100 psi/stage): 70.6

1800

85

120

70.6

120.0

Maximum Pressure:

2400

2200

147

134

40.8

134.0

BMW VFD1

2600

Torque (100 psi/stage):

Test Bench:

Efficiency & Torque VS Differential Pressure

160

100 90

140

80

120

70

100

60 50

80

40

60

30

40

20 20

10

0

0 0

200

400

600

800

Pump Efficiency (%)

1000

1200

1500

Torque (ft-lbs)

Comments:

Weatherford PC Pump Inc. Registered to: BMW Pump Inc

Tuesday, May 27, 2003

11

Identification of the Most Common Stator and Rotor Failures Pump inspections performed by Weatherford pump shops provide the user with general pump conditions. The following provides information on identification, cause and possible solutions for each condition. For a more detailed pump analysis please contact your Weatherford technical support representative.

Stator Conditions: Condition - Worn Identification The efficiency of the stator has decreased. The interference fit has been reduced due to the general operation of the pump. Cause •High rpm. •Normal wear. •Incorrect interference fit. •Abrasive fluids. Possible Solution •Increase to a larger volume pump to lower rpm. •Ensure pump efficiency is matched for application. •Ensure correct elastomer.

Condition - Hardened (No photo) Identification The stator elastomer surface is harder than it was originally. Cause •H2S, heat and time. Possible Solution •Ensure correct elastomer is used for application. •Ensure pump efficiency is matched for application.

Condition - Grooved Identification Worm like holes or grooves in the elastomer in the opposite direction of fluid flow. Cause •Large particles of sand or other matter become lodged in the stator elastomer causing permanent rubber deformation. This produces a small orifice by which high pressure fluid passes, washing away the stator rubber. High GOR wells with low pump efficiency can also cause this type of failure. Possible Solution •Complete thorough wellbore cleanouts. •Use a customized tagbar that will limit inflow of large debris. •If pump efficiency is low make sure landing is correct.

12

®

Condition - Missing Rubber Identification The areas of missing rubber are typically hard, shiny and irregular in shape. Cause •Excessive pressure per stage. •Fatigue of the rubber due to cyclic stresses. •High production fluid temperature. Possible Solutions •Increase to a larger volume pump to lower pump rotational speed. •Ensure pump efficiency is matched for application. •Ensure pump has enough lift.

Condition - Swollen Identification Cross-section of elastomer is swollen resulting in an altered geometry from new. Swollen stators may exhibit poor volumetric efficiencies and high rod string torque. Cause •Exposure to fluids that are not compatible with the elastomer Possible Solutions •Check elastomer/fluid compatibility. •Review chemical treatment programs.

Normal

Condition - Burnt Out Identification Rubber surface will be hard, brittle and extensively cracked. Cause Excessive heat due to: •Poor inflow. •Plugged intake. Possible Solutions •Ensure sufficient fluid level. •Use slotted tagbar and insure wellbore is cleaned out. •Wellbore perforations are open.

Condition - Mechanical Influence Identification The rubber is torn or pitted. Cause •Production of large foreign particles. Possible Solutions •Complete thorough wellbore cleanouts. •Use a customized tagbar that will limit inflow of large debris. •Consider routine flush-by. •Use a PC pump with large cavities.

13

Swollen

Rotor Conditions: Condition - Base Metal Identification Extreme abrasive wear through the chrome plating and into the rotor base metal on the major diameter of the rotor. Cause •Producing highly abrasive fluids. •Incorrect landing procedure causing rotor/tubing contact. •Production of large foreign particles. •Excessively tight rotor/stator interference fit Possible Solutions •Insure proper landing procedures are followed. •Complete thorough wellbore cleanouts. •Use a customized tagbar that will limit inflow of large debris. •Ensure correct rotor/stator interference fit for the application.

Condition - Broken Identification The rotor is in two pieces. Cause •Rotor breaks are usually caused by excessive torque or cyclic fatigue stresses. Possible Solutions Fatigue breaks: •Ensure proper landing procedures are followed. •Avoid landing stator in severe doglegs. Torsional Breaks: •Utilize high torque shutdown devices.

Condition - Checked Identification Chrome has fine cracks on the surface. Cause Excessive heat due to: •Tight interference fit. •Poor inflow or restricted intake. •High operating temperatures. Possible Solutions •Complete thorough wellbore cleanouts. •Ensure correct elastomer is used for application. •Ensure sufficient fluid level. •Ensure pump efficiency is matched for application.

14

Torsional

Fatigue

Fracture surface is typically irregular with no distinctive pattern.

Fracture surface is typically flat with a half-moon shape pattern.

®

Condition - General Wear Identification The chrome surface is highly polished. Cause •Normal wear •High rpm. •Incorrect interference fit. •Abrasive fluids. Possible Solutions •Increase to a larger volume pump to lower rpm. •Ensure pump efficiency is matched for application. •Ensure correct elastomer.

Condition - Pitting Identification Small to large holes in the chrome surface that may or may not extend down into the base metal of the rotor. Pitting can be seen anywhere along or throughout the entire length of rotor in either the major or minor diameters. Cause •Corrosive elements such as H2S, CO2 within the wellbore fluid. Possible Solutions •Corrosion inhibitor.

Condition - Scored Identification Wear lines on the chrome surface usually found on the major diameter. Cause •Due to normal wear and abrasion. •Will be accelerated when pumping abrasive fluids or when rotating at high speeds. Possible Solutions •Increase to a larger volume pump to lower rpm. •Ensure pump efficiency is matched for application. •Ensure correct elastomer.

15

Downhole Accessories Below is a list of the main downhole accessories used to enhance and lengthen the life of progressing cavity pumping systems. Please contact your local Weatherford Artificial Lift representative for more information.

1 Corod ® Continuous Rod Continuous sucker rod is unique because unlike conventional sucker rod it requires couplings only at the top and bottom of the rod string. Advantages of Corod: • • • •

Reduces pin and coupling failures. Prolongs life of tubing especially on directional and horizontal wells. Lowers torque and power requirements. Reduces flow losses through the tubing.

2 Tubing Rotator The majority of tubing failures occur due to rod/tubing contact always at the same spot. A tubing rotator allows the operator to rotate the tubing to lengthen its life. The tubing rotator can be operated by: • • •

Manual. Hydraulic. Electric.

3 Torque Anchor or Tubing Anchors The natural action of a PC pump on the tubing string connection is counterclockwise; therefore causing the potential for the tubing to be backed off. By installing a torque anchor/tubing anchor the chance of backed off tubing is greatly reduced.

4 Open/Close Tagbar (OCT) The design of the OCT provides the producer with all of the benefits of a slotted and a non-slotted tagbar in one piece of equipment. Advantages of the OCT: • • • •

The ability to circulate the well through the tubing string. Reduce cost and shock loading associated with sand bailing. Allows for quick and easy location of pump intake. Easily adaptable to existing PC pumps.

5 Downhole Gas Separators Downhole gas separators are used to help separate the gas from the oil at the pump intake. By eliminating as much gas as possible from the intake, better pump efficiencies can be maintained therefore reducing pump rotational speeds & increasing pump run life.

6 Coated/Spin Thru Rod Couplers and Rod Centralizers If high rod/tubing contact loads occur, premature wear to these components may require specialized rod couplings and centralizers. Specialized equipment helps to reduce rod/tubing contact loads and therefore extend rod/tubing run life. High contact loads typically occur in horizontal or directionally drilled wells.

16

®

Suggested Makeup Torque for Tubing Recommended makeup torque is listed in the table below for common sizes, weights and grades of tubing. Note that PC pump stators should be treated as Grade J55. These values have been extracted from API Recommended Practice 5C1 “Recommended practice for Care and use of Casing and Tubing”. The torque values listed below represent the optimum makeup torque. The minimum and maximum torque are 75% and 125% of the optimum value, respectively. The joint life of tubing under repeated field makeup is inversely proportional to the makeup torque applied. Therefore, in wells where leak resistance is not a significant factor, minimum field makeup torque should be used to prolong joint life.

17

Rod Specifications Weatherford Rod Rod Grade Sucker Rod

MD56 D KD63 T66/XD S-67 S-87 S-88 EL Weight, lbs / ft -

Physical Properties

Maximum Recommended Torque

COROD

Tensile Strength 1000 PSI

Yield Strength 1000 PSI

13/16"

7/8"

1"*

1 1/8"

D Carbon Steel D Chrome Moly D Chrome Moly Alloy Weight, lbs / ft

115-140 115-140 115-140 140-150 120-140 125-140 140-155 N/A 115 Min 115 Min 140 Min -

85 Min 85 Min 85 Min 115 Min 110-125 115-130 130-145 N/A 85 Min 90 Min 110 Min -

500 1.76

675 735 700 800 780 815 920 *1000 2.22 640 640 900 2.04

1000 1100 1000 1200 1165 1220 1380 *1000 2.90 955 955 1300 2.67

1570 1500 1700 1660 1740 1965 2500 3.68 -

1 1/4" x 1" 1 1/4" x 1 1/8"

*1600

*2500

-

-

*Special High Torque Coupling and Makeup Procedures Required.

Norris Rod Rod Grade

Physical Properties

Sucker Rod

Tensile Strength 1000 PSI

Yield Strength 1000 PSI

7/8"

Maximum Recommended Torque 1"*

1 1/8"

1 1/4"**

1 1/2"

54 75 78 96 97 Weight, lbs / ft

115-140 120-140 120-140 135-150 140-150 -

90 Min 90 Min 90 Min 115 Min 115 Min -

675 750 735 800 800 2.22

1010 1110 1100 1200 1200 2.9

1590 1570 1700 1700 3.68

2100 2000 2500 4.17

3150 3750 6

* Available in 1" or 7/8" pin connections. ** Available in 1", 1 1/8" or 1 1/4" pin connections; The 1 1/4" rod is a non-API rod which is specifically designed for torsional applications. Note: The Maximum Recommended Torque rating will remain the same regardless of pin connection. All values are based on new rods, couplings and ideal operating conditions. It is recommended to use a larger diameter rod to increase the allowable torque, rather than the next higher grade. It is recommended to use a 0.8 safety factor to maximize rod fatigue life.

Norris Polished Rod Maximum Allowable Torque - ft-lbs. Rod Size

Piston (C1045), Norloy (8620) 431 SS, 4140 Alloy

1 1/4"

1,800

1 1/2"

2,800

Specifications are subject to change without prior notice

18

®

Tensile Stretch for 7/8" or 22.225mm Rod String Imperial 7

Pump Model

6

Rod Stretch (in per 1000 ft)

5

ASSUMPTIONS: (1) Rod loading is within elastic range. (2) No incremental axial loading due to rotor "digging" into stator.

●

25

◆

45

▲

60 60/80/110 Insert

✱

✱

x

✱

x 95/100 ✱

▲

125/140/200

x ✱ ✱

4

▲

x ▲

✱

x x ✱

3

x

▲

▲

▲

◆ ◆

x

▲

2

✱

◆

x

◆

▲ ✱

x ▲

1 ✱ x ▲ ◆ ●

0 0

500

◆ ●

1000

◆

●

◆

●

◆ ● ●

●

●

● ◆ ●

1500

2000

2500

3000

3500

4000

4500

5000

Net Lift (ft)

Metric 90

Pump Model

80 70 Rod Stretch (cm per 1000 m)


4 ◆ 7 ▲ 10 10/14/17 Insert x 15/16 ✱ 20/22/32 ●

60

✱

✱

x

✱

▲

x

✱

▲

x ▲

✱

50

x ▲ ✱

40

x

◆

▲ ◆

x

✱

30 ✱

▲

◆

x ▲

10

✱ x ▲ ◆ ●

0 0

◆ ●

500

●

◆ ◆

● ●

◆

▲ ✱

● ●

▲

x

20

◆ ◆

x

●

●

●

1000

1500 Net Lift (m)

19

2000

2500

Tensile Stretch for 1" or 25.4mm Rod String Imperial Pump Model

★

45 60

✸

60/80/110 Insert

✦

95/100 125/140/200

●

10

◆ ▲

8 x ✱

6

x x

x

175/195/350/400/520/750 265 500/1000 550 615 820 1010/1100 1150

x

▲ ◆ ✱

x

▲ ◆ ✱

▲ ✱ ●

●

-

-

x

-

-

-

-

-

-

▲ ✱ ● ✤ ✙ ✇

✤ ✦ ★ ✙ ✇

✤ ✦ ★ ✙ ✇

500

1000

1500

x

0

▲ ▲

4

0

▲

x

●

2

▲

x

✤ ✦ ★ ✸ ✙ ✇

2000

2500

▲ ◆ ✱

▲ ◆ ✱ ●

●

-

✤ ✦ ★ ✸ ✙ ✇

-

◆ ✱ ●

-

✤ ✦ ★ ✸ ✙

3000

✤ ✦ ★ ✸ ✙ ✇

3500

◆ ✱

◆ ✱

◆ ✱

● ●

●

-

-

-

-

12

x

-

✤

-


14

✙

-

16


25

-

18

✇

-

20

✤ ✤

✤ ✦ ★ ✸ ✙ ✇

4000

✦ ★ ✸ ✙ ✇

4500

✦ ★ ✸ ✙ ✇

5000

Net Lift (ft)

Metric Pump Model

✸

✤

200

●

150

◆ ▲

x

100

✱

x x

28/31/56/64/83/120 42 80/160 88 98

x ▲

x x x ▲ ◆ ✱

x

x

▲ ✱ ● ✤ ✙ ✇

-

0 0

-

✤ ✦ ★ ✙ ✇

500

-

✤ ✦ ★ ✙ ✇

▲ ◆ ✱ ●

-

-

-

●

-

▲ ◆ ✱ ●

-

50

▲ ◆ ✱ ●

-

x

▲ ▲

130 161/175 180

-

Rod Stretch (cm per 1000m)

✦

x

✤ ✦ ★ ✸ ✙ ✇

✤ ✦ ★ ✸ ✙ ✇

1000

▲ ◆ ✱ ●

-

▲ ◆ ✱ ●

-

✤ ✦ ★ ✸ ✙ ✇

◆ ✱ ●

-

✤ ✦ ★ ✸ ✙ ✇

2000 Net Lift (m)

20

● ●

✤

✤ ✦ ★ ✸ ✙ ✇

◆ ✱

◆ ✱

-

7 10 10/14/17 Insert 15/16 20/22/32

★

-

✙


-

4

-

250

✇

-

300

✦ ★ ✸ ✙ ✇

✤ ✦ ★ ✸ ✙ ✇

2500

®

Tensile Stretch for 1 1/4" or 31.75mm Rod String Imperial 14 ASSUMPTIONS: (1) Rod loading is within elastic range. (2) No incremental axial loading due to rotor "digging" into stator.

265

● ◆

500/1000 550

▲

615

x x x

820 x 1010/1100 ✱ 1150

8

x x

▲

x

▲

x ▲

▲ ◆ ✱ ●

x

2

▲ ✱ ●

-

-

500

1000

1500

-

2500

3000

-

-

-

-

-

-

▲ ✱ ●

-

●

-

-

-

x

▲ ◆ ✱ ●

●

●

● ●

-

x

◆ ✱ ●

◆ ✱

◆ ✱

◆ ✱

-

4

▲ ◆ ✱

▲ ◆ ✱

-

6

-


10

175/195/350/400/520/750

-

-

12

-

-

Pump Model

0 0

2000

3500

4000

4500

5000

Net Lift (ft)

Metric Pump Model

-

28/31/56/64/83/120 42 ● 80/160 ◆ 88 ▲ 98 130 x 161/175 ✱ 180

160

-

140 120 100

x x x

x ▲

x ▲

▲

x ▲ ✱ ●

-

▲ ◆ ✱ ●

-

-

▲ ◆ ✱ ●

-

-

-

-

-

-

-

20

▲ ◆ ✱ ●

●

-

-

x

●

-

40

▲ ◆ ✱ ●

-

x

▲ ◆ ✱ ●

●

●

-

60

◆ ✱

◆ ✱

-

x

◆ ✱

-

▲

x

-

80

◆ ✱

-

Rod Stretch (cm per 1000 m)


-

180

0 0

500

1000

1500 Net Lift (m)

21

2000

2500

Tensile Stretch for 1 1/2" or 38.1mm Rod String Imperial 9 ASSUMPTIONS: (1) Rod loading is within elastic range. (2) No incremental axial loading due to rotor "digging" into stator.

Pump Model

-

8

6

265

● ◆ ◆

500/1000 550

▲

615

x

820 x 1010/1100 ✱ 1150

5

x x

x x ▲

x ▲

▲ ▲ ◆ ✱ ●

x

2 1

▲ ✱ ●

-

-

-

-

-

x

▲ ◆ ✱ ●

500

1000

1500

-

-

2500

3000

-

●

-

●

-

-

-

-

▲ ✱ ●

●

◆ ✱ ●

● ●

-

x

◆ ✱

◆ ✱

◆ ✱

-

3

◆ ✱

-

▲ ▲

-

x

◆ ✱

-

4

-


7

175/195/350/400/520/750

-

0 0

2000

3500

4000

4500

5000

Net Lift (ft)

Metric 120

-

Pump Model

-

100

●

▲

80

28/31/56/64/83/120 42 80/160 88 98 130

x x x

x 161/175 ✱

x

180

▲

x ▲ ▲ ▲

-

▲ ◆ ✱ ●

-

-

-

-

-

-

-

-

-

-

x ▲ ✱ ●

▲ ◆ ✱ ●

-

-

20

▲ ◆ ✱ ●

●

●

-

x

▲ ◆ ✱ ●

-

x

▲ ◆ ✱ ●

●

●

-

40

◆ ✱

◆ ✱

-

x

◆ ✱

-

x

◆ ✱

-

60

-

Rod Stretch (cm per 1000 m)

◆


0 0

500

1000

1500 Net Lift (m)

22

2000

2500

®

Tubing Fill Times

150

Low Fluid Rate

120

90

60

30

0 0/0

5/31

10/63 15/94 Fluid Rate (m3/D)/(BBLS/D)

40

20/126

25/157

High Fluid Rate

30

20

10

0 0/0

100/629

23

200/1258 300/1887 Fluid Rate (m3/D)/(BBLS/D)

400/2516

500/3145

Useful Formulas • Electrical Output HP

=

RPM x Torque (Ft - lbs) 5252

• Electrical Output Hp

=

Amps x Volts x Motor Eff. x Motor P.F. x 1.73 746

• Hydraulic Torque (Ft - lbs)

=

System Press. (psi) x Hyd. Motor Displ. (in3) x Sheave Ratio 2 x 3.1416 x 12 in/ft

• Hydraulic Horse Power

=

System Press. (psi) x Hyd. Pump Displ. (in3) x Hyd. Pump rpm 395,934

• Specific Gravity

=

141.5 API + 131.5

• Fresh Water Gradient

= =

.433 psi / foot 9.8 Kpa / meter

• Head Pressure (Kpa)

=

Fluid Density (kg/m3) x depth (meters) x .00981

Conversions LENGTH

feet x 0.3048 = meters (m) meters x 3.281 = feet (ft)

TEMPERATURE °F = (°C x 9 / 5) + 32 °C = (°F - 32) x 5 / 9

AREA

sq. feet x 0.0929 = meter2 (m2) sq. meters x 10.764 = feet2 (ft2)

PRESSURE

psi x 6.895 = kPa kPa x 0.145 = psi

VOLUME

cu. feet x 0.02832 = meter3 (m3) meter3 x 35.31 = cu.feet (ft3)

FLOWRATE

MASS

pounds (lbs) x 0.4536 = kilograms (kg) kg x 2.205 = pounds (lb)

usgpm x 34.3 = Bpd usgpm x 5.451 = m3/d Bbls x 0.159 = m3 m3 x 6.29 = Bbls 1 Bbl = 42 US gal = 35 imp. gal

FORCE

pound force x 0.445 = decaNewtons (daN) daN x 2.25 = pound force (lb. f)

24

Oil Density (kg/m3) 780 800 820 840 860 880 900 920 940 960 965 970 975 980 985 990 995 1000 1020 1040

Specific Gravity 0.780 0.800 0.820 0.841 0.861 0.881 0.901 0.921 0.941 0.961 0.966 0.971 0.976 0.981 0.986 0.991 0.996 1.001 1.021 1.041

API 49.8 45.3 41.0 36.9 32.9 29.2 25.6 22.2 18.9 15.8 15.0 14.3 13.5 12.8 12.1 11.3 10.6 9.9 7.1 4.5

®

PC Pump Division of Weatherford Canada Partnership Warranty This shall be the only warranty given by PC Pump Division of Weatherford Canada Partnership ("Partnership"), and no other warranty by Partnership, Express or Implied, shall be applicable, including any implied warrant of merchantability or any implied warranty of fitness for a particular purpose. Subject to the limitations and conditions herein, Partnership warrants its products (with the exception of rotating stuffing boxes) to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of installation or eighteen (18) months from the date of shipment, whichever occurs first. Partnership warrants rotating stuffing boxes to be free from defects in workmanship and material under normal use and service for a period of three (3) months from the date of installation or nine (9) months from the date of shipment, whichever occurs first. Partnership's obligations under this warranty shall be limited to repairing, replacing or issuing credit for, at Partnership's option, any product or parts it finds to be defective in material or workmanship. Partnership must be given a reasonable opportunity to investigate. Shipping and handling in connection with this warranty will be at customer's expense. Products sold by Partnership, but manufactured by another company, will carry only the warranty of the manufacturer, and the customer will rely solely on that warranty. Services provided by Partnership are warranted for a period of ninety (90) days from the date the services are rendered. The liability of Partnership for any loss or damage resulting to the customer or user or any third party from any defect in any product or service will not, in any case, exceed the selling price that Partnership received from the customer for the product or service. The above shall be the customer's exclusive remedy with respect to products or services. In no event will Partnership be liable for incidental, consequential, special, indirect or other damages of any nature. This warranty will not apply and will be void if the product fails as a result of downhole corrosion; non-compatibility of produced fluid with the stator and/or rotor; general wear and abrasion; incorrect installation, removal, use or maintenance; operation outside of the manufacturer's recommended guidelines; alteration; accident; abuse or negligence. Hydraulic wellhead drives, hydraulic power transmission units or rotating stuffing boxes sold individually for use with equipment not manufactured by Partnership will not be covered under this warranty. Partnership does not warrant that any of the products sold by it, if used or sold in combination with other equipment or used in the practice of methods or processes, will not, by virtue of such combination or use, infringe patents of other, and Partnership shall not be liable for any patent infringement arising from, or by reason of, any such use or sale. Furthermore, Partnership shall not be liable for any patent infringement arising from, or by reason of, any use or sale of any materials, equipment or products not of Partnership's manufacture or for the use or sale of any materials, equipment or products, or other goods specially made, in whole or in part, to the customer's design specifications.

25


Manufacturing Facility Weatherford Artificial Lift Systems Canada PC Pump Products & Services 4604 - 62nd Avenue Lloydminster, Alberta T9V 2G2 Canada 780/875-0103 Telephone 780/875-0963 Fax

Canada Weatherford Artificial Lift Systems Canada PC Pump Products & Services 2801 - 84th Avenue Edmonton, Alberta T6P 1K1 Canada 780/417-4800 Telephone 780/464-5198 Fax

Worldwide Customer Service Weatherford Artificial Lift Systems Inc. 515 Post Oak Blvd. Houston, Texas 77027 United States 713/693-4800 Telephone 713/693-4323 Fax [email protected]

®

www.weatherford.com

Weatherford products and services are subject to Weatherford's standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford. © Copyright 2001 Weatherford • All rights reserved • • 0703/1000 • Printed in Canada

®

Weatherford Progressing Cavity Pumps

Specifications and Capacities Version 1.5

Progressing Cavity Pump Concept There are two basic components that make up the downhole PC Pump - single helical alloy-steel rotor connected to a rod string and a double helical elastomer-lined stator attached to the tubing string. Using the latest manufacturing technology, rotors are kept to tight tolerances and treated with a chemical and abrasion-resistant coating, typically hard chrome. Stators are comprised of a steel tube with an elastomer molded inside to provide the internal geometry. Each combination of rotor/stator is matched to downhole conditions to provide highly efficient operation and optimum production enhancement.

4E, E = Eccentricity

PR, Rotor Pitch Length

As the rotor turns eccentrically in the stator, a series of sealed cavities forms and progresses from the suction to the discharge end of the pump. The result is a non-pulsating positive displacement flow with a discharge rate proportional to the rotational speed of the rotor and the differential pressure across the pump. Theoretical Pump Capacity for a conventional Single Lobe geometry PC Pump = 4EDR • 2PR • RPM

DR, Rotor Diameter

Advantages

Glossary

• Low Capital Investment

HN

High Nitrile elastomer

O.D.

Outside Diameter

Rotor Drift

Largest diameter found on the rotor

• Low Surface Profile for Visual and Height Sensitive Areas

Rotor Orbit

Largest diameter created by the rotor while oscillating in operation.

• Simple Installation

S

Sectional pump, two piece stator & rotor

SH

Slim Hole stator outside diameter

SHS

Slim Hole outside diameter sectional pump

Tagbar Distance

Distance from bottom of stator rubber to top of tagbar pin

U

Uniform Thickness Stator

1:2 Geometry

Ratio of lobes on rotor to lobes on stater

• High System Efficiency

• Pumps Oils and Waters with Solids • No Internal Valves to Clog or Gas Lock • Low Power Consumption • Portable, Lightweight Surface Equipment • Minimal Maintenance Costs

XL, 2XL, 3XL, etc. Extended length added to standard rotor

1

ROTOR & STATOR ALPHA NUMERIC IDENTIFICATION SYSTEM 1. The stator and rotor have been flow and pressure tested together and are a matched set. The rotor serial number is stamped on the pin end of the rotor and must correspond to the last set of numbers stamped on the top of the stator. 2. The serial number of the pump is always stamped on the top of the stator (the tagbar is on the bottom). Within this serial number there are alphabetical identifiers that distinguish the unique characteristics and/or make-up of each pump. Refer to the chart below. 3. Pumps are tested to ensure the customer receives a pump of proper efficiency for the application. Pump test reports will supply useful information, such as pump efficiency and torque required to turn the pump. Follow-up testing on used pumps can help determine whether or not they can be reused.

EXAMPLES Nomenclature Nomenclature

Description

10 - 1200 - K1234 - U9876 - XL - U

BMW Stator, Uniform Rotor, Buna Elastomer, Standard Speed, XL Rotor Length, Uniform Operating Style

10 - 1200 - 1234 - P9876 - HN - HS - XXXL

BMW Stator, Paddle Rotor, High Nitrile Elastomer, High Speed, XXXL Rotor Length, Standard Operating Style

15 - 1400 - E1234 - H9876 - XL

Weatherford Stator, Hollow Rotor, Buna Elastomer, Standard Speed, XL Rotor Length, Standard Operating Style

15 - 1400 - 1234 - 9876 - XL - Y

BMW Stator, Standard Rotor, Buna Elastomer, Standard Speed, XL Rotor Length, Insert Operating Style

70

1000

K

Net Lift (Metric-meters) (Imperial-feet)

1234

U

9876

HN

HS

XL Rotor Length (length added to standard rotor)

Stator Serial Number Test Speed Stator Brand Identifier

Displacement (m3/d/100rpm) (bbl/d/100rpm)

U

Rotor Type Identifier

Operating Style

"Blank" - Standard Speed HS - High Speed Rotor Serial Number

K - BMW "Blank" - BMW E - Weatherford Edmonton G - Griffin B - Weatherford Brazil R - R&M N - Netszch

Stator Elastomer

"Blank" - Standard U - Uniform P - Paddle H - Hollow AY - Arrowhead Insert

2

"Blank" - Standard Buna HN - High Nitrile SFT - Buna Soft

"Blank" - Standard (+0") XL (+8") XXL (+16") "Blank" - Standard LH - Left hand Rotation SH - Slim Hole U - Uniform ML - Multilobe Y - Insert AY - Arrowhead Insert Top - Sectional Bottom - Sectional ST - Surface Transfer HW - Heavy Wall

BMW™ PC Pump Specifications - Imperial Units Pump PC Pump Series Metric 4-600 4-900 4-1200 4-1600 4-1800 7-600 7-1000 7-1400 7-1600 7-2000 *10-600 10-900 10-1200 10-1600 10-1800 *15-1400 15-1800 15-2000 16-200 16-600 16-900 16-1200 16-1600 16-1800 * 28-600 28-900 28-1200 28-1600 28-1800 42-600 42-900 42-1400 42-1600 42-1800 56-200 56-500 56-800 56-1000 56-1200 56-1500 56-1800 56-1800S

Imperial 25-2100 25-3100 25-4100 25-5200 25-6000 45-2100 45-3200 45-4600 45-5200 45-6500 60-2100 60-3100 60-4100 60-5200 60-6000 95-4600 95-6000 95-6500 100-700 100-2100 100-3100 100-4100 100-5200 100-6000 175-2100 175-3100 175-4100 175-5200 175-6000 265-2100 265-3100 265-4600 265-5200 265-6000 350-700 350-1600 350-2800 350-3200 350-4100 350-5100 350-6000 350-6000S

Stator

Displacement bbl/day/100 rpm 25

45

60

95

100

175

265

350

Lift Capacities psi 900 1350 1800 2250 2600 900 1400 2000 2250 2800 900 1350 1800 2250 2600 2000 2600 2800 300 900 1350 1800 2250 2600 900 1350 1800 2250 2600 900 1350 2000 2250 2600 300 700 1100 1400 1800 2200 2600 2600

Top Connection (in)

ft 2100 2 3/8" EUE Box 3100 4100 5200 6000 2100 2 7/8" EUE Box 3200 4600 5200 6500 2100 2 7/8" EUE Box 3100 4100 5200 6000 4600 2 7/8" EUE Box 6000 6500 700 2 7/8" EUE Box 2100 3100 4100 5200 6000 2100 3 1/2" EUE Box 3100 4100 5200 6000 2100 4ft x 3 1/2" EUE Box Weld Ext. 3100 4600 5200 6000 700 3 1/2" EUE Box 1600 2800 3200 4100 5100 6000 6000

*10 (60), 15 (95) & 28 (175) Series geometry available in left hand. - Dimensions identical

3

Length (in) 54 88 100 128 146 77 111 146 180 215 75 118 141 171 194 176 229 242 42 92 138 176 230 248 93 139 177 231 249 179 233 301 335 369 62 147 224 272 344 427 510 496

Rotor Max Tagbar Weight O.D. Distance (lbs) (in) (in)

Top Connection (in)

Length (in)

Drift Dia. (in)

Weight (lbs)

2.953

3/4" API Pin

57 91 103 131 149 80 114 149 183 218 76 120 143 173 196 178 231 243 44 94 140 178 232 250 95 141 179 233 251 120 174 242 276 310 64 149 226 274 346 429 512 523

1.440

17 27 30 39 44 28 40 53 65 77 45 71 84 102 115 87 113 119 23 49 73 92 120 130 63 93 118 154 166 72 105 146 167 187 42 98 149 181 228 283 338 345

14.7 14.7 14.7 14.7 14.7 3.500 14.6 14.6 14.6 14.6 14.6 3.543 14.6 14.6 14.6 14.6 14.6 3.543 14.6 14.6 14.6 3.543 14.6 14.6 14.6 14.6 14.6 14.6 4.130 14.7 14.7 14.7 14.7 14.7 4.331 14.5 14.5 14.5 14.5 14.5 4.130 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7

42 70 80 103 118 60 87 116 143 171 77 123 147 179 204 185 241 255 42 95 144 185 242 261 109 164 210 275 297 250 332 434 486 537 71 174 267 325 412 512 612 594

7/8" API Pin

7/8" API Pin

7/8" API Pin

7/8" API Box 7/8" API Pin

1" API Pin

1" API Pin

7/8" API Box 1" API Pin

1.620

1.925

1.915

1.925

2.270

2.360

2.270

BMW™ PC Pump Specifications - Imperial Units Pump PC Pump Series Metric 64-600 64-900 64-1200 64-1400 64-1500S 64-1800S 83-200 83-400 83-600 83-800 83-1050 83-1200 83-1600S 88-900 88-1350 95-250 95-500 95-750 95-1000 95-1200 95-1500 120-200 120-600 120-775 120-900 120-900S 120-1075S 120-1200S 180-350 180-500 180-700 180-1050

Imperial 400-2100 400-3100 400-4100 400-4600 400-5100S 400-6000S 520-700 520-1400 520-2100 520-2800 520-3500 520-4100 520-5200S 550-3100 550-4400 600-850 600-1600 600-2500 600-3200 600-4100 600-5100 750-700 750-2100 750-2750 750-3100 750-3100S 750-3550S 750-4100S 1150-1150 1150-1600 1150-2300 1150-3500

Stator Displacement bbl/day/100 rpm 400

520

550 600

750

1150

Lift Capacities psi 900 1350 1800 2000 2200 2600 300 600 900 1100 1500 1800 2250 1350 1900 350 700 1050 1400 1800 2200 300 900 1100 1350 1350 1600 1800 500 700 1000 1500

Top Connection (in)

ft 2100 3 1/2" EUE Box 3100 4100 4600 5100 6000 700 3 1/2" EUE Box 1400 2100 2800 3500 4100 5200 3100 4ft x 3 1/2" EUE Box Weld Ext. 4400 850 4ft x 3 1/2" EUE Box Weld Ext. 1600 2500 3200 4100 5100 700 3 1/2" EUE Box 2100 2750 3100 3100 3550 4100 1150 4ft x 3 1/2" EUE Box Weld Ext. 1600 2300 3500

Rotor

Length (in) 241 349 447 519 590 698 93 177 249 345 417 513 690 303 407 157 246 334 423 511 600 141 377 465 561 570 658 754 271 357 456 641

Max Tagbar Weight O.D. Distance (lbs) (in) (in) 4.130

4.130

5.000 4.250

4.130

5.000

14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.7 14.7 14.7 14.7 14.7 14.7 14.7 14.5 14.5 14.5 14.5

289 420 539 626 710 841 109 210 297 413 500 616 828 518 708 188 305 421 538 655 772 168 457 565 682 691 799 916 460 616 796 1133

Top Connection (in)

Length (in)

Drift Dia. (in)

Weight (lbs)

1" API Pin

243 351 449 521 617 725 95 179 251 347 419 515 717 231 331 98 187 275 364 452 541 143 379 467 563 597 685 781 195 281 380 565

2.235

154 222 284 330 391 459 63 118 166 229 277 340 473 188 269 48 92 135 179 222 266 80 212 262 316 335 384 438 171 246 332 494


1" API Pin 1" API Pin


1" API Pin

Standard Pump Configuration STATOR LENGTH STATOR BOTTOM CONNECTION

TAGBAR DISTANCE

STATOR TOP CONNECTION

STATOR O.D. ROTOR LENGTH CONTOUR LENGTH

ROTOR DRIFT

4

ROTOR CONNECTION

2.270

2.810 2,239

2.185

2.805

BMW™ PC Pump Specifications - Metric Units Pump PC Pump Series Metric 4-600 4-900 4-1200 4-1600 4-1800 7-600 7-1000 7-1400 7-1600 7-2000 10-600 10-900 10-1200 10-1600 10-1800 15-1400 15-1800 15-2000 16-200 16-600 16-900 16-1200 16-1600 16-1800 28-600 28-900 28-1200 28-1600 28-1800 42-600 42-900 42-1400 42-1600 42-1800 56-200 56-500 56-800 56-1000 56-1200 56-1500 56-1800 56-1800 S

Imperial 25-2100 25-3100 25-4100 25-5200 25-6000 45-2100 45-3200 45-4600 45-5200 45-6500 60-2100 60-3100 60-4100 60-5200 60-6000 95-4600 95-6000 95-6500 100-700 100-2100 100-3100 100-4100 100-5200 100-6000 175-2100 175-3100 175-4100 175-5200 175-6000 265-2100 265-3100 265-4600 265-5200 265-6000 350-700 350-1600 350-2800 350-3200 350-4100 350-5100 350-6000 350-6000 S

Stator

Displacement m3/day/100 rpm 4

7

10

15

16

28

42

56

Lift Capacities kPa 6207 9656 12415 15518 17932 6207 9656 13794 15518 19312 6207 9311 12415 15518 17932 13794 17932 19312 2069 6207 9311 12415 15518 17932 6207 9311 12415 15518 17932 6207 9311 13794 15518 17932 2069 4828 7587 9656 12415 15173 17932 17932

m 600 900 1200 1600 1800 600 1000 1400 1600 2000 600 900 1200 1600 1800 1400 1800 2000 200 600 900 1200 1600 1800 600 900 1200 1600 1800 600 900 1400 1600 1800 200 500 800 1000 1200 1500 1800 1800

Rotor

Top Connection (mm)

Length (m)

60.3mm EUE Box

1.37 75.0 2.24 2.54 3.25 3.71 1.96 88.9 2.82 3.71 4.57 5.46 1.91 90.0 3.00 3.58 4.34 4.93 4.47 90.0 5.82 6.15 1.07 90.0 2.34 3.51 4.47 5.84 6.30 2.36 104.9 3.53 4.50 5.87 6.33 4.55 110.0 5.92 7.65 8.51 9.37 1.58 104.9 3.73 5.69 6.91 8.74 10.85 12.95 12.60

73.0mm EUE Box

73.0mm EUE Box

73.0mm EUE Box

73.0mm EUE Box

88.9mm EUE Box

1219mm x 88.9mm EUE Box Weld Ext.

88.9mm EUE Box

*10 (60), 15 (95) & 28 (175) Series geometry available in left hand. - Dimensions identical

5

Max Tagbar Weight O.D. Distance (kgs) (mm) (mm) 373 373 373 373 373 371 371 371 371 371 371 371 371 371 371 371 371 371 371 371 371 371 371 371 373 373 373 373 373 368 368 368 368 368 373 373 373 373 373 373 373 373

19 32 36 47 53 27 40 52 65 78 35 56 67 81 92 84 109 116 19 43 65 84 110 118 49 75 95 125 135 114 151 197 220 244 32 79 121 147 187 232 278 269

Top Connection (mm)

Length (m)

Drift Dia. (mm)

Weight (kgs)

1.45 2.31 2.62 3.33 3.79 22.2mm API Pin 2.03 2.90 3.79 4.65 5.54 22.2mm API Pin 1.93 3.05 3.63 4.39 4.98 22.2mm API Pin 4.52 5.87 6.17 22.2mm API Box 1.12 22.2mm API Pin 2.39 3.56 4.52 5.89 6.35 25.4mm API Pin 2.41 3.58 4.55 5.92 6.38 25.4mm API Pin 3.05 4.42 6.15 7.01 7.87 22.2mm API Box 1.63 25.4mm API Pin 3.78 5.74 6.96 8.79 10.90 13.01 13.28

36.58

8 12 14 18 20 13 18 24 29 35 20 32 38 46 52 40 51 54 10 22 33 42 55 59 28 42 54 70 75 33 48 66 76 85 19 45 68 82 104 128 153 157

19.1mm API Pin

41.15

48.90

48.64

48.90

57.66

59.94

57.66

BMW™ PC Pump Specifications - Metric Units Pump PC Pump Series Metric 64-600 64-900 64-1200 64-1400 64-1500 S 64-1800 S 83-200 83-400 83-600 83-800 83-1050 83-1200 83-1600 S 88-900 88-1350 95-250 95-500 95-750 95-1000 95-1200 95-1500 120-200 120-600 120-775 120-900 120-900 S 120-1075 S 120-1200 S 180-350 180-500 180-700 180-1050

Imperial 400-2100 400-3100 400-4100 400-4600 400-5100 S 400-6000 S 520-700 520-1400 520-2100 520-2800 520-3500 520-4100 520-5200 S 550-3100 550-4400 600-850 600-1600 600-2500 600-3200 600-4100 600-5100 750-700 750-2100 750-2750 750-3100 750-3100 S 750-3550 S 750-4100 S 1150-1150 1150-1600 1150-2300 1150-3500

Stator


83

88 95

120

180

Lift Capacities kPa 6207 9311 12415 13794 15173 17932 2069 4138 6207 7587 10346 12415 15518 9311 13104 2412 4828 7241 9659 12415 15171 2069 6207 7587 9311 9311 11035 12415 3449 4828 6897 10346

m 600 900 1200 1400 1500 1800 200 400 600 800 1050 1200 1600 900 1350 250 500 750 1000 1200 1500 200 600 775 900 900 1075 1200 350 500 700 1050

Top Connection (mm)

88.9mm EUE Box

Length (m)

6.12 8.87 11.35 13.18 14.99 17.73 88.9mm EUE Box 2.36 4.50 6.33 8.76 10.59 13.03 17.53 1219mm x 88.9mm EUE Box Weld Ext. 7.70 10.34 1219mm x 88.9mm EUE Box Weld Ext. 3.99 6.25 8.48 10.74 12.98 15.24 88.9mm EUE Box 3.58 9.58 11.81 14.25 14.48 16.71 19.15 1219mm x 88.9mm EUE Box Weld Ext. 6.88 9.07 11.58 16.28

Rotor Max Tagbar Weight O.D. Distance (kgs) (mm) (mm) 104.9

104.9

127.0 108.0

104.9

127.0

373 373 373 373 373 373 373 373 373 373 373 373 373 368 368 368 368 368 368 368 368 373 373 373 373 373 373 373 368 368 368 368

131 190 244 284 322 382 49 95 135 187 227 279 375 235 321 85 138 191 244 297 350 76 207 256 309 313 362 415 208 279 361 514

Top Connection (mm)

Length (m)

Drift Dia. (mm)

Weight (kgs)

25.4mm API Pin

6.17 8.92 11.41 13.23 15.67 18.42 2.41 4.55 6.38 8.81 10.64 13.08 18.21 5.87 8.41 2.49 4.75 6.99 9.25 11.48 13.74 3.63 9.63 11.86 14.30 15.16 17.40 19.84 4.95 7.14 9.65 14.35

56.77

70 101 129 150 177 208 28 54 75 104 125 154 215 85 122 22 42 61 81 101 121 36 96 119 143 152 174 199 77 111 151 224

22.2mm API Box 25.4mm API Pin

25.4mm API Pin 25.4mm API Pin

22.2mm API Box 25.4mm API Pin

25.4mm API Pin


TAGBAR DISTANCE



ROTOR DRIFT

6

ROTOR CONNECTION

57.66

71.37 56.87

55.50

71.25

BMW™ Slimhole PC Pump Specifications - Imperial Units Pump PC Pump Series

Displacement bbl/day/100 rpm

Metric Imperial *28-600 SH 175-2100 SH 175 28-900 SH 175-3100 SH 28-1200 SH 175-4100 SH 28-1600 SH 175-5200 SH 28-1800 SH 175-6000 SH 42-600 SH 265-2100 SH 265 42-900 SH 265-3100 SH 42-1400 SH 265-4600 SH 42-1500 SH 265-5200 SH 42-1600 SH 265-6000 SH 56-800 SH 350-2800 SH 350 56-1000 SH 350-3200 SH 56-1200 SH 350-4100 SH 56-1500 SH 350-5100 SH 56-1800 SHS 350-6000 SHS 64-600 SH 400-2100 SH 400 64-900 SH 400-3100 SH 64-1200 SH 400-4100 SH 64-1500 SHS 400-5100 SHS 64-1800 SHS 400-6000 SHS 83-600 SH 520-2100 SH 520 83-800 SH 520-2800 SH 83-1050 SH 520-3500 SH 83-1200 SH 520-4100 SH 83-1600 SHS 520-5200 SHS 120-600 SH 750-2100 SH 750 120-775 SH 750-2750 SH 120-900 SH 750-3100 SH 120-900 SHS 750-3100 SHS 120-1075 SHS 750-3550 SHS 120-1200 SHS 750-4100 SHS *28 (175) Series geometry available left hand.

Stator Lift Capacities psi 900 1350 1800 2250 2600 900 1350 2000 2250 2600 1100 1400 1800 2200 2600 900 1350 1800 2200 2600 900 1100 1500 1800 2250 900 1100 1350 1350 1600 1800

ft 2100 3100 4100 5200 6000 2100 3100 4600 5200 6000 2800 3200 4100 5100 6000 2100 3100 4100 5100 6000 2100 2800 3500 4100 5200 2100 2750 3100 3100 3550 4100

Top Connection (in)

Length (in)

4ft x 2 7/8" EUE Box Weld Ext.

170 216 254 308 325 188 242 310 344 378 300 349 421 503 649 317 426 524 743 851 236 422 494 590 843 454 542 637 723 811 907

3 1/2" EUE Box Weld Ext.





Rotor Max Tagbar Weight O.D. Distance (lbs) (in) (in) 3.800

4.180

3.800

3.800

3.800

3.800

14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.7 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5

147 191 228 281 297 208 274 358 399 399 273 320 390 470 595 291 397 492 689 795 228 391 461 554 783 427 514 608 675 762 856

Top Connection (in)

Length (in)

Drift Dia. (in)

Weight (lbs)

1" API Pin

95 141 179 233 251 120 174 242 276 310 226 274 346 429 523 243 351 449 617 725 251 347 419 515 717 379 467 563 597 685 781

2.270

63 93 118 154 166 72 105 146 167 187 149 181 228 283 345 154 222 284 391 459 166 229 277 340 473 212 262 316 335 384 438

1" API Pin

1" API Pin

1" API Pin

1" API Pin

1" API Pin

2.360

2.270

2.235

2.270

2.185

Slimhole Pump Configuration STATOR LENGTH STATOR BOTTOM CONNECTION

TAGBAR DISTANCE



ROTOR DRIFT

∅

ROTOR CONNECTION

7

BMW ™ Slimhole PC Pump Specifications - Metric Units Pump PC Pump Series

Displacement m3/day/100 rpm

Metric Imperial *28-600 SH 175-2100 SH 28 28-900 SH 175-3100 SH 28-1200 SH 175-4100 SH 28-1600 SH 175-5200 SH 28-1800 SH 175-6000 SH 42-600 SH 265-2100 SH 42 42-900 SH 265-3100 SH 42-1400 SH 265-4600 SH 42-1600 SH 265-5200 SH 42-1800 SH 265-6000 SH 56-800 SH 350-2800 SH 56 56-1000 SH 350-3200 SH 56-1200 SH 350-4100 SH 56-1500 SH 350-5100 SH 56-1800 SHS 350-6000 SHS 64-600 SH 400-2100 SH 64 64-900 SH 400-3100 SH 64-1200 SH 400-4100 SH 64-1500 SHS 400-5100 SHS 64-1800 SHS 400-6000 SHS 83-600 SH 520-2100 SH 83 83-800 SH 520-2800 SH 83-1050 SH 520-3500 SH 83-1200 SH 520-4100 SH 83-1600 SHS 520-5200 SHS 120-600 SH 750-2100 SH 120 120-775 SH 750-2750 SH 120-900 SH 750-3100 SH 120-900 SHS 750-3100 SHS 120-1075 SHS 750-3550 SHS 120-1200 SHS 750-4100 SHS *28 (175) Series geometry available left hand.

Stator Lift Capacities k Pa 6207 9311 12415 15518 17932 6207 9311 13794 15518 17932 7587 9656 12415 15173 17932 6207 9311 12415 15173 17932 6207 7587 10346 12415 15518 6207 7587 9311 9311 11035 12415

m 600 900 1200 1600 1800 600 900 1400 1600 1800 800 1000 1200 1500 1800 600 900 1200 1500 1800 600 800 1050 1200 1600 600 775 900 900 1075 1200

Rotor

Top Connection (mm)

Length (m)

Max Tagbar Weight O.D. Distance (kgs) (mm) (mm)


4.32 5.49 6.45 7.82 8.26 4.78 6.15 7.87 8.74 9.60 7.62 8.87 10.69 12.78 16.49 8.05 10.82 13.31 18.87 21.62 5.99 10.72 12.55 14.99 21.41 11.53 13.77 16.18 18.36 20.60 23.04

96.5






106.2

96.5

96.5

96.5

96.5

368 368 368 368 368 368 368 368 368 368 368 368 368 368 368 373 368 368 368 368 368 368 368 368 368 368 368 368 368 368 368

67 87 104 127 135 94 124 162 181 181 124 145 177 213 270 132 180 223 313 360 103 177 209 251 255 194 233 276 306 345 388

Top Connection (mm)

Length (m)

Drift Dia. (mm)

Weight (kgs)

25.4mm API Pin

2.41 3.58 4.55 5.92 6.38 3.05 4.42 6.15 7.01 7.87 5.74 6.96 8.79 10.90 13.28 6.17 8.92 11.41 15.67 18.42 6.38 8.81 10.64 13.08 18.21 9.63 11.86 14.30 15.16 17.40 19.84

57.66

28 42 54 70 75 33 48 66 76 85 68 82 104 128 157 70 101 129 177 208 75 104 125 154 215 96 119 143 152 174 199

25.4mm API Pin

25.4mm API Pin

25.4mm API Pin

25.4mm API Pin

25.4mm API Pin

59.94

57.66

56.77

57.66

55.50

Sectional Pump Configuration STATOR LENGTH* STATOR O.D.

STATOR BOTTOM CONNECTION


PUP JOINT

TAGBAR DISTANCE

ROTOR LENGTH PONY ROD

LENGTH* - STATOR AND ROTOR LENGTH DO NOT INCLUDE PUP JOINT OR PONY ROD

8

ROTOR DRIFT

ROTOR CONNECTION

BMW™ Uniform Thickness PC Pump Specifications - Imperial Units Pump PC Pump Series Metric 10-1200 U 10-2400 U 15-1400 U 15-2800 U 50-500 U 50-1000 U 50-1500 U 70-500 U 70-1000 U 70-1500 U 105-400 U 105-800 U 105-1200 U 140-400 U 140-800 U 140-1200 U

Stator

Displacement bbl/day/100 rpm

Imperial 60-4100 U 60-8000 U 95-4600 U 95-9200 U 310-1600 U 310-3200 U 310-5100 U 440-1600 U 440-3200 U 440-5100 U 660-1400 U 660-2800 U 660-4100 U 880-1400 U 880-2800 U 880-4100 U

60 95 310

440

660

880

Lift Capacities psi 1800 3400 2000 4000 700 1400 2200 700 1400 2200 600 1100 1800 600 1100 1800

ft 4100 8000 4600 9200 1600 3200 5100 1600 3200 5100 1400 2800 4100 1400 2800 4100

Top Connection (in)

Length (in)

2 7/8" EUE Box

76 148 102 224 100 191 282 98 187 276 121 239 345 146 289 420

2 7/8" EUE Box 3 1/2" EUE Box

3 1/2" EUE Box

3 1/2" EUE Box

3 1/2" EUE Box

Rotor Max Tagbar Weight O.D. Distance (lbs) (in) (in) 3.543 3.543 4.130

4.130

4.488

4.488

12.6 12.6 12.6 12.6 12.7 12.7 12.7 12.7 12.7 12.7 12.7 12.7 12.7 12.7 12.7 12.7

78 154 124 271 120 233 346 116 224 333 180 360 486 263 524 767

Top Connection (in)

Length (in)

Drift Dia. (in)

Weight (lbs)

7/8" API Pin

80 146 106 200 104 195 286 102 191 280 125 237 349 150 287 424

1.915

45 83 52 98 52 97 143 60 112 164 69 131 193 85 163 242

7/8" API Pin 1" API Pin

1" API Pin

1" API Pin

1" API Pin

1.915 2.047

2.195

2.185

2.236

BMW ™ Uniform Thickness PC Pump Specifications - Metric Units Pump PC Pump Series Metric 10-1200 U 10-2400 U 15-1400 U 15-2800 U 50-500 U 50-1000 U 50-1500 U 70-500 U 70-1000 U 70-1500 U 105-400 U 105-800 U 105-1200 U 140-400 U 140-800 U 140-1200 U

Imperial 60-4100 U 60-8000 U 95-4600 U 95-9200 U 310-1600 U 310-3200 U 310-5100 U 440-1600 U 440-3200 U 440-5100 U 660-1400 U 660-2800 U 660-4100 U 880-1400 U 880-2800 U 880-4100 U

Stator

Displacement m3/day/100 rpm 10 15 50

70

105

140

Lift Capacities k Pa 12415 23450 13794 27588 4828 9656 15173 4828 9656 15173 4138 7587 12415 4138 7587 12415

m 1200 2400 1400 2800 500 1000 1500 500 1000 1500 400 800 1200 400 800 1200

Top Connection (mm)

Rotor

Length (m)

Max Tagbar Weight O.D. Distance (kgs) (mm) (mm)

1.93 3.76 2.59 5.69 2.54 4.85 7.16 2.49 4.75 7.01 3.07 6.07 8.76 3.71 7.34 10.67

90.0

73.0mm EUE Box 73.0mm EUE Box 88.9mm EUE Box

88.9mm EUE Box

88.9mmEUE Box

88.9mmEUE Box

90.0 104.9

104.9

114.0

114.0

320 320 320 320 323 323 323 323 323 323 323 323 323 323 323 323

35 70 56 123 54 106 157 53 102 151 82 163 221 119 238 348

Uniform Thickness Pump Configuration STATOR LENGTH STATOR TOP CONNECTION

STATOR BOTTOM CONNECTION

TAGBAR DISTANCE STATOR O.D. ROTOR LENGTH CONTOUR LENGTH

ROTOR DRIFT

9

ROTOR CONNECTION

Top Connection (mm)

Length (m)

Drift Dia. (mm)

Weight (kgs)

22.2mm API Pin

2.03 3.71 2.69 5.08 2.64 4.95 7.26 2.59 4.85 7.11 3.18 6.02 8.86 3.81 7.29 10.77

48.64

21 38 24 44 23 44 65 27 51 74 31 59 88 39 74 110

22.2mm API Pin 25.4mm API Pin

25.4mm API Pin

25.4mm API Pin

25.4mm API Pin

48.64 51.99

55.75

55.50

56.79

Weatherford PC Pump Specifications - Imperial Units Pump PC Pump Series Metric 13-1200 13-1500 13-1800 22-200 22-600 22-900 22-1200 22-1500 22-1800 32-200 32-600 32-900 32-1200 32-1600 32-1800 80-600 80-800 80-1000 80-1200 80-1400 80-1600 98-800 98-1200 98-1600 130-800 130-1200 130-1600 160-200 160-400 160-600 160-800 160-1000 160-1200 161-1800 175-800 175-1200

Imperial 82-4100 82-5100 82-6000 140-700 140-2100 140-3100 140-4100 140-5100 140-6000 200-700 200-2100 200-3100 200-4100 200-5200 200-6000 500-2100 500-2800 500-3200 500-4100 500-4600 500-5200 615-2800 615-4100 615-5200 820-2800 820-4100 820-5200 1000-700 1000-1400 1000-2100 1000-2800 1000-3200 1000-4100 1010-6000 1100-2800 1100-4100

Stator

Displacement bbl/day/100 rpm 82

140

200

500

615

820

1000

1010 1100

Lift Capacities psi 1800 2200 2600 300 900 1350 1800 2200 2600 300 900 1350 1800 2250 2600 900 1100 1400 1800 2000 2250 1100 1800 2250 1100 1800 2250 300 600 900 1100 14000 1800 2604 1100 1800

ft 4100 5100 6000 700 2100 3100 4100 5100 6000 700 2100 3100 4100 5200 6000 2100 2800 3200 4100 4600 5200 2800 4100 5200 2800 4100 5200 700 1400 2100 2800 3200 4100 6000 2800 4100

Top Connection (in)

Length (in)

3 1/2" EUE Box

117 144 171 86 133 175 217 259 301 99 183 251 318 385 453 235 288 340 393 445 498 228 315 403 268 363 458 183 288 393 498 603 708 431 232 342







5 1/2" LTC Box 5 1/2" LTC Box

Rotor Max Tagbar Weight O.D. Distance (lbs) (in) (in) 4.130

3.543

3.543

4.500

5.500

5.500

4.500

6.000 6.000

14.7 14.7 14.7 14.6 14.6 14.6 14.6 14.6 14.6 14.6 14.6 14.6 14.6 14.6 14.6 14.5 14.5 14.5 14.5 14.5 14.5 15.0 15.0 15.0 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 13.6 15.1 15.1

123 153 182 83 80 119 157 195 233 95 126 187 248 309 371 306 384 459 536 612 689 575 803 1035 534 736 938 231 384 536 689 842 996 1015 541 803

Top Connection (in)

Length (in)

Drift Dia. (in)

Weight (lbs)

1" API Pin

119 146 173 47 94 136 178 220 262 60 144 212 279 346 414 167 220 272 325 436 430 186 273 361 201 296 391 115 220 325 430 535 640 432 232 342

2.135

68 83 99 16 33 47 62 77 91 22 53 78 103 128 153 114 150 186 222 298 294 157 230 305 204 300 396 79 150 222 294 365 437 543 292 430



1' API Pin

1" API Pin

1 1/8" API Pin

1" API Pin

2 3/8" PAC Pin 1 1/8" API Pin


TAGBAR DISTANCE



ROTOR DRIFT

10

ROTOR CONNECTION

1.875

1.883

2.531

2.899

3.190

2.531

3.563 3.563

Weatherford PC Pump Specifications - Metric Pump PC Pump Series Metric 13-1200 13-1500 13-1800 22-200 22-600 22-900 22-1200 22-1500 22-1800 32-200 32-600 32-900 32-1200 32-1600 32-1800 80-600 80-800 80-1000 80-1200 80-1400 80-1600 98-800 98-1200 98-1600 130-800 130-1200 130-1600 160-200 160-400 160-600 160-800 160-1000 160-1200 161-1800 175-800 175-1200

Imperial 82-4100 82-5100 82-6000 140-700 140-2100 140-3100 140-4100 140-5100 140-6000 200-700 200-2100 200-3100 200-4100 200-5200 200-6000 500-2100 500-2800 500-3200 500-4100 500-4600 500-5200 615-2800 615-4100 615-5200 820-2800 820-4100 820-5200 1000-700 1000-1400 1000-2100 1000-2800 1000-3200 1000-4100 1010-6000 1100-2800 1100-4100

Stator


22

32

80

98

130

160

161 175

Top Connection (in)

Lift Capacities kPa 12415 15173 17932 2069 6207 9311 12415 15173 17932 2069 6207 9311 12415 15518 17932 6207 7587 9656 12415 13794 15518 7589 12415 15521 7589 12415 15521 2069 4138 6207 7587 96558 12415 17960 7587 12415

m 1200 1500 1800 200 600 900 1200 1500 1800 200 600 900 1200 1600 1800 600 800 1000 1200 1400 1600 800 1200 1600 800 1200 1600 200 400 600 800 1000 1200 1800 800 1200

Length (m)

88.9mm EUE Box

2.97 3.66 4.34 1219mm x 73.0mm EUE Box Weld Ext. 2.18 3.38 4.45 5.51 6.58 7.65 1219mm x 73.0mm EUE Box Weld Ext. 2.51 4.65 6.38 8.08 9.78 11.51 1219mm X 88.9mm EUE Box Weld Ext. 5.97 7.32 8.64 9.98 11.30 12.65 1219mm x 114.3mm EUE Box Weld Ext. 5.79 8.00 10.24 1219mm x 114.3mm EUE Box Weld Ext. 6.81 9.22 11.63 1219mm x 88.9mm EUE Box Weld Ext. 4.65 7.32 9.98 12.65 15.32 17.98 139.7mm LTC Box 10.95 139.7mm LTC Box 5.87 8.66

Rotor Max Tagbar Weight O.D. Distance (kg) (mm) (mm) 104.9

90.0

90.0

114.3

139.7

139.7

114.3

152.4 152.4

373 373 373 371 371 371 371 371 371 371 371 371 371 371 371 368 368 368 368 368 368 381 381 381 368 368 368 368 368 368 368 368 368 345 384 384

56 69 82 38 37 54 71 89 106 43 57 85 113 140 168 139 174 208 243 277 313 261 364 469 242 334 425 105 174 243 313 382 452 461 245 364

Top Connection (mm) 25.4mm API Pin

3.02 3.71 4.39 22.2mmAPI Box 1.19 22.2mm API Pin 2.39 3.45 4.52 5.59 6.65 22.2mm API Box 1.52 22.2mm API Pin 3.66 5.38 7.09 8.79 10.52 25.4mm API Pin 4.24 5.59 6.91 8.26 11.07 10.92 25.4mm API Pin 4.72 6.93 9.17 28.6mm API Pin 5.11 7.52 9.93 25.4mm API Pin 2.92 5.59 8.26 10.92 13.59 16.26 60.3mm PAC Pin 10.97 28.67mm API Pin 3.89 8.69


TAGBAR DISTANCE



ROTOR DRIFT

11

Length (m)

ROTOR CONNECTION

Drift Dia. (mm)

Weight (kg)

54.23

31 38 45 7 15 21 28 35 41 10 24 35 47 58 69 52 68 84 101 135 133 71 104 138 92 136 179 36 68 101 133 166 198 246 132 195

47.63

47.83

64.29

73.63

81.03

64.29

90.50 90.50

Available Pump Options Elastomers Selecting the correct elastomer for your specific well conditions is crucial in getting the maximum run time and performance from your PC Pump.

Elastomer Reference Name

Elastomer Reference Code

Characteristics

Typical Applications

Buna

•0366/68 •N080

•Excellent Wear and Mechanical Properties.

•Heavy Oil (<15 API) •Coal Bed Methane

•0311 (Mid-Nitrile)

Dewatering.

•590 •G062A

•Excellent Wear and Mechanical

•Water Source Wells. •Heavy Oil (<15 API). •High sand and

Soft Buna

Properties. •Lower Hardness compared to •G60 •0328

High Nitrile

•0356 •68A

regular Buna. •Excellent Wear and Mechanical Properties. •Better resistance to Aromatics

foreign debris concentrations (ex. Iron Pyrite). •Light Oil (>15 API)

Very careful consideration must be taken when installing PC Pumps into applications with H2O, CO 2, Aromatic Concentrations, and High Temperatures. Please consult with your local Weatherford Distributor for further information on these applications.

Extended Rotor Lengths (XL) All pumps are available with the following extended rotor lengths. Extended length rotors are used for two main reasons: 1. To help break up obstructions at the pump intake. 2. Allows the producer to have a rod lift program and still use all stages of the PC Pump. Standard lengths are shown for all available pumps on the previous pages.

Length Designation

Standard XL 2XL 3XL

Length added to Tagbar Standard Rotor Distance ± 1/2"

+0" +8" +16" +24"

15 23 31 39

Longer extended lengths are available upon request.

TAGBAR DISTANCE

12

Tagbar Slotting All XL length pumps are available with all three of our standard slotting options. Each slotting style has similar advantages and their own distinct advantages. For XL lengths additional slots are added as the tagbar length increases, giving you maximum inflow.

Slot Size

Slot Benefits

1 4

/"

• Very effective in keeping small and large particles out of the pump (ex. Iron Pyrite).

1"

• Greatly improved inflow directly at the intake of the pump. • Excellent with XL rotor lengths to mix up sand ladden viscous fluids.

2"

• Maximum inflow directly at the intake of the pump. • Excellent with XL rotor lengths to mix up sand ladden viscous fluids.

3XL 2XL XL STD.

TAGBAR PIN

1/4" SLOTS 2" SLOTS

NO SLOTS 1" SLOTS

Custom pin placement, rotor lengths, and slotting are available upon request.

13

Paddle Rotor Generally pumps built to this configuration would be in the 3XL length accompanied with the corresponding length slotted (or non-slotted) tagbar. The idea is to have the flat or Paddle portion of the rotor landed optimally in the slotted tagbar to generate mixing action at the intake of the pump. Ideal for heavy oil and / or high sand cuts.

Open/Close Tagbar - OCT The design of the OCT will provide the producer with all the benefits of a non-slotted and a slotted tagbar all in one piece of equipment. The OCT gives the producer the ability to circulate the well through the tubing, reducing the shock loading and costs of sand bailing problem wells during work overs and allows fluid to enter the pump through slots directly at the intake when the well is on production. The OCT is available for a variety of PC Pumps with XL and 3XL rotor lengths. Available Sizes & General Dimensions OCT Description

Rotor Length Required

Outside Diameter

Open Length

Closed Length

Standard Top Connection

Standard Bottom Connection

2 7/8" XL 2 7/8" 3XL 3 1/2" XL 3 1/2" 3XL 3 1/2" XL Welded* 3 1/2" XL Welded* 4" XL 4" 3XL

XL 3XL XL 3XL XL 3XL XL 3XL

3 1/2" 3 1/2" 4 1/2" 4 1/2" 4 1/2" 4 1/2" 4 1/2" 4 1/2"

40 1/2" 55 3/4" 36" 52" 38" 54" 36" 52"

33 1/2" 49" 28" 44" 30" 46" 28" 44"

2 7/8" EUE Pin 2 7/8" EUE Pin 3 1/2" EUE Pin 3 1/2" EUE Pin Welded Welded 4" EUE Pin 4" EUE Pin

2 7/8" EUE Pin 2 7/8" EUE Pin 3 1/2" EUE Pin 3 1/2" EUE Pin 3 1/2" EUE Pin 3 1/2" EUE Pin 3 1/2" EUE Pin 3 1/2" EUE Pin

*A weld on version is also available for new or replacement of current weld on tagbar assemblies within the Weatherford PC Pump product line.

SHOWN IN THE OPEN POSITION

TAGBAR PIN

14

PRODUCTION PUMP

Charge/Recirculating Pumps When producing problem wells that slug sand, water, and or gas the use of a Charge/Recirculating Pump can be an advantage. The Charge/Recirculating Pump consists of three main parts: a bottom pump that is a higher volume lower pressure pump that helps keep the wellbore fluid consistent by mixing the fluid before it can enter the production pump, a pup joint located between the two pumps usually having slots or holes added to it depending on the application and your production pump determining your final volume and lift capacity (shown on the right). Please consult with your Weatherford Distributor when considering the use of a Charge/Recirculating Pump.

PUP JOINT

PONY ROD

Possible Combinations Charge / Recirculating Pump (Metric)

Production Pump (Metric)

16-200 XL 32-200 XL 32-200 XL 32-200 XL 56-200 XL 83-200 XL 120-200 XL

Series 10, 3XL Series 10, 3XL Series 15, 3XL Series 28, 3XL Series 28, 3XL Series 56, 3XL Series 88, 3XL

CHARGE/RECIRC. PUMP

BMW™ Left Hand Pumps In the majority of PC Pump installations a no-turn tool is required below the stator to prevent the tubing from backing off. There are some applications where it is not possible or advantageous to use a no-turn tool. For these applications, PC Pumps & Products, offers a left-hand pump which eliminates the need for a no-turn tool. To date, there are 3 series of Left Hand Pumps available, Series 10, 15 & 28. For more information on the specifics of using a Left Hand Pump, please contact your local Weatherford distributor.

15

Recommended Pup Joint and Pony Rod Connections PC Pump Series

Rotor Minimum Tubing Drift Size for Rotor Diameter (1) Installation (1)(2)

Rotor Orbit Diameter(1)

Metric

Imperial

4 7 10 15 16 28 28SH 42 42SH 56 56SH 64 64SH 83 83SH 88 95 120 120SH 180

25 45 60 95 100 175 175SH 265 265SH 350 350SH 400 400SH 520 520SH 550 600 750 750SH 1150

1.440 1.620 1.925 1.915 1.925 2.270 2.270 2.360 2.360 2.270 2.270 2.235 2.235 2.270 2.270 2.810 2.239 2.185 2.185 2.805

2 3/8" EUE 2 3/8" EUE 2 7/8" EUE 2 7/8" EUE 2 7/8" EUE 2 7/8" EUE 2 7/8"EUE 3 1/2" EUE 3 1/2" EUE 2 7/8" EUE 2 7/8"EUE 2 7/8" EUE 2 7/8"EUE 2 7/8" EUE 2 7/8"EUE 3 1/2" EUE 2 7/8" EUE 2 7/8" EUE 2 7/8" EUE 3 1/2" EUE

1.670 1.991 2.225 2.348 2.325 2.820 2.820 3.075 3.075 2.820 2.820 2.785 2.785 2.820 2.820 3.710 2.993 2.785 2.785 3.630

10U 15U 50U 70U 105U 140U

60 95 310 440 660 880U

1.915 1.915 2.047 2.195 2.185 2.236

2 7/8" EUE 2 7/8" EUE 2 7/8" EUE 2 7/8" EUE 2 7/8" EUE 2 7/8" EUE

2.236 2.348 2.599 2.769 2.795 2.874

13 22 32 80 98 130 160 161 175

82 140 200 500 615 820 1000 1010 1100

2.135 1.875 1.883 2.531 2.899 3.190 2.531 3.563 3.563

2 7/8" EUE 2 3/8" EUE 2 3/8" EUE 3 1/2" EUE 4" EUE 4" EUE 3 1/2" EUE 4 1/2" EUE 4 1/2" EUE

Seating Nipple Compatibility(1)(5) Minimum Pup Size & Length Minimum Pony Length for Rotor 2 7/8" STD 2 7/8" O/S 3 1/2" STD for Stator Top Connection(4) 2.290" ID Top Connection (1)(2)(3) 2.325" ID 2.780" ID

BMW 4 ft of 2 3/8" EUE 4 ft of 2 3/8" EUE 4 ft of 2 7/8" EUE 4 ft of 2 7/8" EUE 4 ft of 2 7/8" EUE 4 ft of 3 1/2" EUE 4ft Weld Ext. Included 4ft Weld Ext. Included 4ft Weld Ext. Included 4 ft of 3 1/2" EUE 4ft Weld Ext. Included 4 ft of 3 1/2" EUE 4ft Weld Ext. Included 4 ft of 3 1/2" EUE 4ft Weld Ext. Included 4ft Weld Ext. Included 4ft Weld Ext. Included 4 ft of 3 1/2" EUE 4ft Weld Ext. Included 4ft Weld Ext. Included

Uniform 4 ft of 2 7/8" EUE 4 ft of 2 7/8" EUE 4 ft of 3 1/2" EUE 4 ft of 3 1/2" EUE 4 ft of 3 1/2" EUE 4 ft of 3 1/2" EUE

8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8f 8ft 8ft 8ft 8ft 8ft 8ft

Yes Yes Yes Yes Yes Yes Yes No No Yes Yes Yes Yes Yes Yes No Yes Yes Yes No

Yes Yes Yes Yes Yes Yes No No Yes Yes Yes Yes Yes Yes No Yes Yes Yes No

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes No

Yes Yes Yes Yes Yes Yes



8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft 8ft

Yes Yes Yes No No No No No No

Yes Yes Yes No No No No No No

Yes Yes Yes Yes No No Yes No No

Weatherford 2.671 2.500 2.479 3.312 3.653 4.250 3.312 4.751 4.751

4ft of 3 1/2" EUE 4ft Weld Ext. Included 4ft Weld Ext. Included 4ft Weld Ext. Included 4ft Weld Ext. Included 4ft Weld Ext. Included 4ft Weld Ext. Included 4ft Weld Ext. Included 4ft Weld Ext. Included

1All

information calculated for rotor only, does not include couplings or additional connections directly above rotor. tubing sizes are based on the following tubing weights: Tubing Size Grade I.D. (in) Drift I.D. (in) Tubing Size Grade I.D. (in) Drift I.D. (in) 2 3/8" EUE x 4.70 J55 1.995 1.902 4" EUE x 9.50 J55 3.548 3.423 2 7/8" EUE x 6.50 J55 2.441 2.346 4 1/2" EUE x 12.75 J55 3.958 3.833 3 1/2" EUE x 9.30 J55 2.992 2.867 For all other tubing weights check tubing drift I.D. vs. rotor drift diameter for rotor installation, and tubing I.D. vs. rotor orbit diameter for stator top connection. 3This pup joint is required above the pump to allow for rotor movement during operation. If the pup diameter is smaller than recommended the rotor will wear into or through the pup, or cause the rotor to fail. 4If possible connect rotor directly to rod string eliminating all pony rods. 5Ability of rotor (drift diameter) to pass through the seating nipple located in tubing string. 2Minimum

16

We offer the ability to predict all elements of a Downhole Progressing Cavity Pumping System including differential pressure, estimated pump speed, polished rod drive torque and total input power required for any given set of well parameters. From this information it is possible to correctly select the bottomhole pump based on volume and lift capabilities, sucker rod diameter and grade, prime mover horsepower and surface drive type most suitable for your application.

Company Name:

Country:

Date:

Contact:

E-mail:

Phone:

Well Name:

Location:

Fax:

WELL DATA



Total Depth:

Ft - m

Current Production:

Bfpd - M3pd

Mid-point of Perforations:

Ft - m

Desired Production:

Bfpd - M3pd


Ft - m

Water Cut:

TMD:

Ft - m

Abrasive Cut:

% % Scf/Bbl - M3/M3

Gas/Oil Ratio:

Producing Fluid Level From Surface (TVD)


Cp@

˚F - ˚C

Cp@

˚F - ˚C

Current:

Ft - m

Projected:

Ft - m

Flowline Pressure:

Psi - Kpa

Oil Gravity:

Casing Pressure:

Psi - Kpa

Water Gravity:

Water Salinity:

Casing size:

Psi - Kpa

C02:

Ppm%

Tubing Size:

Inches -mm


˚F - ˚C

Inches -mm

Bottomhole Temperature:

˚F - ˚C

Rod Size & Grade:

❏

Coupling

Slimhole

❏

Standard

❏

˚API


H2S:

Ppm%


IPR DATA Static Reservoir Pressure:

Psi - Kpa

SURFACE EQUIPMENT


Psi - Kpa

Primer Mover Type:

Gas

Surface Drive:

Direct

Test Point #1

Test Point #2

❏ ❏

Producing Pressure:


Fluid Rate (Bfpd-m3pd):

Specify Flow-Tee to Drivehead Connection:

Productivity Index:

Electric Hydraulic

Hz Line Voltage:

❏ ❏

Volts

Bbl/Psi - M3/Kpa


Note: Please ensure that all production and well data information is completed. This information is critical to the surface equipment design, PCP and elastomer selection. If key information is missing, designs cannot be completed accurately and delays in quotations will result. Please circle unit of measure where applicable. To receive this Data Sheet or an electronic copy please contact your local Weatherford Distributor.

17


Sold & Serviced by:

Worldwide Customer Service 515 Post Oak Blvd. Houston, Texas 77027 Phone: (713) 693-4800 [email protected] [email protected] www.weatherford.com

WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Calgary Sales: (403) 269-7788 Lloydminster: (780) 875-2730

Europe / W. Africa Phone: 44 (0) 1224 21 41 81




®

Insertable PC Pump Manual

Version 1.0

®

Preface Foreword The information, specifications and illustrations in this publication are up to date at time of printing. Our policy is one of continued development and therefore we reserve the right to amend any of the information contained in this manual or binder without prior notice.

Disclaimer This manual is intended to give our customers basic information regarding the design, installation and operation of Weatherford Insertable PC Pumps. It is not intended to be a complete source of information on these matters. The customer is responsible for using this information in a correct and safe manner. For assistance, contact your nearest Weatherford representative. The operation of any Weatherford Insertable PC Pump beyond the parameters outlined in this manual without factory approval may be damaging to the equipment and/or personnel in which case PC Pump Products & Services cannot accept any responsibility whatsoever and disclaims all liability thereof.

Insertable PC Pump Manual

Table of Contents Introduction

Pg. 1-2

Production Tubing Installation

Pg. 3-4

Pump Insertion

Pg. 5-6

Pump Seating

Pg. 7

Rotor Landing

Pg. 8

Seating Test

Pg. 9

Pumping

Pg. 9

Flush-By

Pg. 10

Pump Removal

Pg. 11-12

Insertable PC Pump Illustrations

Pg. 13-14

Sizes and Dimensions

Pg. 15

®

Introduction The main objective of an Insertable PC Pump is to help reduce down time related to pulling tubing when changing or replacing a tubing installed PC Pump. The Insertable PC Pump is installed down hole by first installing the tubing string with a corresponding Pump Seating Nipple (PSN) and the correct amount of tubing below the PSN at the desired pump landing depth. Once the tubing Is installed, the Insertable PC Pump assembly is ran down hole on the bottom of sucker rod or continuous rod until it seats in the PSN, sealing the production fluid away from the pump in-take.

Key Features

Cloverleaf Design

• Patent Pending Arrowhead design Corod or Sucker Rod String

• Reduce the down time and cost related to pulling or replacing a tubing PC Pump • The only special piece of equipment in the tubing string is the Pump Seating Nipple (PSN)

Production Tubing

• PSN and Seating rings are located at the top of the assembly, reducing the chance of sand packing in the annular space between the pump and the tubing • Similar to Insertable Rod Pumps, using only a PSN downhole • Allows for special intake screens (snivees) and/or other equipment to be used below the pump


• Allows for pump volume/lift changes without having to pull tubing

Cloverleaf

• All pumps utilize a No-turn tool on the bottom of the insert assembly

Pull Rod

Extension Tube

Pick-Up Coupling

Insertable PC Pumps "Cloverleaf Design"

Tubing

• Intended for 2 7/8" tubing • This design is similar to other conventional Insertable PC Pumps that are available • The assembly is removed by a rod coupling on the top of the rotor, and a "Cloverleaf" pick-up acting like a no-go at the top of the assembly • When the rod coupling and the "Cloverleaf" meet, the pump can be pulled from the seating nipple and raised to surface

Rotor

Stator

CLOVERLEAF


SUCKER-ROD

Tagbar Pin

ROD COUPLING

ROTOR

Tagbar Optional Tagbar Slotting

• The pump has a flush tube between the top of the stator and the "Cloverleaf" to allow the pump to be flushed and maintained. • The flush tube is approximately the length of the rotor to allow fluid to pass around the rotor and through the stator during a flush-by

No-Turn Tool


1

Insertable PC Pumps "Arrowhead Design" •Utilizes patent pending "Arrowhead" technology to make Insertable PC Pumps more practical and compact • Intended for 3 1/2", 4 1/2" & 5 1/2"tubing • Rotor features a special shaped Arrowhead structure on the bottom of the rotor designed to mate with a floating ring acting as a no-go at the top of the insert assembly • When these two parts come into contact the entire assembly can be removed from the well

Arrowhead Design

ROTOR

FLOATING RING ARROWHEAD

Corod or Sucker Rod String

Production Tubing

• The ability to pick up from the bottom of the rotor reduces the length of the flush tube between the stator and the floating ring • When a flush is required, the Arrowhead structure is positioned between the stator and the floating ring in a 4’ tube, extending the rest of the rotor into the production tubing • Once the rotor is positioned fluid can be flushed around the rotor and through the stator Available in XL and longer lengths only


Floating Ring

Note: Additional rotor length reduces the chance of having the Arrowhead operate in the stator

Pull Rod

Applications & Considerations Tubing & Equipment • New or like new tubing is recommended • Tubing should be cleaned and drifted during tubing installation • Tubing weight is not an option, heavier tubing weights than stated may prevent the insert from being properly installed • Recommended to have tubing below the PSN drilled with holes near the pump intake to increase inflow • Tubing below the PSN should be long enough to allow for different length of pumps to be installed • Consider possible future pump sizes in order to get the maximum payback from the insert concept without having to pull tubing

Extension Tube

Rotor

Well & Well Bore

Stator Optional Tubing Perforations

Arrowhead Tagbar


Tubing

No-Turn Tool


Tagbar Pin

• Applications with extremely high sand content may not be good candidates • Wells with deviations near the PSN landing location may prevent the insert from being seated properly

Insert Components • Nearly all components in the insert assembly are reusable • Allowing only stators and/or rotors to be purchased, once the initial components are purchased • A back up assembly is recommended to reduce turn around time • Insert tagbars are similar to conventional tagbars therefore slotting can be requested to allow for greater inflow

Operation • Proper rotor landing is critical with the patent pending "Arrowhead" style insert pump - rotor only needs to be 8"-12" off of the tagbar • If the "Arrowhead" is landed in the stator it may cause a restriction and cause damage to the stator

Maintenance • Regular flushing can extend the life of an insert pump assembly • Make sure flush-by and service rig crews are aware that it is an insert pump, and they know the proper procedures Note: Drive head should be tagged or marked, advising an Insertable PC Pump is down hole, refer to Page 10.

2

®

Production Tubing Installation • A corresponding Weatherford Pump Seating Nipple (PSN) must be properly located in the string of Production Tubing.

Production Tubing Below PSN & PSN Sizes: INSERT SIZE

PRODUCTION TUBING SIZE

PSN BORE

2 7/8" Y

2 7/8" EUE x 6.50 lb/ft or 9.67 kg/m

2.235"

59.06mm

3 1/2" AY

3 1/2" EUE x 9.30 lb/ft or 13.84 kg/m

2.830"

71.88mm

4 1/2" AY

4 1/2" EUE x 12.75 lb/ft or 18.97 kg/m or

3.810"

96.77mm

4.625"

117.48mm

4 1/2" STC or LTC x 12.60 lb/ft or 18.75 kg/m 5 1/2" AY

5 1/2" STC or LTC x 17.00 lb/ft or 20.83 kg/m

(2 7/8" Y PSN is an API bore, 3 1/2" AY, 4 1/2" AY & 5 1/2" AY sizes are custom bore by Weatherford.)

• The entire length of the pump to be run will hang down below the seating nipple, while inside of the production tubing. The tubing size below the PSN must be as specified for the No-Turn Tool to engage properly.

Production Tubing Above PSN: INSERT SIZE


2 7/8" Y

2 7/8" EUE x 6.50 lb/ft or 9.67 kg/m or lighter

3 1/2" AY

3 1/2" EUE x 9.30 lb/ft or 13.84 kg/m or lighter

4 1/2" AY

4 1/2" EUE x 12.75 lb/ft or 18.97 kg/m or lighter or 4 1/2" STC or LTC x 12.60 lb/ft or 18.75 kg/m or lighter

5 1/2" AY

5 1/2" STC or LTC x 17.00 lb/ft or 20.83 kg/m or lighter

• To locate your pump intake properly install the seating nipple approximately the overall length of the insert assembly (bottom of no-turn to top of seating mandrel) above the desired pump intake location. At this point, the intake of the pump should be at the proper depth once seated.

3

PRODUCTION TUBING

TUBING DRAIN

• Prior to production tubing installation, the tubing and any other equipment the insert assembly passes through downhole (drains, no-turn tools, etc.) should be flushed and drifted prior to installing the insert assembly.

INSERT SIZE


TUBING DRIFT SIZE

2 7/8" Y

2 7/8" EUE x 6.50 lb/ft or 9.67 kg/m

2.347"

59.61mm

3 1/2" AY

3 1/2" EUE x 9.30 lb/ft or 13.84 kg/m

2.867"

72.82mm

4 1/2" AY

4 1/2" EUE x 12.75 lb/ft or 18.97 kg/m or

3.833"

97.36mm

4.767"

121.08mm

4 1/2" STC or LTC x 12.60 lb/ft or 18.75 kg/m PRODUCTION TUBING

PSN

5 1/2" AY

5 1/2" STC or LTC x 17.00 lb/ft or 20.83 kg/m

• Tubing allowances below the seating nipple must be made to ensure that the insert no-turn tool is operating inside the production tubing. • Tubing allowances below the PSN should also be considered for future pump size changes, larger volume & lift pumps will require more tubing below the PSN due to increased length. • As an option below the PSN, holes can be drilled in the tubing directly at the insert pump intake, increasing inflow to the pump.

TUBING BELOW PSN

• In conjunction with tubing holes tagbar slotting can be requested, allowing inflow to occur directly below the pump. Tagbar slotting can be requested for insert pump tagbars the same as any other pump for 1", 2" or 1/4" slots depending on the insert pump size. • It is recommended that a No-Turn tool be used on the bottom of the production tubing to prevent the tubing from backing off during pump operation.

OPTIONAL TUBING PERFORATIONS

• We suggest a Male Reducing Swage or Stop-bar be installed on the bottom of the tubing string below the insert pump as a precaution to aid pump retrieval. Note: Using the stop-bar may limit the use of ETU for clean out. • Run the PSN, tubing, and other equipment into the well tighten all connections between optimal and maximum torques according to the API specifications.

NO-TURN TOOL

• With the seating nipple and equipment properly positioned downhole, the Insert Pump can be lowered inside the production tubing string using the rod string. • A pressure unit should be available in case the insert assembly needs to be pumped down to seating location.

SWAGE

4

®

Pump Insertion 1. Prior to inserting any insert PC Pump the installed tubing should be flushed with clean light fluid to speed up and assist in the insertion of the Insertable PC Pump. 2. Prior to raising the insert assembly into the rig rotate the rotor a couple rotations with a crescent or pipe wrench in each direction while in the stator to make seating easier, reducing the chance of the rotor "sticking" in the stator.

Arrowhead Insert PC Pump 3 1/2" AY, 4 1/2" AY, 5 1/2" AY - Patent Pending • Warning - Failure to follow these procedures can place an operator at risk. For ease of handling, the pump is shipped with the rotor in the stator. Do not attempt to raise the insert pump assembly by the sucker rod end. Lifting the pump by the sucker rod connection alone could result in the rotor coming out of the stator and becoming fully extended at any time during handling. 1. A special install tool (shipped with the pump) should be hand tightened into the top seating mandrel. 2. Attach slings to the Install tool wings and raise the pump into the rig derrick. 3. Align the pump and lower downhole, you may need to push the No-Turn Tool door closed to start the pump down hole. 4. Continue lowering the pump with the slings until all the weight is resting on the wings of the install tool at the wellhead. 5. The pump may now be attached to the rod string. Once attached lift the rod string until all weight has been removed from the wings of install tool. Note: During this process the rotor may or may not come free from the stator, the pump can be installed with the rotor in either position. 6. At this point, the install tool can be unthreaded and removed from service. The tool is designed to be removed from the sucker rod, continuous or conventional via the axial slot while connected to the pump.

TOP OF MANDREL

INSTALL TOOL

5

INSERT SIZE

MAXIMUM RECOMMENDED ROD SHEAR SIZE

3 1/2" AY

40,000lbs

18140kg

4 1/2" AY

40,000lbs

18140kg

5 1/2" AY

50,000lbs

22680kg

7. It is good practice to run a rod shear approximately 1 joint of sucker rod above the pump. 8. The insert pump can now be lowered downhole on the end of the rod string. 9. Check the rods and couplings for excessive wear or other defects. 10. Tighten all sucker rod couplings to API specifications or as recommended by rod supplier. 11. In viscous fluids it may be necessary to pump fluid downhole to aid the insertion of the insert pump assembly. 12. Lower the rod string/insert pump assembly until there is a reduction in rod weight to near zero. At this point the seating mandrel should be seated within or on top of the seating nipple.

Cloverleaf Insert PC Pump 2 7/8" AY 1. Connect to the sucker rod end on the top of the insert pump assemlby and raise into the rig's derrick. • NOTE: During this process the rotor may or may not come free from the stator, the pump can be installed with the rotor in either position. 2. Align the pump and lower downhole, you may need to push the No-Turn Tool door closed to start the pump down hole. 3. It is good practice to run a rod shear approximately 1 joint of sucker rod above the pump.

INSERT SIZE

MAXIMUM RECOMMENDED ROD SHEAR SIZE

2 7/8" AY

20,000lbs

9070kg

4. The insert pump can now be lowered downhole on the end of the rod string. 5. Check the rods and couplings for excessive wear or other defects. 6. Tighten all sucker rod couplings to API specifications or as recommended by rod supplier. 7. In viscous fluids it may be necessary to pump fluid downhole to aid the insertion of the insert pump assembly. 8. Lower the rod string/insert pump assembly until there is a reduction in rod weight to near zero. At this point the seating mandrel should be seated within or on top of the seating nipple.

6

®

Pump Seating 1. Prior to entering the PSN with the insert assembly record the rod string weight. 2. Lower the rods until the rotor and assembly rests on the tagbar & PSN. This will be indicated when the rod string weight reaches zero. 3. To make sure the insert pump is seated or has started to seat mark the rod string at the well head and slowly lift the rods up and down two or three times tapping the tagbar, making sure this mark stays at or near the same location. 4. Once the mark appears to stay near the same location lift rod string 2' - 3'or 0.5 - 0.75m and allow to free fall downwards. This action should ensure that the rings have seated or started into the PSN, the mark on the rod string should be 2"-3" or 50-80mm lower than previously.

3. Once the rod string weight is resting on the tagbar pin and a seal has been achieved at surface fill the tubing with fluid and pressure to 250-500psi (1700-3500kPa) at surface. At this point the tubing string should hold the pressure steady, if not another problem other then seating may be present. 4. While the tubing string is holding pressure slowly lift the rod string until the pressure quickly drops off, then stop raising the rod string. CAUTION: While lifting the rod string back spin may be seen at surface until the rotor is free from the stator, keep personnel away from the rod string while completing this seating method. 5. The rotor may now be landed as required; another pressure test can be completed to ensure everything is seated properly.

5. Mark the Rod String again at the wellhead and repeat the previous free fall step; your new mark should remain at or near the same location. Pressure Assisted Seating 1. If the previous steps cannot achieve a seating test it may be necessary to apply fluid pressure on top of the Insert Pump Assembly then lift the rotor. 2. To complete a pressure assisted seating you will need to be able to create a seal around the polished rod at surface with either the drive head if there is enough stick up, or by other means if you can not rest the rod string weight and stay connected to the rod string with the drive head on.

7

Rotor Landing 1. Lower Rod String to zero string weight to ensure rotor is resting on the tag bar. 2. Monitor rod string as it is being raised, ensuring that the pump does not unseat. If the pump is unseated a sharp jerk in the string will be noticed. 3. Slowly pick the rods up until rod string weight is achieved. Pick up an additional 8" or 200mm off the tag bar as indicated by dimension "A" in illustrations page 13 & 14. 4. Pick up the rod string an additional amount for rod stretch. 3 /4" rods = 90mm per 300 meters (3.5 inches per 1000 feet) 7 /8" rods = 65mm per 300 meters (2.5 inches per 1000 feet) 1" rods = 55mm per 300 meters (2 inches per 1000 feet) THIS IS ONLY A GUIDELINE, EACH FIELD HAS INDIVIDUAL AND UNIQUE CHARACTERISTICS THAT NEED TO BE MONITORED AND ANALYZED TO ESTABLISH THE PROPER ROTOR LANDING. THE C-FER PC PUMP PROGRAM CALCULATES ROD STRETCH BASED ON ALL OPERATING PARAMETERS.

8. DO NOT leave wrench marks on the polished rod. 9. Once proper rotor landing has been determined the drive head unit can be installed. 10. Install a polished rod clamp to support the polish rod on the well head drive. A second rod clamp may be installed above the first clamp to prevent polished rod slippage. Summarize: 1. Record string weight before the insert assembly rests on the PSN. 2. Land the rotor on the tag bar & PSN. 3. Pull up string weight. 4. Pull up an additional 8" or 200mm. 5. Pull up to allow for rod stretch-operating position. 6. Measure and allow for wellhead height-clamping position. 7. Remove sucker rod(s) and replace with the polished rod and pony rods. 8. Run the polished rod into the well and clamp off.

5. The rotor should now be in the operating position. Do not lift the rotor from this position. Landing with the least amount of rotor sticking out of the stator minimizes downhole vibration. 6. Measure the height of the wellhead drive being used. 7. Add the length of the well head drive assembly to the operating position. This becomes the clamping point. Allow an additional 6" to 12" or 300mm for polish rod to stick up above the clamping point.

8

®

Seating Test 1. WARNING: Under certain conditions fluid in the tubing may cause backspin, exercise caution when pressure testing Insert Pumps.

3. Install and start the drive head unit as outlined in Weatherford Progressing Cavity Drive Manual, or as suggested by the drive manufacturer.

2. Fill production tubing with fluid to ensure that the insert pump has been seated properly. Note: This test may not be successful with low efficiency pumps, and may create backspin at surface.

4. The well head should be marked or tagged notifying of a Weatherford Insertable PC Pump installation, along with the proper information to complete a flush-by. (See page 10 for example of tag)

3. If the tubing string holds fluid and can hold pressure, a proper seal has been made with the seating assembly. 4. If the tubing string does not fill with fluid or hold pressure, a proper seal has not been made between the seating mandrel and the seating nipple. You may need to repeat previous Pump Seating and Rotor Landing procedures to ensure that the mandrel is seated properly inside the seating nipple. 5. If these steps cannot produce a successful seating test Pressure Assisted Seating may be required, see Pump Seating for proper steps (see page. 7).

Pumping 1. Once all previous steps have been followed and completed the Weatherford Insertable PC Pump should be ready to operate. 2. The insert no-turn tool will naturally engage and prevent rotation of the stator with rotation of the rotor. It does not require to be set in either direction. Initial contact points allow it to set once a torsional load is applied to the system.

9

Flush-By 1. Look closely around the well site for a similar tag stating the following information before servicing a Weatherford Insertable PC Pump. 2. If an information tag can not be found and you know that you are or could possibly be servicing an Insertable PC Pump, contact the operator or the local Weatherford Artificial Lift Systems representative for assistance before beginning. Not having the proper Insertable PC Pump knowledge or information can lead to more costly downtime. 3. Exercise caution and patience before starting to lift the rod string & rotor, or you could very easily unseat the pump assembly. 4. In the case that the pump becomes unseated you may need to remove the drive head depending on the amount of stickup above the drive, and then follow previous proper pump seating and rotor landing procedures in this manual.

8. When pumping fluid if the tubing appears to be holding steady pressure slowly raise the rotor another 12" or 300mm or until pressure drops to ensure the rotor is out of the stator. Once the additional lift is completed if fluid does not begin to flow or pressure does not decrease, it is possible a different downhole complication may have occurred during pump operation. 9. From this point the rotor can be worked up and down if necessary, but do not pull higher than distance "B" +12" or 300mm a risk of unseating the pump assembly is possible. 10. Once the flush-by is completed lower the rod string & rotor to the original position. If polished rod clamp was removed or pump needs to be re-landed follow steps previously outlined in this manual.

5. Dimension "B" is equivalent to the rotor contour length, see page 15. 6. During a flush-by lift the rod string & rotor the specified length to ensure that the rotor is completely out of the stator, shown as distance "B" in illustrations page 13 & 14. Lifting the rod string more than the specified length may result in unseating the pump, depending on where the rotor was positioned during operation. 7. Once the rod string & rotor has been lifted the specified distance begin the flush-by as normal, pumping the requested amount and type of fluid through the pump.

10

®

Pump Removal 1. Remove drive head then connect to the rod string.

Arrowhead Insert PC Pump 3 1/2" AY, 4 1/2" AY, 5 1/2" AY Patent Pending 3. Once the "break" connection is unthreaded the rotor and seating mandrel housing can be separated from the stator assembly and then removed from the well.

1. Dimension "B" indicates the overall length of the rotor contour in the pump assembly. Lifting the rotor distance "B" (see page 15) and an additional 48"-60" or 1.2-1.5m will unseat the pump

4. The install tool can now be threaded into the connection marked "break" and the stator assembly can be removed from the well using a sling with the install tool.

2. When the arrowhead engages with the floating ring, there will be a sharp increase in string weight (approximately 10,000lbs or 4500kg increase) as the pump is unseated, then decrease once unseated as the pump is being raised to surface.

Note: In 3 1/2" AY Insert pump situations the install tool will need to be flipped end over end and the acme threads will thread into the insert pump break connection.

3. Continue to raise the rod string until the pump is at surface. 4. Slide over rods and thread install tool into the top of the mandrel to aid in removing insert assembly from well.

Long Assembly Situations 1. Notice - In longer assembly situations, when exceeding total rig height once rotor is extended from stator, it may be necessary to split the assembly into two parts - Rotor & Stator. 2. To split the assembly, hang up the stator assembly with a dog collar located below the connection marked "break"(below seating rings).

3 1/2" Break Connection

4 1/2" AY & 5 1/2" AY Break Connection

INSERT SIZE

BREAK CONNECTION

PUMP OD FOR DOG COLLAR "C"

3 1/2" AY

2.5 - 8 Stub Acme

See chart Page 15

4 1/2" AY

2 7/8" EUE

for exact stator OD

5 1/2" AY

3 1/2" EUE

11

Cloverleaf Insert PC Pump 2 7/8" Y

1. Dimension "B" indicates the overall length of the rotor contour in the pump assembly. Lifting the rotor off of tag bar distance "B" and an additional 12"- 24" or 300-600mm will unseat the pump. 2. When the rotor coupling engages with the cloverleaf, there will be a sharp increase in string weight as the pump is unseated, then decrease once unseated as the pump is being raised to surface. 3. Continue to raise the rod string until the pump is at surface.

12

®

Illustrations Cloverleaf Insert PC Pump 2 7/8" Y INSERTION

SEATING

LANDING

13

FLUSH-BY

REMOVAL

Arrowhead Insert PC Pump 3 1/2" AY, 4 1/2" AY, 5 1/2" AY - Patent Pending INSERTION

SEATING

LANDING

ROTOR MAY OR MAY NOT BE EXTENDED FROM STATOR

14

FLUSH-BY

REMOVAL

®

2 7/8" Y Insertable Inside of 2 7/8" EUE x 6.50 lbs/ft & 9.67 kg/m or Lighter Tubing PC Pump Series Metric

Imperial

1-1200 Y 4-1200 Y 7-1000 Y

6-4100 Y 24-4100 Y 44-3200 Y

Displacement m3/day/100 rpm bbl/day/100 rpm 1 4 7

6 24 44

Lift Capacity (m)

(f)

1200 1200 1000

4100 4100 3200

Stator Top Connection

Bottom Connection 1 1/4" NPT Pin

PSN ID - 2.325"

Overall Length Rod (m)

(in)

5.00 6.93 7.29

197 273 287

Flush-By & Removal

Max Operating Rotor Contour "B" Torque (in) (m) 72 3/4" API Pin 3/4" Sucker Rod 460 18.29 ft*lbs 100 25.40 115 29.21

Pump (OD) "C" (in) (mm) 2.25 57.15 2.25 57.15 2.25 57.15

Connection

Lengths specified for standard Length Tagbars only

3 1/2" AY Insertable Inside of 3 1/2" EUE x 9.30 lbs/ft & 13.84 kg/m or Lighter Tubing Metric

Imperial

7-1000 AY

45-3200 AY

7-1400 AY

45-4600 AY

7-1600 AY

45-5200 AY

10-1200 AY

60-4100 AY

10-1600 AY

60-5200 AY

14-1200 AY

88-4100 AY

14-1800 AY

88-6000 AY

17-1000 AY

110-3200 AY

17-1500 AY

110-5100 AY

m3/day/100 rpm bbl/day/100 rpm

7 10 14 17

45 60 88 110

Top Connection

Bottom Connection

(m)

(in)

2 3/8" EUE Box 1.900 EUE Pin

5.00

197

(m)

(f)

1000

3200

1400

4600

5.89

232

1600

5200

6.76

266

1200

4100

5.13

202

1600

5200

6.05

238

1200

4100

6.05

238

1800

6000

7.87

310

1000

3200

6.05

238

1500

5100

7.87

310

PSN ID - 2.830"

Distance "B" (m) (in) 118 1" API Pin 1" Sucker Rod 1000 29.97 ft*lbs 39.88 157 47.50 187 30.99 122 40.13 158 40. 13 158 58.42 230 40.13 158 58.42 230

Pump (OD) "C" (mm) (in) 71.12 2.800 71.12 2.800 71.12 2.800 71.12 2.800 71.12 2.800 71.12 2.800 71.12 2.800 71.12 2.800 71.12 2.800

Max Operating Connection Torque

XL Minimum Rotor Length

Lengths specified for XL Length Tagbars only

4 1/2" AY Insertable Inside of 4 1/2" EUE x 12.75 lbs/ft & 18.75 kg/m or, 4 1/2" LTC & STC x 12.60 lbs/ft. or 18.75 kg/m Lighter Tubing Metric

Imperial


10-900 AY

60-3100 AY

10-1200 AY

60-4100 AY

10-1600 AY

60-5200 AY

10-1200 AYU

60-4100 AYU

10

15-1400 AY

95-4600 AY

15-1800 AY

95-6000 AY

15-1400 AYU

(m)

(f)

Top Connection

Bottom Connection

2 7/8" EUE Box 2 7/8" EUE Pin

(m)

(in)

900

3100

5.51

217

1200

4100

6.10

240

1600

5200

6.86

270

60

1200

4100

4.47

176

15

95

1400

4600

7.01

276

15

95

1800

6000

8.31

327

95-4600 AYU

1400

4600

5.13

202

22-900 AY

140-3100 AY

900

3100

5.72

225

22-1200 AY

140-4100 AY

1200

4100

6.78

267

22-1500 AY

140-5100 AY

1500

5100

7.85

309

32-900 AY

200-3100 AY

900

3100

7.65

301

32-1200 AY

200-4100 AY

1200

4100

9.35

368

32-1600 AY

200-5200 AY

1600

5200

11.05

435

10

22

32

60

140

200

PSN ID - 3.810"

Distance "B" (m) (in) 124 7/8" API Pin 1" Sucker Rod 1000 31.50 ft*lbs 37.34 147 44.96 177 21.34 84 46.23 182 59.69 235 27.94 110 35.56 140 46.23 182 56.90 224 54.86 216 71.88 283 88.90 350

Connection

Pump (OD) "C" (mm) (in) 90.00 3.543 90.00 3.543 90.00 3.543 90.00 3.543 90.00 3.543 90.00 3.543 90.00 3.543 88.90 3.500 88.90 3.500 88.90 3.500 88.90 3.500 88.90 3.500 88.90 3.500




5 1/2" AY Insertable Inside of 5 1/2" LTC & STC x 17.00 lbs/ft & 20.83 kg/m or Lighter Tubing Metric

Imperial

80-800 AY

500-2800 AY

80-1200 AY

500-4100 AY


80

500

(m)

(f)

Top Connection

Bottom Connection

3 1/2" EUE Box 3 1/2" EUE Pin

(m)

(in)

800

2800

8.23

324

1200

4100

10.90

429

80-1600 AY

500-5200 AY

1600

5200

13.56

534

105-400 AYU

660-1400 AYU

400

1400

5.56

219

105-800 AYU

660-2800 AY

800

2800

8.41

331

105-1200 AYU

660-4100 AY

1200

4100

11.25

443

160-400 AY

1000-1400 AY

400

1400

8.23

324

160-800 AY

1000-2800 AY

800

2800

13.56

534

105 160

660 1000


Y - Clover Leaf Insert

PSN ID - 4.625"

Distance "B" (m) (in) 1 1/4" Sucker Rod 56.64 223 1500 ft*lbs 83.31 328 109.98 433 32.51 128 60.96 240 89. 41 352 56.64 223 109.98 433

Max Operating Connection Torque 1" API Pin

Pump (OD) "C" (mm) (in) 114.30 4.500 114.30 4.500 114.30 4.500 114.00 4.488 114.00 4.488 114.00 4.488 114.30 4.500 114.30 4.500


AY - Arrow head Insert

Other Lifts Available upon request

AYU - Arrowhead Insert Uniform Rod Connection

Length

Top Connection

Bottom Connection

15

PC Pump Division of Weatherford Canada Partnership Warranty This shall be the only warranty given by PC Pump Division of Weatherford Canada Partnership ("Partnership"), and no other warranty by Partnership, Express or Implied, shall be applicable, including any implied warrant of merchantability or any implied warranty of fitness for a particular purpose. Subject to the limitations and conditions herein, Partnership warrants its products (with the exception of rotating stuffing boxes) to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of installation or eighteen (18) months from the date of shipment, whichever occurs first. Partnership warrants rotating stuffing boxes to be free from defects in workmanship and material under normal use and service for a period of three (3) months from the date of installation or nine (9) months from the date of shipment, whichever occurs first. Partnership's obligations under this warranty shall be limited to repairing, replacing or issuing credit for, at Partnership's option, any product or parts it finds to be defective in material or workmanship. Partnership must be given a reasonable opportunity to investigate. Shipping and handling in connection with this warranty will be at customer's expense. Products sold by Partnership, but manufactured by another company, will carry only the warranty of the manufacturer, and the customer will rely solely on that warranty. Services provided by Partnership are warranted for a period of ninety (90) days from the date the services are rendered. The liability of Partnership for any loss or damage resulting to the customer or user or any third party from any defect in any product or service will not, in any case, exceed the selling price that Partnership received from the customer for the product or service. The above shall be the customer's exclusive remedy with respect to products or services. In no event will partnership be liable for incidental, consequential, special, indirect or other damages of any nature. This warranty will not apply and will be void if the product fails as a result of down hole corrosion; non-compatibility of produced fluid with the stator and/or rotor; general wear and abrasion; incorrect installation, removal, use or maintenance; operation outside of the manufacturer's recommended guidelines; alteration; accident; abuse or negligence. Hydraulic wellhead drives, hydraulic power transmission units or rotating stuffing boxes sold individually for use with equipment not manufactured by Partnership will not be covered under this warranty. Partnership does not warrant that any of the products sold by it, if used or sold in combination with other equipment or used in the practice of methods or processes, will not, by virtue of such combination or use, infringe patents of other, and Partnership shall not be liable for any patent infringement arising from, or by reason of, any such use or sale. Furthermore, Partnership shall not be liable for any patent infringement arising from, or by reason of, any use or sale of any materials, equipment or products not of Partnership's manufacture or for the use or sale of any materials, equipment or products, or other goods specially made, in whole or in part, to the customer's design specifications.

16


Canada Weatherford Artificial Lift Systems Canada PC Pump Products & Services 4604 - 62nd Avenue Lloydminster, Alberta T9V 2G2 Canada 780/875-0103 Telephone 780/875-0963 Fax

Manufacturing Facility Weatherford Artificial Lift Systems Canada PC Pump Products & Services 2801 - 84th Avenue Edmonton, Alberta T6P 1K1 Canada 780/417-4800 Telephone 780/417-3146 Fax


®

www.weatherford.com


®


Disclaimer This manual is intended to give our customers basic information regarding the design, installation and operation of PC Pump Products & Services pumps. It is not intended to be a complete source of information on these matters. The customer is responsible for using this information in a correct and safe manner. For assistance, contact your nearest Weatherford representative. The operation of any Weatherford PC pump beyond the parameters outlined in this manual without factory approval may be damaging to the equipment and/or personnel in which case Weatherford Canada Partnership cannot accept any responsibility whatsoever and disclaims all liability thereof.

PC Drive Manual

Table of Contents Progressing Cavity Drive General Information Introduction

Pg. 1-2

Input Data Sheet

Pg. 3

Drivehead Design Considerations

Pg. 4

Surface Equipment Design

Pg. 5

Drivehead Selection

Pg. 6

Drive Specifications Chart

Pg. 7-8

Drive Installation Procedures (for all Drives)

Pg. 9

Special Drive Installation Instructions for Slant Wells

Pg. 10

Polished Rod Clamp Installation Procedures

Pg. 10

Drivehead Start-up Procedures

Pg. 11

Drivehead Shut-down Procedures

Pg. 12

Safe Operation of Wellhead Drives

Pg. 13

Motor and Sheave Ratio Limitations

Pg. 14-15

Belt and Sheave Selection Considerations

Pg. 16

Torque/Horsepower/Speed Relations

Pg. 17

Statement of Manufacturing and Inspection

Pg. 18

Weatherford Canada Partnership Warranty

Pg. 19

Appendix A: Definitions

Pg. 20

Appendix B: Unit Conversions and Equivalents

Pg. 21

Appendix C: Rules of Thumb

Pg. 22

Appendix D: Useful Formulas

Pg. 23-24

Appendix E: Prime Mover Specifications

Pg. 25

Appendix F: Sucker Rod Specifications

Pg. 26

Appendix G: Viscosity - Temperature Charts

Pg. 27-28

®

Introduction A. Typical Progressing Cavity Pump and Drive Installation The two major components of the PC Pump System are illustrated as follows. These are: 1. Wellhead Drive Assembly 2. Downhole Pump (Rotor and Stator)

Driven Sheave

Drive Sheave

17

Equipment List 1. Torque Anchor/No-Turn Tool

11. Polished/Sucker Rod Change Over Coupling

2. Tag-bar Sub (part of Stator)

12. Polished Rod

3. Rotor

13. Stuffing Box/Pin Plate Wellhead Connection

4. Stator (includes Tag-Bar sub)

14. Booth Guard

5. Rotor/Sucker Rod Change Over Coupling

15. Drive Head

6. Tubing Pup-Joint

16. Electric Motor or Hydraulic Motor

7. Stator Thread to Tubing Thread Change-Over

17. Belts and Sheaves

8. Sucker Rods

18. Polished Rod Guard

9. Sucker Rod Couplings

19. Remote Tachometer

10. Rod Guides

1

18

16

15

19 14 13

12 11 10 9 8 7 6 5 4 3 Production Zone

2

Typical Progressing Cavity Pump Set-up

1

2

®

Input Data Sheet We offer the ability to predict all elements of a Downhole Progressing Cavity Pumping System including differential pressure, estimated pump speed, polished rod drive torque and total input power required for any given set of well parameters. From this information it is possible to correctly select the bottom hole pump based on volume and lift capabilities, sucker rod diameter and grade, prime mover horsepower and surface drive type most suitable for your application.

®

Company Name:

Country:

Date:

Contact:

E-mail:

Phone:

Well Name:

Fax:

Location:

WELL DATA



Total Depth:

Ft - m

Current Production:

Bfpd - M3pd

Mid-point of Perforations:

Ft - m

Desired Production:

Bfpd - M3pd


Ft - m

Water Cut:

TMD:

Ft - m

Abrasive Cut:

% % Scf/Bbl - M3/M3

Gas/Oil Ratio:

Producing Fluid Level From Surface (TVD) Current:

Ft - m

Projected:

Ft - m


˚F - ˚C

Cp@

˚F - ˚C


Flowline Pressure:

Psi - Kpa

Oil Gravity:

Casing Pressure:

Psi - Kpa

Water Gravity:

Water Salinity:

Casing size:

Psi - Kpa

C02:

Ppm%

Tubing Size:

Inches -mm


˚F - ˚C

Inches -mm

Bottom Hole Temperature:

˚F - ˚C

Rod Size & Grade: Coupling

❏

Slimhole

❏

Standard

❏

˚API

Cp@

H2S:

Ppm%


IPR DATA Static Reservoir Pressure:

Psi - Kpa

SURFACE EQUIPMENT


Psi - Kpa

Primer Mover Type:

Gas

Surface Drive:

Direct

Test Point #1

Test Point #2

Producing Pressure:


Fluid Rate (Bfpd-m pd): 3

Bbl/Psi - M /Kpa


To Receive this Data Information Sheet please contact your local Weatherford Distributor. For an electronic copy please contact us at weatherford.com (May not be the same version, a general one for all types of lift will be)

3

Electric Hydraulic

Hz Line Voltage:

Specify Flow-Tee to Drive Head Connection:

3

Productivity Index:

❏ ❏

❏ ❏

Volts

Drivehead Design Considerations* When purchasing a PC pumping unit, the design considerations play an important role in the safe operations of the unit. The application designer must establish the maximum surface loading and ensure the equipment being purchased will operate within its maximum limit. The loading or work done by a PC pumping system is primarily determined by the following: • Pump intake pressure • Pump discharge pressure • Rod string/tubing friction • Internal pump friction Several other factors influence these parameters and they usually change throughout the life of an oil well. Other factors may include: • Fluid contaminants • Pressure, volume, temperature properties of the production medium, reservoir characteristics, tubing roughness • Side wall stress as a result of tubing/rod contact • Tubing and casing pressure fluctuations • Interference pump fit between rotor/stator Computer aided software tools are available to help determine these factors. Calculations must be made before purchasing a unit. When predicting load limits, a safety factor of at least 10 percent should be considered to account for error associated with the reliability of assumptions or the accuracy of mathematical correlations. Operating loads may change through the operating cycle life. After the initial start up, actual operating loads should be confirmed to verify design expectations. If the system loading exceeds the design, changes to operating parameters or equipment are necessary. Control devices that will protect the unsupervised system and provide the operator with an indication of equipment condition are equally important. The PC drive systems could include instrumentation to monitor and control the following: braking mechanism temperature, backspin speed, operating torque, and hydraulic fluid levels. 1. The following items are recommended best practices outlined to reduce hazards while working around PC pumping equipment. Production personnel should consider: All new installations require a design input data sheet be filled out, ensuring that a qualified person within the producing company has reviewed the design of the unit being installed.

A file should be maintained for each PC pump system in the field. The file should include the following information: a) Equipment Specifications Equipment specifications should include the maximum allowable: forward speed, backspin speed, drivehead fluid temperature, hydraulic fluid levels, pressures, braking mechanism temperature, horsepower/torque, thrust loading, and motor fan speed. It should also include the power factor and motor efficiency, nameplate volt/amps and motor speed. b) Sheave and Belt Information Sheave dimensions, belt types and sizes, maximum rated sheave rpm. c) Sizing Data Normal operating horsepower at the motor, start-up horsepower requirements and torque, normal operating torques and operating speed, production volumes, bottom hole flowing pressure, static reservoir pressure, maximum tubing head pressure, and thrust loading. d) Commissioning/Start-up Measurements Start-up values at design speed such as: starting volts/amps, running volt/amps, calculated starting and running horsepower and torque, forward and backspin rpm hydraulic fluid level, braking mechanism temperature, production volumes, annular fluid level data, and polished rod stick up amount. e) Limit Set Points -Control Devices (if applicable) Shut down settings for the following: hydraulic drivehead fluid levels, maximum braking temperature, backspin speed, forward speed, running torque, start-up torque and low torque shutdown. f) Equipment/Operating Changes A list of any changes to operating parameters or equipment. After changes are made, the operator must ensure the system is still operating within the design parameters. 2. The operator must ensure that the equipment is operating within its design after every PC workover. 3. The production operator should review the design predictives to ensure the equipment will operate within the calculated parameters. 4. The operator must be familiar with the limit shutdowns for the equipment. The operator can refer to the operator's manual for these maximum limit values. 5. The actual loads should be checked at least every 6 months to ensure the operating loads fall within the design parameters. 6. For right angle drive assemblies, the drive assembly should be installed perpendicular to the control panel to ensure that in the event of a sheave failure, debris would be deflected away from personnel standing at the control panel. Caution must also be used in the placement of other equipment on the lease, to ensure that a sheave failure would not adversely effect other equipment or personnel.

*reprinted from Canadian Association of Petroleum Producers(CAPP) Safety Alert Guide

4

®

Surface Equipment Design Progressing cavity pumping systems are extremely flexible in terms of their ability to work in a diverse range of applications. However, their success in a particular application requires that the pumping equipment be properly matched to the well conditions and operating environment. Because PC pumping systems function in an integrated manner, it is also important that the individual pieces of equipment are configured so that they operate together effectively as a system. These wellhead drive manuals should be used in conjunction with the Weatherford PC Pump Manuals in order to design the optimum PC system for your application. There are generally 4 applications where PC pumping systems are utilized: 1.Heavy Oil 2.Coalbed Methane Dewatering 3.Medium Crude Oil 4.Light Crude Oil The following descriptions characterize each of these applications: Heavy Oil - Gravity usually less than 18 API (specific gravity heavier than 945 kg/m3) - High viscosity oil (dead oil viscosities range from 500 to 15,000 cp and occasionally up to 30,000 or 40,000 cp) - Shallow reservoirs usually between 300 and 900 m deep - Low to moderate production rates of 1 to 70 m3/day - Typically low gas oil ratios - Sand production from a trace to 30% and occasionally higher Coalbed Methane Dewatering - Completion depths vary from 400 to 1200m - Typical produced water rates vary from near zero to greater than 400 m3/day - Pump speeds of 300 to 500 rpm are common - Can produce substantial quantities of gas - The produced water often contains high concentrations of suspended sand Medium Crude Oil - Gravity between 18 and 30 API (specific gravity between 875 and 945 kg/m3) - Low viscosity, usually less than 500 cp - Wells are between 600 and 1000 m deep - Fluid production rates from 50 to 500 m3/day - Pumps may be required to turn as fast as 600 rpm or higher - Higher gas oil ratios than heavy oil - Often water cuts are high (up to and exceeding 95%) - Sand production can vary from 0 to 1% Light Crude Oil - 30 API oil or higher (specific gravity less than 875 kg/m3) - Viscosity usually less than 20 cp - Oil reservoir normally deeper than 1000 m - Production fluid rates from 50 to 500 m3/day - Speeds as high as 600 rpm - Normally high water cuts and minimal to 0% sand

5

Drivehead Selection In order to choose the best drive for the application the following should be considered: -

Depth of well Fluid level Pump size Size of sucker rods, polished rod and tubing connection Operating torque Desired speed range Prime mover (electric or gas driven motor or engine)

Weatherford PC Pump currently manufactures 13 types of wellhead drives to match the various applications encountered by progressing cavity pumping systems. Essentially, any or all of the 13 drives can and are used in each of the 4 applications itemized on page 5, but each one is designed with a different purpose in mind. These are summarized below. HTD and HTD-I, Inline and Inline-I - ideal for applications requiring precise torque control and adjustable wellhead speed - can operate with gas or electric prime mover - these hydraulic drives can be manufactured to meet most every PC situation M2 and M2-I - a 2:1 right angle gearbox designed for medium horsepower applications - generally used in lower speed situations - primarily sold as an electrically driven direct drive unit but can be constructed as a gas or hydraulically driven unit. M3 - a direct drive (1:1) designed for higher horsepower applications - generally used in deeper wells or with larger pumps where braking requirements are more severe - primarily sold as an electrically driven direct drive unit but can be constructed as a hydraulically driven unit. M4 and M4-I - a direct drive (1:1) designed for medium horsepower applications - primarily sold as an electrically driven direct drive unit but can be constructed as a hydraulically driven unit. MC4 and MC4-I - a direct drive (1:1) designed for low horsepower applications - primarily sold as an electrically driven direct drive unit but can be constructed as a hydraulically driven unit. MG and MG-I - a direct drive (1:1) designed for higher horsepower applications - generally used in deeper wells or with larger pumps where braking requirements are more severe - primarily sold as an electrically driven direct drive unit but can be constructed as a hydraulically driven unit. These are only guidelines. For more information please refer to the "Drive Specifications Table" on Pages 7 and 8 which itemizes the limits of all drives. Specific manuals for the various types of drives are also available. They include detailed information on each drive such as: -

Motor and sheave ratio limitations Brake operation Optional equipment Maintenance Troubleshooting

To determine the optimum drive for your particular application please contact your nearest Weatherford Technical or Sales Representative.

6

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M2, M3, M4, MC4, MG, HTD and In-line Drive DRIVE NAME / MODEL

M2, M2-I

M313

M4, M4-I

Drive Type Drive Ratio Drive Style Input Shaft Shaft Type Ratings Maximum Input Polish Rod Torque (ft-lbs) Thrust Bearing - ISO Rating (lbs) - Ca90 Rating (lbs)1 Maximum Polished Rod Speed (rpm) Maximum Motor Size (hp) (single motor)2 Polished Rod Size (in) Maximum Suggested Temperature (Component-Temperature) Dimensions & Weights (excluding motor) Height (in) Input Shaft Size (in) Drive/Frame Weight (lbs) Backspin control

Direct Drive 2:1 gear box right angle hollow shaft

Direct Drive 1:1 bearing box vertical hollow shaft


12506 129,0007, 8 33,5007, 8 600 60 1 1/4 or 1 1/29 Disk-215˚C

2000 129,0007 33,5007 600 12510 1 1/4 or 1 1/29 Clutch Housing-100˚C

2000 129,000 33,500 600 60 1 1/4 or 1 1/29 Disk-215˚C

49, 35 2 3/4 1290, 1250 automatic external caliper and disc brake8 2 7/8" pin or 3 1/8" 3000 psi flange gas, electric or hydraulic 30 14 4.9

60 2 3/4 1580 automatic water/glycolcooled disc brake 2 7/8" pin or 3 1/8" 3000 psi flange electric or hydraulic 30 14 4.9

53, 39 2 3/4 1120, 1090 automatic external caliper and disc brake 2 7/8" pin or 3 1/8" 3000 psi flange electric or hydraulic 30 14 4.9

API Wellhead Connection

Prime Mover Driven Sheave Maximum Diameter (in) Drive Sheave Maximum Diameter (in)3 Drive Sheave Minimum Diameter (in)4 Drive Belt Type

V-Belts or Synchronous Belts/Sprockets

Max. Number of Belts

Minimum Center Distance (in)5

21 3/8" - 32 15/16" (depends on motor size)

7

4 ea Type C 6 ea Type 5V 115mm Synchronous 90mm Powerchain standard motor mount rails 15.5"+D 3" motor mount rails 16.5"+D

Specifications 1

MC4, MC4- I

MG, MG-I

HTD, HTD- I

Inline, Inline- I



Hydraulic 1:1 bearing box vertical hollow shaft

Hydraulic 1:1 bearing box vertical hollow shaft

1500 129,000 33,500 600 60 1 1/4 Disc -215˚C 53, 39 2 3/4 850, 800 automatic external caliper and disc brake 2 7/8" pin or 3 1/8" 3000 psi Flange electric or hydraulic 30 11.5 4.9

2000 194,000 50,300 600 125 1 1/4 or 1 1/29 Seal -110˚C 64, 48 2 3/4 1780, 1600 centrifugal braking system 2 7/8" pin or 3 1/8" 3000 psi Flange electric or hydraulic 30 14 4.9

V-Belts or Synchronous Belts/Sprockets 6 ea Type C 8 ea Type 5V 115mm Synchronous 120mm Powerchain 19 1/2" - 24 1/2" 25" - 31" (depends on motor size) (depends on motor size)

1347 11 100,000 25,900 740 12 N/A 1 1/4 Seal-110˚C 14

1554 11 100,000 25,900 369 N/A 1 1/4 90˚C

56, 25 2 1/2, 2 3/4 688, 600 hydraulic fixed orifice restriction brake 2 7/8" pin or 3 1/8" 3000 psi Flange hydraulic 24 9 4.9 Wood's HPR or QT or equivalent

50, 33 N/A 672,492 hydraulic fixed orifice restriction brake 2 7/8" pin or 3 1/8" 3000 psi Flange hydraulic N/A N/A N/A

1

N/A

N/A

N/A

NOTE: Maximum ratings are individual specs. Maximum torque, hp, and speed cannot occur simultaneously.

8

N/A

Ca90 load rating is for 90 million revolutions. Reducing load by one half increases life ten times. Reducing the RPM by one half doubles the hours of life. 2 Maximum HP is based upon frame size only. Care must be taken in selecting motor and sheave combinations to ensure input rod torque is never exceeded.

3

Maximum sheave diameter depends on motor size. Smaller motors can accommodate larger drive sheaves.

4

There are NEMA minimum recommended sheave sizes on motors. Ensure that the top bearing in your motor can handle the additional overhung load that results from using smaller sheaves.

5

D = Distance from the base of selected motor to its centerline.

6

Allowable rated gear torque is 1350 ft.lbs. Rated gear torque is 1650 ft.lbs.

7

Capable of supporting an Extra Capacity (E/C) thrust bearing (ISO 194,000 lbs, Ca90 50,300 lbs.) eg. M3 E/C.

8

When an Extra Capacity (E/C) bearing is used, the water/glycol cooled disc brake backspin control system is used and the integral stuffing box option is not available..

9

1 1/2" Polished rod not available with integral rotating stuffing box.

10

Maximum HP limited by NEMA frame size (405T).

11

Various torques are available depending on which hydraulic pump and motor are used.

12

740 rpm only available with F11-58 hydraulic motor and Vickers PVH98 hydraulic pump. See brochure for more details.

13

M3 drives are not available with integral rotating stuffing boxes.

14

This limitation applies to the drivehead only. Ensure that the maximum operating temperatures for the hydraulic motor and pump are not exceeded. Refer to the Weatherford Hydraulic Drive Operators Manual for individual motor and pump maximum operating temperatures.

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Drive Installation Procedures (for all Drives): Do not lift wellhead drive by the sheave. Use lifting hook on the guard or frame.

With the rod string and polished rod installed and supported from the flow tee, follow this procedure: 1.

Pump a few shots of grease into the wellhead drive stuffing box.

2.

File off burrs and rough spots on the polished rod or you may damage the bushings in the drive shaft.

3.

Apply lubricating oil on the polished rod to clean and lubricate it. This important step will prevent the polished rod from being caught in the tight tolerances of the shaft and stuffing box. Never leave pipe wrench marks on polished rods.

4.

Place the wellhead drive onto the polished rod with a picker truck or a winch line. Use a polished rod alignment tool (bullet) to keep threads from damaging stuffing box packing.

5.

If the polished rod does not go through the stuffing box easily: On conventional stuffing boxes - loosen the cap, then the three allen screws (1/4") holding the top brass to the stuffing box and try again - tighten the top brass to the stuffing box cap after the polished rod is installed On retrofit stuffing boxes - loosen the cap On integral stuffing boxes - lift drive and reset, catching on seals in top of shaft

6.

Remove the polished rod alignment tool and install the polished rod clamp then a pony rod.

7.

Support the wellhead drive with the picker truck or winch line.

8.

Support the rod string weight from the pony rod using elevators, and remove the polished rod clamp that was supporting the rod weight.

9.

Connect the wellhead drive to the flow tee with a hammer union or directly with flange mount. Ensure proper alignment of the drive to the flow tee to avoid premature wear of drive components. Tighten all wellhead fittings to maximum torque specifications. Remove the picker truck or the winch line.

10. Tighten the polished rod clamp on the polished rod. Do not leave more than one foot of polished rod sticking up above the wellhead drive. Longer stickup presents a safety hazard in the event of high speed backspin. Some stickup is necessary to be able to grasp the polished rod with the elevator when pulling the rod string. Remove the pony rod and attach a rod coupling. 11. On the M3 drive, install the lower polished rod clamp. The clamp must be fully engaged with the main shaft and the bolts must be torqued to 240lb-ft. to ensure proper braking. 12. Tightly wrap the safety chain on the wellhead frame around the flow tee to prevent the wellhead drive from backing off. Safety chain not required with flange mount. 13. Grease the conventional style stuffing box prior to startup. Do not grease the rotating or integral stuffing boxes at time of installation. Refer to the Weatherford Stuffing Box Operators Manual for maintenance procedures and installation procedures of the three stuffing boxes available. 14. Check and tighten all nuts and bolts on the wellhead drive and check and tighten belt tension. 15. Turn power back on to the site, and start the drive.

9

Special Drive Installation Instructions for Slant Wells 1. When installing the M2, M3, and M4 drives on slant wells, the electric motor should be oriented above the drive (as shown to the right). This ensures that the hydraulic fluid reservoir is above the control manifold and hydraulic pump. This orientation will provide sufficient suction pressure in the pump to keep the hydraulic system fully charged. 2. When pulling up on the polished rod, a number of precautions must be taken to avoid damaging the drive shaft and polished rod: • Ensure that there are no wrench marks on the polished rods. • Use a polished rod alignment tool on the polished rod to help guide it through the shaft. • Align the rig carefully with the drive before pulling up on the polished rod. • Support the rod as it is withdrawn from the well so that it does not deflect and drag on the shaft. • Withdraw the polished rod slowly from the drive. • Lubricate the polished rod with grease or lube oil when pulling it up. 3. A support system should be used to stabilize the drive. Support arms are available should the drive need to be stabilized. A support structure will prevent movement that may cause the stuffing boxes to leak unnecessarily.

Polished Rod Clamp Installation Procedures Once the drivehead has been installed on the wellhead the polished rod clamp must be secured to the mainshaft and polished rod. 1. 2.

3. 4. 5. 6.

Place the polished rod clamp on the mainshaft ensuring that the slot on the bottom of the clamp is aligned with the mainshaft. Install the nuts and bolts into the clamp and tighten loosely. Bolts 1, 2 and 3 should have the nuts showing and bolts 4, 5 and 6 should have the bolt head showing. The bolts for the clamp should be tightened in the sequence numbered above. Evenly tighten bolts 1, 2 and 3. (ie do not tighten bolt 1 all the way then move on to bolt 2) Evenly tighten bolts 4, 5 and 6. (ie do not tighten bolt 4 all the way then move on to bolt 5) Once all the bolts have been installed ensure that they have been tightened to 250 ft-lbs.

10

Polished Rod Clamp

3/4" x 4" Structural Bolts

Drive Mainshaft

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Drivehead Start-up Procedures 1. Approach the lease with caution taking note of any surrounding wells that are operating. It is recommended that prior to start-up you establish a barrier between yourself and the drive head. It is also good operating practice to account for all personnel on the lease and ensure that they are sufficiently clear prior to well start-up. 2. If for any reason you feel that conditions are unsafe, do not approach the wellhead, and call your supervisor for assistance. 3. Ensure that the polished rod clamp is adequately tightened, all guards are in place and properly attached and that the stuffing box is not over tightened. 4. Ensure that someone else knows that you will be performing a startup procedure, specifically well location and time. 5. Any startup is to be performed only by experienced, competently trained personnel. 6. Make all personnel on site aware of potential hazards and safety concerns. 7. Ensure rotation indicator is installed on polished rod to indicate rod spin and direction. It is important that the indicator cannot be dislodged and act as a projectile in the event of an uncontrolled backspin. 8. In any circumstance, the maximum polished rod stick up shall not exceed 30 cm (12 inches). No pony rods shall be attached above the polished rod, even if under the stick up limit. 9. Check that all flowline, casing, tubing and drive head components are set correctly and are ready for operation. 10. On driveheads with the M3 liquid cooled braking system ensure that the lower polished rod brake clamp is engaged securely to the shaft and that the bolts are tightened to 240 ft-lbs. 11. For hydraulic skids and drives: • Start the gas engine or electric motor making sure the stop/run valve is in the stop position and ensure that all lines are coupled to the wellhead drive. • To start rotation of the wellhead drive, move the stop/run valve to the run position slowly; watching the hydraulic gauge and preparing to shut the unit down if torque up is indicated. If excessive rod torque is noticed shut the unit down and inspect the surface equipment and ensure that there are no downhole problems. 12. For wells equipped with VFD (Variable Frequency Drive): • Turn on/off switch to off position then turn on main breaker • Verify shut down parameters are set • Turn VFD switch to zero frequency or minimum RPM • Set for normal operating mode with external shut down enabled • Set the panel for amperage display to indicate torque and ensure that all safety shutdowns are properly set • Turn unit "ON". 13. From the electrical panel only, start the drive for the test period listed below and then turn it off. Watch for any unusual noises or vibrations as well as excessive backspin. If no problems are encountered, start-up the drive again and leave it running. Operating Speed < 100 RPM 100 to 300 RPM 300 to 500 RPM

Test Period 15 seconds 7 seconds 3 seconds

14. For driveheads equipped with a test on the fly, conduct a check of the brake system as outlined on pages 12 and 13 of the Direct Drive Operators Manual. 15. 16. 17. 18. 19.

Warning: Excessive restarts may cause over heating of braking or oil system, which may create a hazardous situation. Check and adjust the flow line high pressure shutdown (eg., Presco) as required until the desired shut down level is established. Check that all pressures are normal and there are no fluid leaks. Ensure that the stuffing box is operating correctly. Refer to the Stuffing Box Manual for the correct operating conditions. Advise appropriate personnel that you have completed your startup and that you are leaving the location.

11

Drivehead Shut-down Procedures 1. Be familiar with well history, speeds, production, amperage and recent workovers. 2. Ensure the well lease, drivehead and wellhead are kept clean. Approach the lease with caution, including a visual inspection. If for any reason you feel that conditions are unsafe, do not approach the wellhead, and call your supervisor for assistance. 3. Ensure that someone else knows that you will be performing a shutdown procedure, specifying well location and time. Minimize personnel on lease. 4. Make all personnel on site aware of potential hazards and safety concerns. 5. Approach the well with caution, including a visual inspection; note the rotation of the reflector tape. Listen for any abnormal operating noises. If for any reason you feel conditions are unsafe, do not approach the wellhead. Call for assistance. 6. If provisions have not been made for control of backspin a protective barrier must be made available in the near proximity of the control panel while performing the shut down procedure. Account for all personnel on the lease, and ensure that they are sufficiently clear prior to well shutdown. If the brake is non-functional then follow the manual lockout procedures outlined on pages 14 and 15 of the Direct Drive Operators Manual. 7. Conduct the following checks: • Surface wellhead pressures • Motor amperage (note if amperage readings are higher than normal expect high backspin speeds) • Oil level in the site glass 8. Turn drive off at master control panel and observe braking performance. If the well is equipped with a VFD, use it to gradually slow the unit down to minimum speed prior to shutting down the drive unit. 9. While shielded, observe for abnormal backspin. Note if brake is engaging and rate of decreasing backspin speed. 10. Do not approach the wellhead until backspin has come to a complete stop. Shut off and lock out the breaker on the main control panel before performing well service operations. 11. For systems with adjustable orifices, when the rod string has come to rest, mark the positioning of the orifice valve. Next open the orifice valve to ensure the rod string is at equilibrium. Return the valve to its original setpoint. 12. For hydraulic skids and drives: • Shut down by turning the stop/run valve slowly to the stop position, watch the polished rod for backspin that is normal and controlled. If abnormal, contact supervisor for assistance. • Lock out the circuit breaker and tag at MCC (Motor Control Centre) or shut down gas engine. 13. After a drivehead has been shut down and backspin stops, there is still potential for additional recoil. This additional recoil is caused by the fluid in the tubing equalizing with the fluid in the casing. 14. Follow manufacturers recommended polished rod clamp lockout procedures to prevent any further backspin prior to and during servicing/maintenance.

12

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Safe Operation of Wellhead Drives When undergoing a controlled or uncontrolled shut down of a Progressing Cavity Pumping System, it is critical to understand that the recoil speed, if left unrestricted, can exceed the surface drive component (brake/belts/sheaves) ratings and cause that component to fail. The worst type of failure from a personal safety standpoint is to exceed the rim speed of the sheaves causing the sheaves to explode. Remember that the recoil control unit of any surface drive should be considered as a safety device to control the release of torque from the rod string during shut down, but it is not the only means of safe operation. For improved overall safety in operation and shut down of Progressing Cavity Surface Drive systems the following steps should be considered.

Properly designed surface equipment • • • • •

Do not exceed manufacturers recommended specifications for torque and speed ratings Design the belts and sheaves for the prime mover horsepower using correct safety factor Use sheaves that are in new condition only Use a straight polished rod with minimum stick up Use PC Pump polished rod clamps only (not conventional clamps)

Improved stability of the surface drive in higher torque/speed applications •

Flange mount drives

Limit the input torque to the polished rod • •

Maximum input torque should not exceed the surface drive ratings Maximum torque generated by an electric motor can be as high as 250% of the rated torque so a high amp shut down must be properly set

Surface drive preventative maintenance •

During every oil change (every 3 to 6 months - depending on the application) -ensure the belts are not worn or loose, including small hydraulic belt -ensure the sheaves are not cracked or damaged -check and tighten all nuts and bolts on the motor support frames and belt guard -inspect the gear box or bearing box and brake system and repair as required every 6 - 12 months depending on the application.

13

Motor and Sheave Ratio Limitations Weatherford PC Pump has recently made the decision to be more thoroughly involved in the application of PC Pump driveheads for a number of reasons. History shows that throughout the industry most of the serious incidents with any PC Pump driveheads have occurred when the pump is seized downhole and the PC Pumping system has been torqued up in an attempt to free the pump. In a direct electric application, this input torque is typically limited only by the maximum horsepower the motor can deliver and the rod strings ability to transmit torque down to the pump. Unknown to most operators is the fact that all electric motors have the ability to deliver over 250% of the full load nameplate horsepower. This potential applied torque can far exceed the published structural and braking limits of the drivehead. In new installations, the best way to limit the maximum torque input is to restrict the motor size and sheave ratio in order to limit the maximum torque that can potentially be applied. The graphs on page 14 have been prepared to illustrate safe operating limits, and define where there is a potential problem with applying excessive torque to the system. By using the relevant graph, for a chosen drivehead model and comparing the sheave ratio versus connected horsepower for any given application the operation of the PC pump system will be as follows: • In the Light Grey area the PC Pumping System is inherently safe. It is not possible to apply more torque than the recommended maximum input torque with the equipment specified. • In the White Zone operation should be carefully considered. If the motor was operated at its extreme torque limit (potentially 250% of nameplate rated horsepower) such as to free a stuck pump during startup, it may be possible to exceed the recommended load rating of the drivehead.

Applying any Weatherford Surface Drivehead with a sheave/horsepower combination that falls within the White zone, or Dark Grey zone of the relevant curve does not mean that the combination can not be used. What is being illustrated is that under certain circumstances the potential exists for a recoil event to occur where the stored energy in the rod string and the fluid column may be greater than the drivehead is designed to control. This potential is based on the sheave ratio and the connected horsepower in direct electric motor applications and the ability of the drivehead recoil control device to safely handle the recoil. When operating any PC Pumping system in the White zone or Dark Grey zone it is recommended that some type of accurate torque limiting device be utilized. This torque control can be in one of several forms. 1.

A vector drive controller, such as the Northlander, with the torque limits set properly. It is important to remember that not all VFD's are the vector type, a scalar drive will not provide accurate torque control. Torque limits on the vector drive must not be adjusted upwards to free a stuck pump. Damage to equipment may result.

2.

A Weatherford torque limiting device, such as the M-1, that uses motor power and not motor current to control torque. Reading motor current, or using motor heaters are not accurate, or fast enough to protect the user.

Once the proper drive has been selected and installed, they need to be maintained. It is imperative that the manufacturer's maintenance procedures be followed, including routine oil changes and checks of the recoil control device performance.

• In the Darker Grey Zone operation is potentially dangerous unless an acceptable torque-limiting device is used. Without such a device, it is likely that the load rating of the system can be exceeded.

14

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Motor and Sheave Ratio Limitations for M2 Driveheads 6

Sheave Ratios

5 4 3 2 1 0 0

10

20

30

40

50

60

70

80

90

100

Electric Motor Horse Power Electric Motor and Sheave Ratio Limitations for MC4 Driveheads 6

Sheave Ratios

5 4 3 2 1 0 0

10

20

30

40

50

60

70

80

90

100

Electric Motor Horse Power LIGHT GREY ZONE

Safe Operating Range

Motor and Sheave Ratio Limitations for M3, M4 & MG Driveheads 6

WHITE ZONE

Limited Operating Range

DARK GREY ZONE

This area of the operating range is safe only if an approved torque limiting device is used.

Sheave Ratios

5 4 3 2 1 0 0

10

20

30

40

50

60

70

Motor Horse Power

15

80

90

100

Belt and Sheave Selection Considerations A variety of sizes, styles and lengths of belts and sheaves are available. Due to the numerous alternatives and complexity of selecting the correct belts and sheaves it is recommended that the procedure in a Power Transmission Products Manual be followed, or contact your nearest Weatherford Technical or Sales Representative to ensure your needs are met. The following is a simplistic example of the steps necessary to select the right belt and sheave combination for your application: 1. Determine The Size And Speed Of Electric Motor • Estimate the desired polished rod speed and maximum torque the system will operate under. • From Table on page 17 "Torque/HP/Speed Relations", select the electric motor that best meets the aforementioned speed and torque. • Example - Desired speed of 200 rpm and a maximum torque of 900 ft lbs • From table, a 40hp, 1200 rpm, 460 volt, 60 hz, 3-phase motor produces 175 ft lbs of torque at full load ratings. To develop a polished rod speed of 200 rpm a 6:1 sheave ratio is required (1200/200). This assumes a 1:1 drive ratio drive. With a 6:1 sheave ratio; 1050 ft. lbs (175 x 6) of torque can be applied to the polished rod (assuming the belts and sheaves will transfer it). Torque will vary with changes to line voltage, line current, and line frequency. With the addition of a Variable Frequency Drive (VFD) motor speeds can be increased 50% and then the maximum polished rod speed becomes 300 rpm in this example. Note that motor torque decreases as motor frequency increases above rated speed.

3. Belt Selection There are various styles and sizes of V-belts available for PC pumping systems. These include: • classical, sizes "A", "B", "C" and "D" • narrow, sizes "3V", "5V", and "8V" • joined or banded • wrapped • cogged In our example, with a small driver sheave of 5" the amount of "rubber on the sheave" is limited and a cogged belt will transfer more power than the other styles. • Using a Power Transmission Products Manual the horsepower each belt transfers can be determined; and knowing the Horsepower requirements, calculating the number of belts is simple. Ensure that the combined horsepower rating of all the V-belts exceeds the design horsepower of the system. • If the amount of power transferred by V-belts is a concern then a high Torque Drive (HTD) belt and corresponding sprockets are recommended. This combination provides a positive slip-proof engagement when the belt teeth mesh with the sprocket grooves.

2. Sheave Selection • The Drivehead Specification Table on pages 7 and 8 indicates the sheave size limitations of the various drives. • A 6:1 ratio can be achieved with a 5" driver sheave and a 30" driven sheave (both sizes are within drive limitations). • The majority of sheave sizes are available with 1-4, or more grooves. • Sheaves are made with either cast iron or ductile iron. Cast iron has a maximum sheave rim velocity of 6500 ft/min. Depending on the situation; recoil speeds in excess of this can be reached. A spoked wheel ductile iron sheave is rated for a maximum RPM speed of 10,000 ft/min and a solid wheel ductile sheave for 15,000 ft/min.

16

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Torque/Horsepower/Speed Relations This chart may be used on any kind of drive - electric motor, hydraulic or air motor, engine, rotary actuator, etc., to find either the speed, torque, or horsepower of the drive if the other two values are known. The chart is a tabular solution to the basic formulae: To find HP: Use the formula: To find Torque: Use the formula: To find Speed: Use the formula:

HP = (T x RPM) / 5252 T = (HP x 5252) / RPM RPM = (HP x 5252) / T

In all formulae, torque is in foot pounds. Figures in the body of the chart are torque values in foot pounds

HP

100 RPM

500 RPM

750 RPM

1000 RPM

1200 RPM

1500 RPM

1800 RPM

2400 RPM

3000 RPM

3600 RPM

1/4

13.1

2.63

7.76

1.31

1.10

.876

,730

.548

.438

.365

1/3 1/2

17.5 26.3

3.50 5.25

2.34 3.50

1.75 2.63

1.46 2.20

1.17 1.75

.972 1.46

.730 1.10

.584 .875

.486 .730

3/4

39.4

7.87

5.24

3.94

3.28

2.62

2.18

1.64

1.31

1.09

1

52.5

10.5

7.0

5.25

4.38

3.50

2.92

2.19

1.75

1.47

1 1/2

78.8

15.7

10.5

7.88

6.56

5.26

4.38

3.28

2.63

2.19

2

105

21.0

14.0

10.5

8.76

7.0

5.84

4.38

3.50

2.92

3

158

31.5

21.0

15.8

13.1

10.5

8.76

6.57

5.25

4.38

5

263

52.5

35.0

26.3

22.0

17.5

14.6

11.0

8.75

7.30

7 1/2

394

78.8

53.2

39.4

32.8

26.6

21.8

16.4

13.1

10.9

10

525

105

70.0

52.5

43.8

35.0

29.2

21.9

17.5

14.6

15

788

158

105

78.8

65.6

52.6

43.8

32.8

26.5

21.9

20

1050

210

140

105

87.6

70.0

58.4

43.8

35.0

29.2

25

1313

263

175

131

110

87.7

73.0

54.8

43.8

36.5

30

1576

315

210

158

131

105

87.4

65.7

52.6

43.7

40

2100

420

280

210

175

140

116

87.5

70.0

58.2

50

2626

523

350

263

220

175

146

110

87.5

72.8

60

3131

630

420

315

262

210

175

131

105

87.4

75

3940

788

532

394

328

266

218

164

131

109

100

5250

1050

700

525

438

350

292

219

175

146

125

6570

1313

882

657

548

441

364

274

218

182

150

7880

1580

1050

788

656

526

438

328

265

219

200

10500

2100

1400

1050

876

700

584

438

350

292

250

13130

2630

1750

1310

1100

877

730

548

438

365

17

Statement of Manufacturing and Inspection Weatherford certifies that inspection and testing will be carried out in accordance with Weatherford Quality Assurance manuals and procedures. Weatherford is an authorized manufacturer of progressing cavity pumps and surface equipment and has in place a Quality Control Program in accordance with ISO 9002.

Formal written procedures, competent personnel, and sufficient inspection throughout all phases of the work establish the quality assurance program. Every effort is made to ensure prompt detection of non-conformances, and to ensure timely and effective corrective action is taken to prevent reoccurrence in the future.

18

M2,Pump M3, M4, MC4, MG and HTD Drive PC Products & Services Weatherford Canada Partnership DRIVE NAME / MODEL M3 M2, M2-I Warranty Drive Type Direct Drive Direct Drive

M4, M4-I

Direct Drive Drive Ratio 1:1 2:1 1:1 Drive Style bearing box box bearing box This shall be the only warranty given by PC Pump Productsgear & Services Weatherford Canada Partnership Input Shaft vertical ("Partnership"), and no other warranty by Partnership, express or implied, shall be applicable, including any vertical right angle implied of fitness purpose. Shaft Typewarrant of merchantability or any implied warranty hollow shaft hollow shaft for a particular hollow shaft Ratings Subject to the limitations and conditions herein, Partnership warrants its products (with the exception of rotating stuffing boxes) 6 Polish Rod Torqueand (ft-lbs) 2000(12) months from the 2000 toMaximum be free fromInput defects in workmanship material under normal use1250 and service for a period of twelve 7 7, 8 occurs first. Company date of installation eighteen months from the date of shipment, whichever warrants rotating stuffing Thrust Bearing -orISO Rating(18) (lbs) 129,000 129,000 129,000 7 7, 8and service for a period boxes to be free from-defects in workmanship use of three (3) months from 33,500 Ca90 Rating (lbs)1 and material under normal 33,500 33,500 the date of installation or nine (9) months from the date of shipment, whichever occurs first. Maximum Polished Rod Speed (rpm) 600 600 600 2 10 Maximum Motor Size under (hp) (single motor)shall be limited to repairing, 60 60replacing or issuing credit125 Partnership's obligations this warranty for, at Partnership's option, 9 any productRod or parts finds to be defective in material or workmanship. Partnership must be given a reasonable opportunity to Polished Sizeit(in) 1 1/4 or 1 1/2 1 1/4 or 1 1/29 1 1/4 or 1 1/2 investigate. Shipping and handling in connection with this warranty will be at customer's expense. Products sold by Partnership, Clutch Housing-100˚C Maximum Suggested Temperature (Component-Temperature) Disk-215˚C Disk-215˚C but manufactured by another company, will carry only the warranty of the manufacturer, and the customer will rely solely on that Dimensions & Weights (excluding motor) warranty. Services provided by Partnership are warranted for a period of ninety (90) days from the date the services are rendered. Height (in)of Partnership for any loss or damage resulting to the customer 49, 35 or user or any third party60from any defect in any 53, 39 The liability product or service will not, in any case, exceed the selling price that Partnership received from the customer for the product or Input Shaft Size (in) 2 3/4 2 3/4 2 3/4 service. The above shall (lbs) be the customer's exclusive remedy with respect to products or services. In no event will Partnership Drive/Frame Weight 1580 1290, 1250 1120, 1090 be liable for incidental, consequential, special, indirect or other damages of any nature. Backspin control automatic automatic automatic water/glycolexternal This warranty will not apply and will be void if the product fails as a result of down hole corrosion; non-compatibility of produced external fluid with the stator and/or rotor; general wear and abrasion; incorrect installation, removal, use or maintenance; cooled disc operation outside caliper and caliper and of the manufacturer's recommended guidelines; alteration; accident; abuse or 8negligence. Hydraulicbrake wellhead drives, hydraulic disc brake disc brake power transmission units or rotating stuffing boxes sold individually for use with equipment not manufactured by Partnership 2 7/8" pin or APIwillWellhead Connection 2 7/8" pin or 2 7/8" pin or not be covered under this warranty. 3 1/8" 3000 3 1/8" 3000 3 1/8" 3000 Partnership does not warrant that any of the products sold by it, if used or sold in combination with other equipment or used in psi flange psi flange psi flange the practice of methods or processes, will not, by virtue of such combination or use, infringe patents of other, and Partnership electric or hydraulic Prime Mover electric or hydraulic gas, elecric or hydraulic shall not be liable for any patent infringement arising from, or by reason of, any such use or sale. Furthermore, Partnership shall 30 Driven Sheave Maximum Diameter (in) 30 30 use or sale of any materials, equipment or products not be liable for any patent infringement arising from, or by reason of, any 3 14 goods specially made, Drive Maximum Diameteror(in) not Sheave of Partnership's manufacture for the use or sale of any materials,14 equipment or products, or other 14 4 in whole or in part, to the customer's design specifications. 4.9 Drive Sheave Minimum Diameter (in) 4.9 4.9 Drive Belt Type V-Belts or Synchronous Belts/Sprockets Max. Number of Belts



19

4 ea Type C 6 ea Type 5V 115mm Synchronous 90mm Powerchain standard motor mount rails 15.5"+D 3" motor mount rails 16.5"+D

Appendix A: Definitions PC-Pump Surface Drive

Applied Torque

prime mover to the rod string, transfers axial load from the rod string to a

drive.

The surface transfers rotational the Applied MC4, MC4-drive I is a machine which MG4, MGI power fromHTD, HTD-torque I is that applied to the top of the rod string by the surface

Direct Drive Hydraulic surfaceDrive foundation, and managesDirect stored energy during shutdown events. Safe Operating Torque 1:1String 1:1 1:1 Rod Safe Operating torque is that applied torque which will never result in an The rod string is a rod or series of rods capable of transferring torsion from unsafe operating condition. This value will be very low; specific applications bearing box bearing box bearing box the surface drive to the pump. The rod string typically reacts axial load from will permit assignment of a less conservative operating torque. vertical vertical vertical the pump to the surface drive. Backspin PC-Pump hollow shaft hollow shaft hollowBackspin shaft is the process by which the surface drive turns in the direction A progressing cavity pump is comprised of a stator and rotor. The geometry opposite to normal operation. Backspin is driven by the strain energy of the rod string and the differential fluid pressure across the pump. of the assembly is such that it constitutes two or more series of spiral, 11 separate inside the stator, the cavities move 1347 2000 cavities. When the rotor rotates2000 Stuck Pump Case spirally from one end of the stator the other, creating a positive displacement The stuck pump case describes one extreme of the possible conditions at 129,000 194,000 100,000 pumping action. shutdown. PC-Pump rotors sometimes become "stuck" in the stator and 33,500 50,300 25,900 Friction Brake become effectively locked together. The top of the rod string continues to 12 while the bottom stops, causing the rod string to further wind up as a turn A friction by applying a normal force to a 740 600 braking system reacts torque 600 torsional spring causing increased torque. When drive torque is removed, sliding surface creating drag. 60 125 varies backspin occurs. Hydraulic Brake 9 1 1/4 1 1/4 or 1 1/2 1 1/4 Fluid Dump Case A hydraulic braking system reacts torque by pumping liquid through an The fluid dump case describes most normal shutdowns where power to the orifice resulting in a pressure drop. Disk-215˚C Seal-110˚C Seal -110˚C surface drive is removed thereby allowing backspin. The differential fluid Electric Motor Brake pressure across the pump causes the rotor and rod string to rotate in the Electric motor brakes control the power to and/or from the electric prime direction 53, 39 56, 25 opposite to normal pumping, allowing fluid to flow from the 64, 48 mover during backspin to create a braking effect on the system. production tubing back through the pump. Backspin continues until torque Auxiliary 2 3/4 Equipment 2 1/2,resulting 2 3/4 from differential pressure across the pump equals friction torque 2 3/4 Auxiliary equipment is any component which can be changed by the end in the system. 850, 800 are sheaves, belts, 1780, 1600motor controllers, torque688, 600 user. Examples motors guards, Fluid Head limiting devices, and speed limitingcentrifugal devices. automatic hydraulic fixed Fluid head is pressure resulting from gravity acting on a column of fluid. Thrust Bearing external orifice braking Fluid head is used to describe the pressure differential between two fluid Device typically contained in the surface drive which reacts axial load from columns contributing to the total differential pressure across the pump caliper and restriction system the rod string while allowing it to rotate. which in turn produces torque. disc brake brake Torque Limiting Device Dynamic Fluid Level A torque system 2 7/8" pinlimiting or device prevents2the7/8" 2 7/8"Dynamic pin or fluid level is the distance from the wellhead to the top of the liquid pinfromorapplying torsion greater than a prescribed value to the rod string. Slow reaction time and dependence column in the annular space between the tubing and casing during normal 3 1/8" 3000temperature makes "heaters" 3 1/8"operation. 3000 3 1/8" 3000 on ambient in the electric power supply system unacceptable Acceptable devices will apply psi flange psi flange as torque limiting devices. psi flange Residual Fluid Head torque no greater than 110% of the torque limiter setpoint during a stuck Residual fluid head is the condition caused by friction in the PC-Pump, electricpump or hydraulic hydraulic electric or hydraulic event. torque generated by fluid pressure over the effective area of the 30 Capacity 24equaling 30 Energy pump, resulting in non-obvious presence of energy in the system which The energy capacity of a surface drive is14 a measure of the total work the 11.5 9may be released unexpectedly. brake can do over the expected duration of a shutdown event. For example, Tubing Head Pressure/Casing Head Pressure 4.9 4.9 4.9 a braking system which manages stored energy by absorption and not Tubing head pressure/casing head pressures are measured at the wellhead dissipation has a finite energy capacity defined by thermodynamic Wood's HPR or QT to the total differential pressure across the PC-Pump. and contribute characteristics and maximumBelts/Sprockets allowable operating temperature. A brake V-Belts or Synchronous Flow Losses which can dissipate energy as fast as it is generated by the shutdown or equivalent Flow losses refer to internal friction of moving fluids resulting in pressure process has an infinite energy capacity. 4 ea Type C loss. Strain Energy 6 ea Type 5V 1 Strain energy is the work potentially done by the elastic torsional deformation Mass Moment of Inertia 115mm Synchronous Mass moment of inertia is a measure of rotating equipment response to of the rod string. Strain energy is typically of smaller magnitude than the applied torque. fluid energy, but may be released much more quickly thereby placing 90mm Powerchain different requirements on the braking system. Dissipation Rate 19 1/2" - 24 1/2" 25" - 31" N/A Dissipation rate refers to the power transferred to the surroundings by the Fluid Energy (dependsWork on potentially motor size) (depends onthemotor size) done by gravity acting on fluid in the production system. braking system in the form of heat.


20

®

Appendix B: Unit Conversions and Equivalents

S.I.

S.I. to Imperial multiply by

Imperial to S.I. multiply by

Imperial

celsius degrees (°C)

1.800 + 32

0.5556 - 17.8

fahrenheit degrees (°F)

cubic metre (m3) cubic metre (m3)

6.29 0.03531

0.159 28.32

barrel (bbls) thousand cubic feet (mcf)

standard cubic metre gas per standard cubic metre oil

5.618

0.178

standard cubic foot gas per standard barrel oil (scf/STB)

kilogram (kg)

2.205

0.454

pound-mass (lbs)

kilogram-metre squared (kg•m2)

23.70

0.0422

pound-mass-per cubic foot (lbs/ft3)

kilogram per cubic metre (kg/m3)

0.0624

16.02

pound-mass per cubic foot (lbs/ft3)

kilojoule (kJ)

0.9479

1.055

British thermal unit (Btu)

kilonewton (kN)

0.2248

4.448

thousand pound-force (kip)

kilopascal (kPa)

0.145

6.895

pound-force per square inch (psi)

kilowatt (kW) litre (I)

1.341 0.220

0.7457 4.54

horsepower (hp) US gallon (g)

megapascal (MPa)

0.145

6.895

thousand pound-force per square inch (ksi)

metre (m)

3.281

0.3048

foot (ft)

millimetre (mm) Newton (N)

0.0394 0.2248

25.4 4.448

inch (in) pound-force (lbf)

Newton-metre (N•m)

0.7376

1.356

foot-pound (ft•lb)

21

Appendix C: Rules of Thumb 1. Gas Engines Fuel Consumption: Fuel

Heat Value

Fuel Consumption*

Liquid Propane

96,400 BTU/USG

2.5 USG per hp day

BTU/ft3

Ethane Gas

1,730

Methane Gas

962 BTU/ft3

140 ft3 per hp day 250 ft3 per hp day

* Assumes 10,000 BTU per hp hour @ 25% efficiency

Horsepower Derating: Altitude: 3% per 300 m above 150 m (3% per 1000 ft above 500 ft) Temperature: 2% per 5˚C above 30˚C (2% per 10˚F above 85˚F)

2. Electric Motor Power Consumption: 2.4 Amps per hp for 230 V (assuming three phase, sixty cycle current) 1.2 Amps per hp for 460V (assuming three phase, sixty cycle current)

3. Fluid Level Depression 0.7 m (2.3 ft) per psi of annulus pressure

4. Fresh Water Density 1000 kg/m3 = 62.43 lbs/ft3 = 9.80 kPa/m = 0.434 psi/ft

22

®

Appendix D: Useful Formulas 1. Fluid Rate

5. POWER (ELECTRICAL)

VNη volumetric Q=

P=

431.2

100

where:

I line Vηp

Q = Fluid Rate (m3/D) V = Pump Displacemnent (m3/D/100RPM) N = Pump Rotational Speed (RPM) η volumetric = Pump Volumetric Efficiency (%)

where:

P = Power (hp) I line = Line Current (amps) V = Line-to-Line Voltage (V) η = Motor Efficiency (%) p = Motor Power Factor

2. Pump Torque T=

VP net

+ T friction

124.6 where:

6. Fluid Density (based on API Gravity) T = Pump Torque (ft.lbs) V = Pump Displacement (m3/D/100RPM) Pnet = Net Lift (m of head) T friction = Pump Friction (ft.lbs)

ρ=

141.5 API +131.5

where: 3. Net Lift Pnet =

(P thp + P tbgliquid + P

tbglosses

7. Belt Length

P net = Net Lift (m Head) P thp = Tubing Head Pressure (kPa) P tbgliquid = TubingLiquid Column Pressure (kPa) P tbglosses = Tubing Flow Losses (kPa) P chp = Casing Head Pressure (kPa) P csggas = Casing Gas Column Pressure (kPa) P csgliquid = Casing Liquid Column Pressure (kPa)

L = 2C +

π(D + d) 2

where:

4. Power (mechanical) TN P= 5252 where:

ρ = Fluid Density (kg/m3) API = API Gravity

) - (P chp + P csggas + P csgliquid) 9.81

where:

x 1000

P = Power (hp) T = Torque (ft.lbs) N = Rotational Speed (RPM)

23

+

(D - d)2 4C

L = Belt Length (in) C = Center Distance (in) D = Driven (Large) Sheave Pitch Diameter (in) d = Driver (Small) Sheave Pitch Diameter (in)

12. Hydraulic Motor Speed Hydraulic Motor Speed (RPM) =

8. Sheave Rim Velocity V=

πDN

Flow (USgpm) x 231 Hydraulic Motor Displacement (in3)

12 where:

V = Sheave Rim Velocity (ft/min) D = Sheave Diameter (in) N = Sheave Rotational Speed (RPM)

13. Rod Speed Rod Speed = Hydraulic Motor Speed ÷ Drive Ratio

9. Polish Rod Speed

14. Viscosity Motor Sheave RPM x Motor Sheave Diameter Polish Rod RPM =

µ=

Drive Sheave Diameter Drive Ratio

γρ 1000

where:

Polish Rod RPM =

Production Rate (m3/d) Pump displacement (m3/d/RPM)

10. Hydraulic Motor Torque Hydraulic Motor Torque (ft.lbs) =

Hydraulic Motor Displacement (in3) x Pressure (psi) 75

11. Rod Torque Rod Torque = Hydraulic Motor Torque x Drive Ratio

24

µ= Dynamic Viscosity (centipoise) γ = Kinematic Viscosity (centistokes) ρ = Fluid Density (kilograms per cubic meter)

®

Appendix E: Prime Mover Specifications Electric Motors (60 Hz TEFC) Size

Speed

Frame Size

Weight

Shaft Diameter

3 hp

1200 RPM

213T

99 lbs

1 3/8 in

5 hp 7.5 hp

1200 RPM 1200 RPM

215T 254T

123 lbs 203 lbs

1 3/8 in 1 5/8 in

10 hp

1200 RPM

256T

243 lbs

1 5/8 in

15 hp

1200 RPM

284T

287 lbs

1 7/8 in

20 hp

1200 RPM

286T

397 lbs

1 3/8 in

25 hp

1200 RPM

324T

494 lbs

2 1/8 in

30 hp

1200 RPM

326T

511 lbs

2 1/8 in

40 hp

1200 RPM

364T

750 lbs

2 3/8 in

50 hp

1200 RPM

365T

811 lbs

2 3/8 in

60 hp

1200 RPM

404T

1160 lbs

2 7/8 in

75 hp

1200 RPM

405T

2 7/8 in

7.5 hp

1800 RPM

213T

1300 lbs 95 lbs

10 hp

1800 RPM

215T

110 lbs

1 3/8 in

15 hp

1800 RPM

254T

155 lbs

1 5/8 in

20 hp

1800 RPM

256T

188 lbs

1 5/8 in

25 hp

1800 RPM

284T

267 lbs

1 3/8 in

30 hp

1800 RPM

286T

316 lbs

1 3/8 in

40 hp

1800 RPM

324T

386 lbs

2 1/8 in

50 hp

1800 RPM

326T

2 1/8 in

60 hp

1800 RPM

364T

75 hp

1800 RPM

365T

437 lbs 810 lbs 910 lbs

Horsepower

Speed

Weight

1 3/8 in

2 3/8 in 2 3/8 in

Gas Engines Model

Clutch

Shaft Diameter

Arrow C46

5 - 10 hp

400 - 800 RPM

1360 lbs

C107-SP5

1 7/16 in

Arrow C66 Arrow C96

7 - 14 hp 11 - 20 hp

350 - 700 RPM 300 - 600 RPM

1640 lbs 2580 lbs

C110-HP4 C110-HP3

2 1/4 in 2 1/4 in

Arrow C106

17 - 32 hp

300 - 800 RPM

2690 lbs

SP111-HP3

2 1/4 in

Arrow C255

32 - 55 hp

350 -750 RPM

3980 lbs

SP114-P1

3 in

Arrow Y12

6 - 10 hp

475 - 950 RPM

1151 lbs

C107-SP5

1 7/16 in

Arrow Y18

8 - 14 hp

350 - 700 RPM

1455 lbs

C110-HP4

2 1/4 in

Arrow Y24

13 - 22 hp

400 - 800 RPM

2145 lbs

C110-HP3

2 1/4 in

Arrow Y33

17 - 30 hp

400 - 800 RPM

2980 lbs

SP111-HP3

2 1/4 in

Arrow L795

35 - 65 hp

300 - 600 RPM

4510 lbs

SOE114-PO

3 in

Continental TM 27 Gemini G26P

33 - 41 hp 8 - 22 hp

1500 - 1800 RPM 600 - 1600 RPM

950 lbs 1350 lbs

C110-HP4

2 1/4 in

35-52 hp

1200 -1800 RPM

980 lbs

C111-HP4 SP111-HP3

2 1/4 in

GM 4.3 l (262 ci) GM 5.7 I (350 ci)

48-71 hp

1200 -1800 RPM

2 1/4 in

GM 7.4 I (454 ci) Hercules G2300

1200 -1800 RPM 1200 - 2400 RPM

SP111-HP3 SP111-HP31 SP111-HP31

2 1/4 in 2 1/4 in

Hercules G3400 Kubota 16

65-98 hp 33 - 57 hp 52 - 98 hp 6 - 16 hp

1080 lbs 1225 lbs 950 lbs 1065 lbs

SP111-HP3

992 lbs

C108-HP4

2 1/4 in 1 3/4 in

Kubota 32 Lister HR2

9 - 32 hp

300 - 1100 RPM

2 1/4 in

1000 - 1800 RPM

Lister HR3

17 - 34 hp

1000 - 1800 RMP

1764 lbs 840 lbs 970 lbs

C110-HP4

11 - 23 hp

C108-HP4 C108-HP4

1 3/4 in 1 3/4 in

1200 - 2400 RPM 300 - 1100 RPM

1

will also accept SP111-HP4, C111-HP3 or C111-HP4

25

2 1/4 in

Appendix F: Sucker Rod Specifications Weatherford Rod Rod Grade Sucker Rod COROD

MD56 D KD63 T66/XD EL Weight, lbs / ft -

Physical Properties Tensile Yield Strength Strength 1000 PSI 1000 PSI

D Carbon Steel D Chrome Moly D Chrome Moly Alloy Weight, lbs / ft

115-140 115-140 115-140 140-150 N/A 115 Min 115 Min 140 Min -

Maximum Recommended Torque 13/16" 7/8" 1"* 1 1/8"

500 1.76

85 Min 85 Min 85 Min 115 Min N/A 85 Min 90 Min 110 Min -

700 750 700 800 1000 2.22 640 640 900 2.04

1000 1100 1000 1200 1500 2.90 955 955 1300 2.67

1600 1500 1700 2000 3.68 -

Norris Rod Rod Grade Sucker Rod

54 75 78 96 97 Weight, lbs / ft

Physical Properties Tensile Yield Strength Strength 1000 PSI 1000 PSI 115-140 120-140 120-140 135-150 140-150 -

90 Min 90 Min 90 Min 115 Min 115 Min -

7/8"

Maximum Recommended Torque 1"* 1 1/8" 1 1/4"**

700 750 700 800 800 2.22

1000 1100 1000 1200 1200 2.9

1600 1500 1700 1700 3.68

2100 2000 2500 4.17

1 1/2"

3150 3750 6

* Available in 1" or 7/8" pin connections ** Available in 1", 1 1/8" or 1 1/4" pin connections; The 1 1/4" rod is a non-API rod which is specifically designed for torsional applications. Note: The Maximum Recommended Torque rating will remain the same regardless of pin connection. All values are based on new rods, couplings and ideal operating conditions. It is recommended to use a larger diameter rod to increase the allowable torque, rather than the next higher grade. It is recommended to use a 0.8 safety factor to maximize rod fatique life. Values are based on actual test results.

Norris Polished Rod Maximum Allowable Torque - ft-lbs. Rod Size

Piston (C1045), Norloy (8620) 431 SS, 4140 Alloy

1 1/4"

1,800

1 1/2"

2,800

Specifications are subject to change without prior notice

26

®

Appendix G: Viscosity Charts

ISO Grades for Common Oils ISO Grade

Mobile SHC

Esso Teresstic SHP

Conoco Syncon R&O

ISO 32

SHC 624 N/P

SHP 32

R&O 32

SHP 46 SHP 68 SHP 100 SHP 150 SHP 220 SHP 320

R&O 46 R&O 68 R&O 100 N/P

ISO 46 ISO 68

SHC 626 SHC 627 SHC 629 SHC 630 SHC 632

ISO 100 ISO 150 ISO 220 ISO 320

R&O 220 N/P

N/P = No product available

Dynamic Viscosity as a function of Temperature and Oil Grade

Dynamic Viscosity (Cp)

1000

ISO GRADE 32 46 68 100 150 220 320

100

-80

10 -60

-40

-20

0

20

40

Temperature (C)

27

60

80

100

120

Kinematic Viscosity as a function of Temperature and Oil Grade

Kinematic Viscosity (cSt)

100

ISO GRADE 32 46 68 100 150 220 320

100

-80

10 -60

-40

-20

0

20

40

60

80

Temperature (C)

KINEMATIC VISCOSITY, CENTISTOKES

1

Crude Oil API Gravity

TEMPERATURE, DEGREES CELSIUS

28

100

120


Direct Drive

0

®


Disclaimer This manual is intended to give our customers basic information regarding the design, installation and operation of PC Pump Products & Services wellhead stuffing boxes. It is not intended to be a complete source of information on these matters. The customer is responsible for using this information in a correct and safe manner. For assistance, contact your nearest Weatherford representative. The operation of any Weatherford wellhead stuffing boxes beyond the parameters outlined in this manual without factory approval may be damaging to the equipment and/or personnel in which case Weatherford Canada Partnership cannot accept any responsibility whatsoever and disclaims all liability thereof.

Direct Drive Operators Manual

Table of Contents Specifications and Capacities

Pg. 1-11

Introduction to Weatherford Direct Drives

Pg. 1

Figure 1

M2-I Wellhead Drive Assembly

Pg. 2

Figure 2

M3 Wellhead Drive Assembly

Pg. 3

Figure 3

M4-I Wellhead Drive Assembly

Pg. 4

Figure 4

MC4 Wellhead Drive Assembly

Pg. 5

Figure 5

MG Wellhead Drive Assembly

Pg. 6

Table 1

Weatherford Direct Drive Specifications

Pg. 7

Table 2

Direct Drive Equipment Options

Pg. 7

Direct Drive Capacity Ratings

Pg. 8

Electric Prime Movers Specifications

Pg. 8

Direct Drive Typical Operating Conditions

Pg. 9-11

Table 3

Operation

Pg. 12-16 Operating Instructions for Backspin Control

Pg. 12-15

Drive Head Shutdown Procedures

Pg. 16

Maintenance Table 4

Pg. 17-28 Drive Maintenance Schedule

Pg. 17

Direct Drive Maintenance Procedures

Pg. 18-28

Direct Drive System Troubleshooting

Pg. 29-30

Weatherford Canada Partnership Ltd. Warranty

Pg. 31

®

Weatherford currently manufactures five types of direct drives; M2, M3, M4, MC4 and MG designed for various speed and torque applications. The units are driven through belts and sheaves; typically by an electric motor, but can be driven via a hydraulic motor. With the exception of the M2 the motors are mounted on an adjustable door on the drive frame and feature a hinged belt guard. The M2 is a right angle drive with a sliding motor mount and can be adapted to be driven by a gas engine and is equipped with a belt guard that has a removable cover plate. The belt guards on all drives completely enclose the belts and sheaves but provide easy access and maximum safety. The drive unit's hollow shaft is coupled to the polished rod through a polished rod clamp. Precision bushings inside the shaft ensure proper alignment of the polished rod, yet allow the polished rod to be pulled for well maintenance. A sturdy wellhead frame supports the assembly with a variety of stuffing box options available. The M2, M4, MC4 and MG are available with an integral rotating stuffing box, which is denoted by "-I". Inside the drive, large roller bearings support the rod string and fluid column. These bearings are run in a synthetic lubricant bath. These direct drives all feature automatic backspin control.

M2, M3, M4 and MC4 Direct Drives The backspin retarder on the M2, M4 and MC4 has an external caliper and disc brake. The M3 has an internal, water/glycol-cooled disc brake. These units are actuated hydraulically, with a selfpowered system, which engages the brake automatically when the polished rod begins to spin back. Braking action is immediate, and the braking force decreases as the torque in the well is released, allowing the fluid to drain from the tubing as completely as possible. With the exception of the MC4 the backspin speed is adjustable and the brake system can be tested before the drive is shut down. The MC4 does not have a brake manifold therefore the Test on the Fly feature and adjustable backspin speed is not available on this drive. Additionally, the brake may be manually engaged if the hydraulic system should fail.

MG Direct Drives Incorporated inside the MG is a patented* braking system that utilizes centrifugal force created during backspin to engage large braking shoes against a stationary housing. The result is an aggresive brake that engages each and every time there is a shutdown. A unique design feature of the MG brake is that braking resistance does not occur until the polished rod speed reaches approximately 250 rpm. Once the polished rod speed slows to below 250 rpm, the brake shoes retract to allow for a complete, quick and controlled fluid dump. The MG brake is totally enclosed and immersed in synthetic lubricant to control temperature fluctuations, while lubricating all moving parts to ensure a long service life. *US Patent# 6,079,489, others pending. All drives are delivered with a drive stand, which may be purchased, for use during well maintenance on site. A tachometer is available. Drive support arms, which bolt to the casing bowl, are available to support the drive framework on the well. Pin or flanged mounts are provided at the customer's option. Pin mounts are only available with conventional stuffing boxes.

1

Figure 1 : M2-I Wellhead Drive Assembly (with Integral Stuffing Box and Drive Stand)

POLISHED ROD CLAMP

BELT GUARD BELT GUARD COVER PLATE

BRAKE CALIPER OIL FILTER

ELECTRIC MOTOR (NOT SUPPLIED)

DISC GUARD

BRAKE SYSTEM HYDRAULIC PUMP

ADJUSTABLE MOTOR MOUNT

BRAKE SYSTEM CONTROL MANIFOLD WITH BRAKE PRESSURE GAUGE

TACHOMETER (OPTIONAL) DRIVE STAND (OPTIONAL) DETACHABLE INTEGRAL STUFFING BOX (OPTIONAL)

2

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Figure 2 : M3 Wellhead Drive Assembly (with Drive Stand)

OIL FILTER ZINGA (BE-10-18) LIFTING LUG ACCESS DOOR

POLISHED ROD CLAMP

BEARING HOUSING HINGED ENCLOSED GUARD BRAKE SYSTEM HYDRAULIC PUMP ELECTRIC MOTOR (NOT SUPPLIED)

BRAKE SYSTEM CONTROL MANIFOLD WITH BRAKE PRESSURE GAUGE

SELF-POWERED TACHOMETER (OPTIONAL)

BRAKE MODULE

LOWER POLISHED CLAMP

MANUAL BRAKE ADJUSTMENT SCREWS

DRIVE STAND (OPTIONAL)

DETACHABLE STUFFING BOX

WELLHEAD FRAME WITH DRIP TRAY

3 1/8" - 3000 PSI FLANGE MOUNT (OPTIONAL)

2 7/8" API PIN MOUNT

3

Figure 3 : M4-I Wellhead Drive Assembly (with Integral Stuffing Box and Drive Stand)

POLISHED ROD CLAMP

BRAKE CALIPER BRAKE DISC

HINGED ENCLOSED GUARD

OIL FILTER ZINGA (BE-10-18) BRAKE SYSTEM HYDRAULIC PUMP BRAKE SYSTEM CONTROL MANIFOLD WITH BRAKE PRESSURE GAUGE


DETACHABLE INTEGRAL STUFFING BOX

TACHOMETER (OPTIONAL)


4

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Figure 4 : MC4 Wellhead Drive Assembly (with Integral Stuffing Box and Drive Stand)

POLISHED ROD CLAMP BRAKE CALIPER

HINGED GUARD

DISC BRAKE

BRAKE SYSTEM HYDRAULIC PUMP BEARING HOUSING

INTEGRAL STUFFING BOX



5

Figure 5 : MG Wellhead Drive Assembly (with Integral Stuffing Box and Drive Stand)

POLISHED ROD CLAMP BELT GUARD BELT GUARD SUPPORT

BEARING HOUSING

TACHOMETER (OPTIONAL)

DETACHABLE INTEGRAL STUFFING BOX


6


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Table 1 : M2, M3, M4, MC4 and MG Drive Specifications DRIVE NAME / MODEL

M2, M2-I

M3

M4,M4-I

MC4, MC4I

MG, MG-I

Drive Type Drive Ratio Drive Style Input Shaft Shaft Type Ratings Maximum Input Polish Rod Torque (ft-lbs) Thrust Bearing - ISO Rating (lbs) - Ca90 Rating (lbs)1 Maximum Polished Rod Speed (rpm) Maximum Motor Size (hp) (single motor)2 Polished Rod Size (in) Maximum Suggested Temperature (ComponentTemperature) Dimensions & Weights (excluding motor) Height (in) Input Shaft Size (in) Drive/Frame Weight (lbs) Backspin Control

Direct Drive 2:1 gear box right angle hollow shaft





12506 129,0007,8 33,5007,8 600 60 1 1/4 or 1 1/29 Disk-215˚C

2000 129,0007 33,5007 600 12510 1 1/4 or 1 1/2 Clutch Housing 100˚C

2000 129,000 33,500 600 60 1 1/4 or 1 1/29 Disk-215˚C

2000 129,000 33,500 600 60 1 1/4 Disk-215˚C

2000 194,000 50,300 600 125 1 1/4 or 1 1/29 Seal-110˚C

49, 35 2 3/4 1290, 1250 automatic external caliper and disc brake8 2 7/8" pin or 3 1/8" 3000 psi Flange gas, electric or hydraulic 30 14 4.9

60 2 3/4 1580 automatic water/glycolcooled disc brake 2 7/8" Pin or 3 1/8" 3000 psi Flange electric or hydraulic 30 14 4.9

API Wellhead Connection Prime Mover Driven Sheave Maximum Diameter (in) Drive Sheave Maximum Diameter (in)3 Drive Sheave Minimum Diameter (in)4 Drive Belt Type Maximum Number of Belts



53, 39 53, 39 2 3/4 2 3/4 850, 800 1120, 1090 automatic automatic external external caliper and caliper and disc brake disc brake 2 7/8" pin or 2 7/8" pin or 3 1/8" 3000 psi 3 1/8" 3000 psi Flange Flange electric or hydraulic electric or hydraulic 30 30 11.5 14 4.9 4.9 V-Belts or Synchronous Belts/Sprockets 4 ea Type C 6 ea Type 5V 115mm Synchronous 90mm Powerchain 19 1/2" - 24 1/2" Standard motor mount rails 15.5"+D (depends on motor size) 3" motor mount rails 16.5"+D

1

Ca90 load rating is for 90 million revolutions. Reducing load by one half increases life ten times. Reducing the RPM by one half doubles the hours of life. Maximum HP is based upon frame size only. Care must be taken in selecting motor and sheave combinations to ensure input rod torque is never exceeded. Maximum sheave diameter depends on motor size. Smaller motors can accommodate larger drive sheaves. 4 There are NEMA minimum recommended sheave sizes on motors. Ensure that the top bearing in your motor can handle the additional overhung load that results from using smaller sheaves. 5 "D" = Distance from the base of selected motor to its centerline. 6 Allowable Rated Gear Torque is 1350 ft.lbs. Rated Gear Torque is 1650 ft.lbs. 7 Capable of supporting an Extra Capacity (E/C) thrust bearing (ISO 194,000 lbs., Ca90 50,300 lbs). eg. M3 E/C 8 When an Extra Capacity (E/C) bearing is used the water/glycol cooled disc brake backspin control system is used and the integral stuffing box option is not available. 9 1 1/2" polished rod not available with integral rotating stuffing box. 10 Maximum HP limited by NEMA frame size (405T). 2

3

64,48 2 3/4 1780, 1600 centrifugal braking system 2 7/8" pin or 3 1/8" 3000 psi Flange electric or hydraulic 30 14 4.9 6 ea Type C 8 ea Type 5V 115mm Synchronous 120mm Powerchain 25" - 31" (depends on motor size)


Table 2 : Direct Drive Equipment Options OPTIONS

DESCRIPTION

Support Arms Stuffing Box

Support arms mounted on drive frame Retrofit Rotating Integral Rotating (not available on M3) Conventional Threaded Conventional Flanged Stand for transporting and storing the drive Customer defined Customer defined Customer defined Magnetic pickup mounted on drive 24" long rolled perforated plate, fastened w/ 1/4 turn fasteners Complete enclosure of Weatherford booth, fastened w/ spring clips Customer defined

Storage Stand Drive Sheave Driven Sheave Belts CSA ApprovedDigital Tachometer (Class I, DIV II) Polished Rod Guard Booth Guard Electric Motor

7

Direct Drive Capacity Ratings: Maximum speed:

Depends on the speed ratings of the following components: 1. Drive pulleys and sheaves. Cast iron sheaves typically have a rim speed rating of 6500 ft/min. 2. Electric motor speed rating. 3. Bearing life is diminished by half as speed doubles.

Maximum torque:

Drive braking systems have been tested to 2000 lb-ft.

Energy capacity:

M2, M4 and MC4 Drives: The brake disc and caliper can store and dissipate a limited amount of heat energy. These drives must have the energy absorption and dissipation capacity required to prevent caliper and pads from heating to temperatures above 215˚C. This temperature is a safe temperature for the brake system components and will not provide a source of ignition. M3 and MG Drives: These drives are designed with an energy storage capacity to ensure no danger of overheating due to braking, even with successive braking events.

Horsepower rating:

M2 Drives: Drive frame will accept 30 hp to 60 hp, 1200 rpm motor with a 404T motor frame. M3 Drives: Drive frame will accept 30 hp to 125 hp, 1800 rpm motor with a 404T motor frame. M4 Drives: Drive frame will accept 30 hp to 60 hp, 1200 rpm motor with a 404T motor frame. MC4 Drives: Drive frame will accept 30 hp to 60 hp, 1800 rpm motor with a 364T motor frame. MG Drives: Drive frame will accept 30 hp to 125 hp, 1200 rpm motor with a 445T motor frame.

Table 3 : Electric Prime Movers Totally Enclosed Fan Cooled Hp

Nominal Speed (RPM)

NEMA Frame

Shaft Diameter (in)

Shaft Length (in)

Base To Center Line (in)

25

1200 1800 1200 1800 1200 1800 1200 1800 1200 1800 1200 1800 1200 1800 1200 1800

324T 284T 326T 286T 364T 324T 365T 326T 404T 404T 404T 364T 405T 365T 444T 404T

2 1/8 1 7/8 2 1/8 1 7/8 2 3/8 2 1/8 2 3/8 2 1/8 2 7/8 2 7/8 2 7/8 2 3/8 2 7/8 2 3/8 3 3/8 2 7/8

5 1/4 4 5/8 5 1/4 4 5/8 5 7/8 5 1/4 5 7/8 5 1/4 7 1/4 7 1/4 7 1/4 5 7/8 7 1/4 5 7/8 8 1/2 7 1/4

8 7 8 7 9 8 9 8 10 10 10 9 10 9 11 10

30 40 50 30/40/50 40/50/60 60 75 100

8

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Direct Drive Typical Operating Conditions: Forward Direction Operation: While these drives are running in the forward direction hydraulic fluid is being pumped through the complete system. This continuous flow of fluid prevents the accumulation of air in the braking system that could prevent the brake from operating efficiently. Hydraulic fluid temperature is typically 5 to 25˚C above ambient, depending on drive speed.

Backspin/Braking Operation: M2, M3, M4 & MC4 The M2, M3 and M4 drives feature a hydraulic braking system which consists of a pump, manifold and a disk brake. The M2, M4 and MC4 are equipped with a caliper that engages with an external disk to provide braking. The M3 has brake pads that engage with an internal disk. Both systems feature adjustable backspin speed and a "test on the fly" that allows users to test the brake's functionality prior to shutting down the well. By applying pressure to the test on the fly button on the front of the manifold, the system bypasses fluid to the braking system which temporarily engages the brake. The MC4 does not have a filter nor a brake manifold therefore the test on the fly feature and adjustable backspin speed is not available on this drive. This is the only difference between the M4 and MC4. The self-powered braking system engages when the rod string begins to run in the reverse direction. A belt connects the mainshaft (rod string) with the hydraulic pump, which produces pressure that activates the caliper or brake pads. The pressure of the system proportionately varies with the speed of the mainshaft therefore adjusting the braking force. This varying brake force allows for a completed drain of the fluid that is stored downhole. Both styles of brakes can be manually engaged.

MG The MG braking system utilizes centrifugal force created during backspin to engage large braking shoes against a stationary housing. The brake is not activated until the backspin speed reaches 250 rpm, and once the backspin speed has been slowed to 250 rpm the rod string is allowed to rotate freely allowing for a complete, quick and controlled fluid dump. Braking temperature: The temperature of the brake depends on well conditions. Brake noise:

Because the top polished rod clamp is not clamped tightly to the mainshaft, there may be some rattle associated with it during shut down. The rattle is the polished rod moving in the mainshaft, and does not affect the brake performance or the life of the drive.

9

M2, M3 and M4 Drive Typical Operating Conditions: Backspin Speed vs. Braking Torque, M3:

With Two Turn Open Backspin Control Valve

Brake Torque (lb-ft)

1750 1500 1250 1000 750 500 250 0 0

100

200

300

400

500

Backspin Speed @ polished rod (rpm) Average results from dynamometer testing. Individual drive results may vary. Adjusting backspin speed valve will make the brake more aggressive. Curve ends at HP limit of test equipment. Brakes have been tested to 2000 lb-ft.

Backspin Speed vs. Braking Torque, M2 & M4:

With One Turn In Backspin Control Valve Brake Torque (lb-ft)

1750 1500 1250 1000 750 500 250 0 0

100

200

300

400

500

Backspin Speed @ polished rod (rpm) Average results from dynamometer testing. Individual drive results may vary. Adjusting backspin speed valve will make the brake more aggressive. Curve ends at HP limit of test equipment. Brakes have been tested to 2000 lb-ft. Note: These drives are shipped with the backspin control valve fully open therefore reducing the braking torque.

10

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MG and MC4 Drive Typical Operating Conditions: Backspin Speed vs. Braking Torque, MG:

Brake Engages at 250 rpm Backspin Speed 900


800 700 600 500 400 300 200 100 0 0

100

200

300

400

500

600

Backspin Speed @ polished rod (rpm) Average results from dynamometer testing. Individual drive results may vary.

Backspin Speed vs. Braking Torque, MC4: 900


800 700 600 500 400 300 200 100 0 0

100

200

300

400

500

Backspin Speed @ polished rod (rpm) Average results from dynamometer testing. Individual drive results may vary.

11

600

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Operating Instructions for Backspin Controls for Direct Drives (Excluding the MG & MC4): 1. To test the brake system while drive is operating in pumping direction (to test "on the fly"):

A. Push the red button on the control manifold and hold it. Release it when the pressure rises on the gauge to 50 or 100 psi. This pressure forces the friction pads against the brake disc, and is an indication that the hydraulic system is operating properly. The brake system (pump, belts, seals, etc.) is intact, and will function in recoil. B. Although the brake pressure developed in this test is low, it is possible to inadvertently shut the electric motor down on current overload if the motor is operating close to its current limit. The brake will function safely in recoil if this should occur.

12

2. To adjust maximum backspin of the drive: The maximum backspin speed is adjustable from nearly a complete stop up to 650 rpm, depending on the well conditions and the downhole pump. The speed adjustment is made with the right hand knob on the manifold. By unlocking the lock nut and turning the knob clockwise the drive backspin speed is decreased. In the fully open position, the backspin speed will be at its maximum.

On the M3: Start with the speed control two turns out. Turn it clockwise to slow the backspin, and counter clockwise to speed it up. Once the desired speed is attained tighten the lock nut. The speed control knob may be removed after the desired backspin speed is set to prevent tampering with the speed control.

On the M2 & M4: Start with the speed control knob all the way out. Turn it clockwise to slow the backspin down.

13

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Operating Instructions for Backspin Controls for Direct Drives cont... 3. Manual Operation of the Clutch Style Brake In the event that the brake fails to operate hydraulically, the brake can be engaged manually. To manually operate the brake on a clutch style brake, follow these procedures:

Spacer bushing

A. Be aware of the rotating parts and keep hands clear of all moving parts.

C. Turn both bolts up hand tight. D. Using a 15/16" wrench or socket, a half turn at a time, first to one bolt, then the other, turn the mechanical lockout bolts into the drive. If the bolts are not turned up in this manner it will cause the piston within the clutch housing to hang up and the brake will not operate properly. The bolts force the friction materials against the brake disc. The friction materials will drag against the disc, and eventually the motor will shut down on current overload. It does not require excessive force to turn in the mechanical lock out bolts.

Manual lockout bolts B. Loosen the lock nuts on the manual lockout bolts all the way down to the head of the bolt. The spacer bushing may come down to the lock nut.

E. The backspin torque may not be completely released and can be stored in the rod string when using this manual operation of the brake. The drive will not recoil, or it may turn slowly, depending on how far the bolts are turned into the drive. For safety reasons during service, and to protect the motor at restart, the torque should be completely released and the fluid column Position of within the production tubing drained before restarting the locknut or servicing the well. This is accomplished by slowly backing out the bolts, a little at a time, until the drive prior to stops on its own. loosening F. Service the drive before restarting to repair the cause of brake failure.

These lockout bolts must be raised and lowered at the same time.

ie. Do not raise or lower one bolt all the way then do the other bolt.

Never operate a drive system without a properly functioning brake system. Uncontrolled backspin can cause serious equipment failure and possible personal injury.

14

4. To manually operate the caliper style brake on the M2, M4 & MC4: In the event that the brake fails to operate hydraulically, the brake can be engaged manually. To accomplish this, follow these procedures: A. Be aware of the rotating parts and keep hands clear of all moving parts. B. Remove the fitting from the back of the caliper. The fitting has a #4 male SAE O-ring boss thread. C. Replace the fitting with one that will accept your hydraulic hand pump, or Baker Pump. D. Completely close the speed control knob on the manifold. Make sure that the locknut does not jam before the knob is all the way in. E. Apply pressure with the hydraulic hand pump. Have someone shut the drive motor off or allow the current limiting device to do it. F. Slowly release the pressure on the caliper through the hydraulic pump. This will allow the well to backspin at a controlled speed.


G. Once all of the torque is released from the system the drive must be removed from the well.The drive must be serviced to determine the cause of the brake failure.

Lock nut

Speed control knob

15

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Drivehead Shut Down Procedures 1. Be familiar with well history, speeds, production, amperage and recent workovers. 2. Ensure the well lease, drivehead and wellhead are kept clean. Approach the lease with caution, including a visual inspection. If for any reason you feel that conditions are unsafe, do not approach the wellhead, and call your supervisor for assistance. 3. Ensure that someone else knows that you will be performing a shutdown procedure, specifying well location and time. Minimize personnel on lease. 4. Make all personnel on site aware of potential hazards and safety concerns. 5. Approach the well with caution, including a visual inspection; note the rotation of the reflector tape. Listen for any abnormal operating noises. If for any reason you feel conditions are unsafe, do not approach the wellhead. Call for assistance. 6. If provisions have not been made for control of backspin, a protective barrier must be made available in the near proximity of the control panel while performing the shut down procedure. Account for all personnel on the lease, and ensure that they are sufficiently clear prior to well shutdown. If the brake is non functional then follow the manual lockout procedures outlined on pages 14 and 15 of this manual.

9. While shielded, observe for abnormal backspin. Note if backspin is engaging and rate of decreasing backspin speed. 10. Do not approach the wellhead until backspin has come to a complete stop. Shut off and lock out the breaker on the main control panel before performing well servicing operations. 11. For systems with adjustable orifices, when the rod string has come to rest, mark the positioning of the orifice valve. Next open the orifice valve to ensure the rod string is at equilibrium. Return the valve to its original set point. 12. For hydraulic skids and drives: • Shut down by turning the stop/run valve slowly to the stop position, watch the polished rod for backspin that is normal and controlled. If abnormal, contact supervisor for assistance. • Lock out the circuit breaker and tag or shut down gas engine. 13. After a drivehead has been shut down and backspin stops, there is still potential for additional recoil. This additional recoil is caused by the fluid in the tubing equalizing with the fluid in the casing. 14. Follow manufacturer's recommended polished rod clamp out procedures to prevent any further backspin prior to and during servicing/maintenance.

7. Conduct the following checks: • Surface wellhead pressures. • Motor amperage. (note if amperage readings are higher then normal expect high backspin speeds) • Oil level in the site glass. 8. Turn drive off at master control panel and observe braking performance. If the well is equipped with a VFD, use it to gradually slow the unit down to minimum speed prior to shutting down the drive unit.

16

Table 4 : Drive Maintenance Schedule - Direct Drives MAINTENANCE

FREQUENCY

M2, M3, M4 and MC4 BEARING HOUSING Change Oil Filter1 Change Oil Oil Type2 Oil Quantity Filter Type Bearings MG BEARING HOUSING Change Oil Oil Type2 Oil Quantity Bearings Brake Adjustment M3 BRAKE SYSTEM Replace Brake Coolant Coolant Type Coolant Quantity Purging the Brake System

Friction Pads

Bearings Brake Adjustment M2,M4 & MC4 BRAKE SYSTEM Purging The Brake System

First change after 1 month, then annually (N/A for MC4) Annually Esso Terrestic SHP 68 13 litres. Keep filled to oil level line3 Zinga BE-10-18 10 micron (N/A for MC4) Bearings require no maintenance Annually Esso Terrestic SHP 68 26 litres. Keep filled to oil level line3 Bearings require no maintenance Not necessary Not required4 Automotive Antifreeze, mixed 50/50 with water 10 liters antifreeze, 10 liters water. Keep filled to center of sight glass. Every time oil is changed or hoses removed from hydraulic system. See page 18 for detailed procedure. Replacements available, but not necessary for hundreds of shutdowns, depending on application Recommended annual inspection by Weatherford Service personnel. Lower bearing in clutch housing to be greased every 3 months Periodically ensure that lower polished rod clamp is engaged and not damaged or slipping Every time oil is changed or hoses removed from hydraulic system. See page 19 for detailed procedure Replacements available, but not necessary for hundreds of shutdowns, depending on aplication Not necessary

Friction Pads Brake Adjustment

1 Oil change schedule based on 300 RPM, 24 hour operation of drive units. Faster operation may require more frequent oil changes. First month filter change is recommended because tests have shown that the highest concentration of wear particles are generated within the first 500 hours of use. The best way to determine oil change frequency is to have contaminant particles in an oil sample counted. Oil quality should be maintained at an ISO cleanliness level of 18/16/13 or better. With each oil change, check and tighten nuts and bolts on the motor support frames and belt guards, check and tighten belt tension, and recheck oil level.

2

Bearing housing oil must lubricate the bearings and gears and also be suitable for the hydraulic braking system. For consistent braking performance, select oil with a high viscosity index. A synthetic oil gives a longer service life. Alternate acceptable oils: Mobil Pennzoil

3

SHC 626 SHD 68

Conoco R&O 68 Elliot Petroleum Hydra-Blue MG36 (for use in M3, M4 & MC4 only)

Do Not Mix Oil Types. When changing oil types, a complete oil change must be performed.

4 Do not be alarmed with presence of metallic flakes in the brake unit of the M3. Friction materials tend to collect in the sight glass. Brake parts will not be damaged from metal flakes in the coolant reservoir.

17

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Direct Drive Maintenance Procedures Purging The Brake Systems Every time that the oil is changed or any hoses are removed from the hydraulic system it is necessary to bleed the air from the braking system. Air trapped in the system may cause the brake to remain engaged or not operate properly.

D. Press the "test on the fly" button to create pressure in the brake assembly.

Clutch Brake (M3) A. Remove the cap from the elbow at the bottom of the clutch housing and connect a hose to the elbow. A container will be required to catch any fluid that is released through this hose.

E. Continue pressing and releasing the "test on the fly" button until all of the air is relieved through the hose. F. Remove the hose from the elbow and replace the cap.

B. Start the drive. C. Warning: At this point, any air in the braking system, could cause the braking system to not function properly.

G. After the system has been fully purged of air, depressing the "test on the fly" button should cause an increase of pressure on the pressure gauge, create an audible engagement of the brake and cause the motor to generate more power. - If the brake does not actuate, repeat the purging procedures. - If the brake will not actuate follow the manual shut down procedures outlined on page 14 of this manual. Remove the system and return it to the local Weatherford PC Pump Drive Head Distributor for inspection. H. When each component of the system is fully operational, check the oil level and add the appropriate amount of approved oil.

18

Caliper Style Brake (M2, M4 & MC4) Every time that the oil is changed or any hoses are removed from the hydraulic system it is necessary to bleed the air from the braking system. Air trapped in the system may cause the brake to remain engaged or not operate properly. A. Start the drive. B. Warning: At this point, any air in the braking system, could cause the braking system to not function properly. C. Always keep hands clear of the rotating disc. D. Slightly loosen the bleed screw on the back of the caliper so that the bleed screw can be opened and closed easily.

I. Release the "test on the fly" button. J. Repeat steps D through H until all the air is purged through the bleed screw. ** Note: Releasing the "test on the fly" button before tightening the bleed screw will allow air to reenter the brake assembly. K. Once all the air has been purged ensure that the bleed screw on the back of the caliper is tightened. L. After the system has been fully purged of air, depressing the "test on the fly" button should cause an increase of pressure on the pressure gauge, create an audible engagement of the brake and cause the motor to generate more power. - If the brake does not actuate, repeat the purging procedures. - If the brake will not actuate follow the manual shut down procedures outlined on page 15 of this manual. Remove the system and return it to the local Weatherford PC Pump Drive Head Distributor for inspection. M. When each component of the system is fully operational, check the oil level and add the appropriate amount of approved oil.

E. Press the "test on the fly" button to create pressure in the brake assembly. F. Hold the button in. G. Loosen the bleed screw by turning it counter clockwise until a small amount of fluid/gas escapes. H. Tighten the bleed screw by turning it clockwise.

19

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Direct Drive Maintenance Procedures Cont... Checking Clutch Style Brake Pad Wear (M3) To check the brake pad wear on a clutch style brake follow these procedures: A. Ensure the drive is shut down and the breaker to the main control panel is turned off or the ignition on the motor is locked out. B. Before making any adjustments to the brake system make sure all of the torque has dissipated from the system. Follow the safe shut down procedures outlined on page 16 of this manual. C. Install a lockout clamp on the polished rod to prevent further backspin.

F. Using a 15/16" wrench or socket, a half turn at a time, first to one bolt, then the other, turn the mechanical lockout bolts into the drive. If the bolts are not turned up in this manner it will cause the piston within the clutch housing to hang up and the brake will not operate properly. G. Measure the distance from the bottom of the spacer bushing to the top of the nut on the lockout bolt. Record this measurement for drive records and monitoring. If this measurement is 3/8" or less the brake pads require replacement. The clutch housing must be returned to Weatherford PC Pump Ltd. for brake pad replacement.

These are the two points to measure the distance between

D. Loosen the lock nuts on the manual lockout bolts all the way down to the head of the bolt. The spacer bushing may come down to the lock nut.

Position of the locknut prior to loosening

H. If it has been determined that there is still adequate brake pad remaining then back the lockout bolts out, following the half turn at a time procedure. I. Once the bolts can be turned by hand the brake is in the proper operating position. J. Tighten the bolts by hand, just until there is resistance. If they are tightened further than this it will incorrectly position the brake.

These lockout bolts must be raised and lowered at the same time. ie. Do not raise or lower one bolt all the way then do the other bolt.

K. Turn the locknut up until it is above the grooves on the lockout bolt and hand tighten the lockout bolts into the housing.

Groove in lockout bolt Spacer bushing L. Remove the lockout clamp. M. Start the drive.

E. Turn both bolts up hand tight.

Never operate a drive system without a properly functioning brake system. Uncontrolled backspin can cause serious equipment failure and possible injury.

20

Caliper Disc Brake Pad Wear Determination To check the pad wear on the M2, M4 and MC4 caliper disc brake follow these procedures:

Inspection Notch

A. Ensure the drive is shut down and the breaker on the main control panel is turned off or the ignition on the motor is locked out. B. Before making any adjustments to the brake system make sure all of the torque has dissipated from the system. Follow the safe shut down procedures outlined on page 16 of this manual. C. Install a lock out clamp on the polished rod to prevent further backspin. Lockout clamps are available for both Integral and Retrofit style stuffing boxes. D. The caliper and brake pad have a notch machined into the side, above and below the caliper disc, to allow for visual inspection of the wear that has occurred on the brake pad.

Inspection Notch

21

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Direct Drive Maintenance Procedures Cont... E. The brake pad must be replaced once the pad has worn down to the point that the notch is no longer visible. The top and bottom pads must both be checked, if either pad is worn out they must both be replaced. The picture below illustrates a new brake pad. This is the brake pad. The area between the arrows is the material that can be worn

Brake pad removed from caliper. Illustrates the notch in the brake pad

Interface between the pad material and the steel backing plate

Pad wear beyond the notched thickness may allow hydraulic fluid to escape and/or the steel backing plate to come in contact with the brake disc both of which are potential fire hazards.

F. Once the visual inspection is complete and it has been determined that the brake pads are acceptable the drive can be restarted.

22

Caliper Brake Maintenance (M2, M4 & MC4) To inspect pads for wear and to replace worn brake pads in calipers without inspection slots on the caliper style brake, follow these procedures:

G. The hose connecting the caliper to the hydraulic pump must be removed at the caliper end. H. Remove the complete brake assembly from the disc.

A. Ensure the drive is shut down and the breaker on the main control panel is turned off or the ignition on the motor is locked out.

Remove this hose

B. Before making any adjustments to the brake system make sure all of the torque is dissipated from the system. Follow the safe shut down procedures on page 16 of this manual. C. Open the sheave guard on the M4 & MC4 or remove the disc guard on the M2.

Remove these bolts

D. Install a lockout clamp on the polished rod to prevent further backspin. Lockout clamps are available for both Integral and Retrofit style stuffing boxes. E. Ensure that the bearing housing is full of oil. F. Remove the foot mount bolts that attach the caliper to the foot mount. Do not loosen the bolts that attach and adjust the foot mount on the bearing housing if these bolts are moved the caliper will have to be readjusted.

Do not adjust these bolts

23

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Direct Drive Maintenance Procedures Cont... Caliper Brake Maintenance Cont... I. Remove the bolts that hold the top of the caliper to the bottom.

J. In the top portion of the caliper housing there is a spring that holds the brake pad in place - this spring will probably pop out and will have to be replaced when the caliper is reassembled. This spring can easily be made from a piece of metal banding cut 5 1/4" long with the ends trimmed at an angle.

Remove these bolts that hold the top of the caliper to the bottom

Metal band

K. Remove the pads by manually picking them up out of the caliper and measure them with a caliper or micrometer. (Use attached sheet to record the data) Replace the pads with new ones if necessary.

24

L. If the piston in the caliper is leaking the brake pads will have hydraulic oil on them and the brake assembly must be disassembled. The piston must be removed and the o-rings and back-up rings must be replaced. Use only approved replacement brake linings and rebuild kits. The use of improper parts could compromise the safety of the drive operators. Replacement parts are available from Weatherford PC Pump Ltd.

M. Place the brake pad back into the housing. Install the metal spring that holds the brake pad. This spring prevents the brake pad from rattling in the caliper housing while the drive is running and does not affect the way the brake performs. It is not crucial that this spring be installed.

Spring installed. This spring is only required on the top portion of the caliper

Caliper Piston

25

®

Direct Drive Maintenance Procedures Cont... Caliper Brake Maintenance Cont... N. Reassemble caliper. A thick piece of cardboard will have to be placed between the brake pads to prevent the pads from falling together.

P. Re-connect the hose that goes to the pump back on to the caliper and tighten snuggly. Q. Remove the lockout clamp and replace all guards. R. Start the drive. S. Warning: At this point, any air in the braking system, could cause the braking system to not function properly. Purge all the air out of the system following the brake purging procedures outlined on page 19 of this manual.

O. Replace the caliper on the disc, sliding the cardboard out as the caliper is placed on the disc and replacing the cardboard with a 1/16" spacer to prevent the top brake pad from falling down onto the disc (A metal name plate works well as a spacer). Tighten the bolts that attach the caliper to the foot mount. Once the bolts have been tightened the spacer can be removed.

T. After the system has been fully purged of air, depressing the "test on the fly" button should cause an increase of pressure on the pressure gauge, create an audible engagement of the brake and cause the motor to generate more power. - If the brake does not actuate, repeat the purging procedures. - If the brake will not actuate follow the manual shut down procedures outlined on page 15 of this manual. Remove the system and return it to the local Weatherford PC Pump Drive Head Distributor for inspection.


1/16" spacer

26

Measurement of Caliper Disc Pad Take four measurements of each pad at positions shown below. Measurements should be taken 1/2" in from the edge. Once the pads reach 5/16" they must be replaced.

Top Pad: Position 1__________

1

2

Position 2__________ Position 3__________ Position 4__________

4

3

Bottom Pad: Position 1__________ Position 2__________ Position 3__________

1

2

Position 4__________

4

3

27

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Direct Drive Maintenance Procedures Cont... Clutch Housing Lower Bearing Greasing Procedures (M3) The lower bearing of the clutch housing should be greased every three (3) months. Failure to apply grease to this bearing will reduce the bearing life and could cause premature failure. To grease the lower bearing in the clutch housing, follow these procedures: A. Ensure the drive is shut down and the breaker on the main control panel or the ignition on the motor is locked out.

Grease Zerk

B. Before making adjustments to the brake system make sure all the torque has dissipated from the system. Follow the safe shut down proceedures on page 16 of this manual. C. Install a lockout clamp on the polished rod to prevent further backspin. D. Apply grease into the 90˚ grease zerk until grease comes out the breather on the other side. Grease coming out breather

E. Remove the lockout clamp. F. Start the drive.

28

Direct Drive System Troubleshooting: M2,M3, & M4 When testing on the fly, no pressure develops: 1. Hold the "test on the fly" button in for a few seconds. At low speeds it takes more than a second to develop pressure high enough to be seen on the pressure gauge. 2. If the drive is operating at a speed lower than 100 rpm, and the backspin speed adjustment is completely open, it may be difficult to develop pressure that you can see on the gauge. Turn the speed adjustment inward two turns, and repeat the test on the fly. If pressure develops, then the brake is functioning normally. Put the speed adjustment back where it was and proceed to shut the well down. 3. Check that the pressure gauge is working. Listen for braking noise in the drive or check the current drawn by the motor to see if the brake is working while you test on the fly. 4. Check that the pump is functioning. It should operate at a temperature similar to the bearing housing when it is working. Check to see that belt is intact. There is a small window in the belt guard that you can see through. 5. If the pump is not operating, call for service. To shut the drive down, use the procedures outlined on pages 14 or 15 of this manual.

When testing on the fly, the brake will not release ("locked up"): 1. This will only occur when the speed control knob is completely closed. Open the speed control knob a little and the brake pressure will be released.

Warning: Do not depend on this feature to hold the drive while you work on it. Fluid could leak internally and the drive may continue to turn. Use this lockout feature only to observe the drive.

29

®

Direct Drive System Troubleshooting Cont... M2, M3, M4, MC4 & MG: Stuffing box leaks: Stuffing box leaks are affected by the following conditions: 1. Packing worn or too tight. 2. Bushings worn from misalignment. 3. Drive may be misaligned relative to the equipment below. An indication of misalignment is that the cap will not thread on and off easily. Adjust the position of the drive with support arms to minimize leakage or to minimize current load on the motor. Temperature is also an indicator of how much friction is in the stuffing box. 4. Sometimes using a more rigid frame or attachment system will reduce the severity of stuffing box problems. For best results, use a flanged mount with Weatherford's standard heavy duty wellhead frame. (For additional information regarding stuffing boxes refer to the Weatherford Stuffing Box Manual)

Drive seizes to the polished rod, making it difficult to remove: 1. Shafts and stuffing boxes are designed with tight inside diameter tolerances which could cause them to seize to one another if the polished rod is scored with wrench marks or has other damage. Always file off wrench marks when handling the polished rod.

Tachometer doesn't read the actual polished rod speed: 1. The tach should register polished rod speeds above 35 rpm. 2. If there is no displayed reading, battery replacement may be required. Replace with a 3V lithium battery (Sanyo CR14250SE). 3. The tachometer may not display the speed at operating temperatures below -35C.

30

PC Pump Products & Services Weatherford Canada Partnership Warranty This shall be the only warranty given by PC Pump Products & Services Weatherford Canada Partnership ("Partnership"), and no other warranty by Partnership, express or implied, shall be applicable, including any implied warrant of merchantability or any implied warranty of fitness for a particular purpose. Subject to the limitations and conditions herein, Partnership warrants its products (with the exception of rotating stuffing boxes) to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of installation or eighteen (18) months from the date of shipment, whichever occurs first. Company warrants rotating stuffing boxes to be free from defects in workmanship and material under normal use and service for a period of three (3) months from the date of installation or nine (9) months from the date of shipment, whichever occurs first. Partnership's obligations under this warranty shall be limited to repairing, replacing or issuing credit for, at Partnership's option, any product or parts it finds to be defective in material or workmanship. Partnership must be given a reasonable opportunity to investigate. Shipping and handling in connection with this warranty will be at customer's expense. Products sold by Partnership, but manufactured by another company, will carry only the warranty of the manufacturer, and the customer will rely solely on that warranty. Services provided by Partnership are warranted for a period of ninety (90) days from the date the services are rendered. The liability of Partnership for any loss or damage resulting to the customer or user or any third party from any defect in any product or service will not, in any case, exceed the selling price that Partnership received from the customer for the product or service. The above shall be the customer's exclusive remedy with respect to products or services. In no event will Partnership be liable for incidental, consequential, special, indirect or other damages of any nature. This warranty will not apply and will be void if the product fails as a result of down hole corrosion; non-compatibility of produced fluid with the stator and/or rotor; general wear and abrasion; incorrect installation, removal, use or maintenance; operation outside of the manufacturer's recommended guidelines; alteration; accident; abuse or negligence. Hydraulic wellhead drives, hydraulic power transmission units or rotating stuffing boxes sold individually for use with equipment not manufactured by Partnership will not be covered under this warranty. Partnership does not warrant that any of the products sold by it, if used or sold in combination with other equipment or used in the practice of methods or processes, will not, by virtue of such combination or use, infringe patents of other, and Partnership shall not be liable for any patent infringement arising from, or by reason of, any such use or sale. Furthermore, Partnership shall not be liable for any patent infringement arising from, or by reason of, any use or sale of any materials, equipment or products not of Partnership's manufacture or for the use or sale of any materials, equipment or products, or other goods specially made, in whole or in part, to the customer's design specifications.

31

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Hydraulic Drive Operators Manual

Version 1.4

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Disclaimer This manual is intended to give our customers basic information regarding the design, installation and operation of Weatherford wellhead drive units. It is not intended to be a complete source of information on these matters. The customer is responsible for using this information in a correct and safe manner. For assistance, contact your nearest Weatherford representative. The operation of any Weatherford wellhead drive unit beyond the parameters outlined in this manual without factory approval may be damaging to the equipment and/or personnel in which case PC Pump Products & Services cannot accept any responsibility whatsoever and disclaims all liability thereof.

Hydraulic Drive Operators Manual

Table of Contents Introduction to Weatherford Hydraulic Drives and Power Units

Pg. 1-2

Table 1

Weatherford Hydraulic Drive Specifications

Pg. 3-4

Table 2

Hydraulic Drive Equipment Options

Pg. 5

Figure 1:

Weatherford Hydraulic Wellhead Drive

Pg. 5

Figure 2:

Weatherford InLine HTD Wellhead Drive

Pg. 6

Figure 3:

Weatherford Hydraulic Power Skid

Pg. 6

Table 3

Variable Displacement Hydraulic Pump Specifications

Pg. 7

Table 4

Fixed Displacement Hydraulic Motor Specifications

Pg. 8

Table 5

Weatherford Gas Engine Prime Mover Specifications

Pg. 8

Table 6

Electric Prime Movers - Totally Enclosed Fan Cooled

Pg. 8

Hydraulic Drive Calculations Figure 4:

Hydraulic Pump Details

Pg. 9 Pg. 10

Variable Displacement Hydraulic Pump Setup Procedures

Pg. 11

Hydraulic System Preventive Maintenance

Pg. 12

Contamination Causes Most Hydraulic Failures

Pg. 12

Table 7

Maintenance Schedule - Hydraulic Power Unit (Skid)

Pg. 13

Table 8

Maintenance Schedule - Hydraulic Wellhead Drives

Pg. 13

Table 9

Maintenance Schedule - Weatherford Supplied Gas Engine Prime Movers

Pg. 14

Troubleshooting Hydraulic Skids and Drives

Pg. 15

PC Pump Division of Weatherford Canada Partnership Warranty

Pg. 16

®

Progressing cavity pumps are often driven by hydraulic drive systems. Weatherford hydraulic drives and power units are used when variable speed is required. With a gas engine as the prime mover, electrical power is not required on site. All hydraulic power units have automatic torque control and recoil as standard features.

The hydraulic drivehead is powered by the hydraulic power unit/skid. The skid has a prime mover which drives a hydraulic pump. Fluid flow from the pump then drives the hydraulic motor on the drive, which in turn, drives the rod string.

The hydraulic drivehead is completely assembled including a hydraulic motor, vertical shaft bearing box, belts, sprockets and a single-latched hinged belt guard, all mounted on a wellhead frame with a detachable stuffing box. The inline HTD assembly includes a hydraulic motor mounted on a wellhead frame with a detachable stuffing box. Both drive assemblies are available with an environmental rotating stuffing box.

The hydraulic power unit is completely assembled with an enviro-skid, tank, pump, hoses and oil. This system is designed to adapt to various gas or electric prime movers. The pressure compensator on the pump is preset to customer requirements for automatic torque control. The speed control is easily adjustable in the field with a turn of a knob, located on the pump.

1

Recoil Control When a well is shut down the rods release stored torsional energy and fluid may drain through the pump, turning the rods in reverse. There is potential for the rods to spin back at a high rate of speed, causing a safety hazard if spinning parts (i.e.: sheaves) should fail. The backspin may also cause damage to the hydraulic motor.

A backspin retarder is built into every hydraulic power unit with a check valve in the hydraulic lines on the pressure side of the motor. When the drive is turning in the forward direction, the check valve is forced open by fluid flowing into the motor. When the drive spins in reverse, the check valve is forced closed and drains the fluid at a slow, controlled rate of speed. In order to ensure that there is no loss of suction in the motor the backspin speed is very slow.

Auxiliary Equipment Please be advised that the auxiliary equipment on a single pump hydraulic skid dramatically raises the possibility of heat generation, premature mechanical failure, and uncontrolled recoil of the rod strings. This advisory applies to all hydraulic systems assembled with a single hydraulic pump and a hydraulically driven wellhead drive. Auxiliary equipment includes, but is not limited to: casing gas compressors, chemical injectors, recycle pumps, and continuous load pumps. Please contact Weatherford PC Pump Products & Services for further information and recommendations regarding the operation of auxiliary hydraulic equipment. 780/875-0103

2

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Performance Group Motor

1

2

3

4

5

Kawasaki Volvo F12-60 Volvo F12-80 Volvo F12-110 K3X112S

6

Inline HTD

9

10 Inline HTD

Sunstrand V45-74cc

11

12

Volvo F12-60 Volvo F12-80 Vickers PVH74

F60/L38 F80/L38 F110/L38 K112/L38 S480/L38 F60/V74 F80/V74 F110/V74 K112/V74 S480/V74 F60/P74 F80/P74

Combination Code 1

4:1

4:1

4:1

4:1

N/A

4:1

4:1

4:1

4:1

N/A

4:1

4:1

30-283

25-211

25-150

25-153

0-141

30-557

25-414

25-294

25-300

0-278

30-555

25-412

Torque Range (lb-ft)

0-581

0-781

0-1101

0-1077

0-1166

0-775

0-1042

0-1468

0-1437

0-1554

0-702

0-944

Maximum System Pressure3

3000

3000

3000

3000

3000

4000

4000

4000

4000

4000

3625

3625

lb-ft/100psi

19.4

26

36.7

35.9

38.9

19.4

26

36.7

35.9

38.9

19.4

26.1

N/A

36

36

Drive Ratio

2

Polished Rod Speed

2

1 1/4"

Polished Rod Size

2 7/8" EUE pin or 3 1/8" 3000 psi, R31 flange.

Wellhead Connection Drive Belts4 14Mx55mm Drive Sprocket5 Automatic Backspin Limiter Automatic Torque Control

14mm pitch x 55mm wide x 2450mm long belt. (N/A for Inline HTD) 36

36

36

36

N/A

36

36

36

36

1" fixed orifice check valve supplied at motor to control backspin speed. Pressure compensator which can be set to maximum system pressure.

Variable Speed Control

Adjustment knob provided with pump.

Pressure Gauge

5000 psi liquid filled gauge.

Hose Size/Type

1" Aeroquip high pressure hose.

Quick Couplers

Aeroquip FD45 Series or equivalent. Others available on request.

Motor Case Drain

1/2" x 33' hose w/ 1/2" quick coupler.

Hydraulic Oil Type

Elliott Petroleum Hydra-Blue MG36 or equivalent.

Oil Filters Low Oil Switch

2

8

Kawasaki Volvo F12-60 Volvo F12-80 Volvo F12-110 K3X112S

Sunstrand L38

Pump

1

7

Two - 3 micron filters with 25 psi bypass and indicator or gauge. CSA approved, testable external tank mount device.

Tank Volume and Supplied Equipment

360 litre tank capacity. Tanks equipped w/ return flow downpipes, cover gasket, 5 psi breather cap.

Battery and Locking Battery Box

Standard on gas engines.

Axial Load Capacity

Ca90: 25,900 lbs.

Skid Dimensions (w/o Prime Mover)

5' wide x 8' long x 41" high.

Skid Weight (w/o Prime Mover)

Approximately 1350 lbs (615 kg).

Drive Weight w/ Frame

Approximately 688 lbs (313 kg).

To calculate speed and torque values for ratios other than 4:1 refer to the calculations on Page 9. Tabulated maximum values for speed and torque are based upon 100% theoretical efficiencies. Operating pressure efficiencies (typically 92% @ 2200 psi) and flow rate efficiencies (typically 95% @ a motor speed of 1500 rpm) will affect output speed and torque respectively.

3

13

14

15

Volvo F12-110

Kawasaki K3X112S Vickers PVH74

Inline HTD

16

F110/P74

K112/P74

S480/P74

F60/K80

F80/K80

F110/K80

K112/K80

S480/K80

F60/P98

F80/P98

4:1

4:1

N/A

4:1

4:1

4:1

4:1

N/A

4:1

25-293 0-1331

25-299 0-1302

0-276 0-1409

30-600 0-775

25-447 0-1042

25-317 0-1468

25-324 0-1437

0-300 0-1554

3625

3625

3625

4000

4000

4000

4000

36.7

35.9

38.9

19.4

26.1

36.7

35.9

Volvo F12-60

17 Volvo F12-80

18

19

20

Volvo F12-110

Kawasaki K3X112S

Inline HTD

21

23

24

25

Volvo F12-110

Kawasaki K3X112S

Inline HTD

F110/P98

K112/P98

S480/P98

4:1

4:1

4:1

N/A

30-600 0-702

25-550 0-944

25-390 0-1331

25-399 0-1302

0-369 0-1409

4000

3625

3625

3625

3625

3625

38.9

19.4

26.1

36.7

35.9

38. 9

36

36

36

N/A

Volvo F12-60

22 Volvo F12-80

Vickers PVH98

Kawasaki K3VL-80

1 1/4" 2 7/8" EUE pin or 3 1/8", 3000 psi, R31 flange. 14mm pitch x 55mm wide x 2450mm long belt. (N/A for Inline HTD) 36

36

N/A

36

36

36

36

N/A

36

1" fixed orifice check valve supplied at motor to control backspin speed. Pressure compensator which can be set to maximum system pressure. Adjustment knob provided with pump. 5000 psi liquid filled gauge. 1" Aeroquip high pressure hose. Aeroquip FD45 Series or equivalent. Others available on request. 1/2" x 33' hose w/ 1/2" quick coupler. Elliott Petroleum Hydra-Blue MG36 or equivalent. Two - 3 micron filters with 25 psi bypass and indicator or gauge. CSA approved, testable external tank mount device. 260/360 litre tank standard. Tanks equipped w/ return flow downpipes, cover gasket, 5 psi breather cap. Standard on gas engines. Ca90: 25,900 lbs. 5' wide x 8' long x 41" high. Approximately 1350 lbs (615 kg). Approximately 688 lbs (313 kg). 3

Caution: Exceeding the stated maximum system pressure will void all warranties and may lead to equipment damage and unsafe operating conditions. Alteration or substitution of components may affect the overall pressure rating of the system. The lowest pressure rating of any individual component in a hydraulic system is the maximum pressure rating of the entire system. Wear and fatigue will affect the overall performance of the hydraulic equipment. 4 To alternate configurations, please contact a Weatherford representative to ensure optimized power Transmission. 5 Number of teeth provided on drive sprocket for 4:1 ratio (3:1 = 48 teeth, 5.14:1 = 28 teeth). Driven sprocket always has 144 teeth.

4

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Table 2 : Hydraulic Drive Equipment Options OPTIONS

DESCRIPTION

Tachometer

Magnetic pickup and display mounted on drive, CSA approved Pyro-plug, CSA Class 1 device, 80 C Murphy 20TD, adjustable temperature, not CSA approved 3 1/8", 3000 psi, R31, 1 1/4" bore 3 1/8" Flanged Integral Stuffing Box, 1 1/4" bore 3 1/8" Flanged Retrofit Stuffing Box, 1 1/4" bore Kit includes cooler, hoses and brackets Customer defined

Temperature Switch

Wellhead Flange Oil Cooler Install Customer Supplied Equipment

Figure 1 : Weatherford Hydraulic Wellhead Drive POLISHED ROD CLAMP

LIFTING EYE

HINGED ENCLOSED GUARD

SYNCHRONOUS DRIVE BELT BELT TENSION ADJUSTMENT SCREWS

BEARING BOX

CASE DRAIN LINE

SUPPORT FRAME STUFFING BOX CAP WELLHEAD FRAME

HYDRAULIC MOTOR QUICK CONNECT COUPLERS TO SKID UNIT

FLANGED CONNECTION 3 1/8", 3000# (OPTION) PIN CONNECTION 2 7/8" API

5

Figure 2 : Weatherford Inline HTD Wellhead Drive LIFTING EYE

POLISHED ROD CLAMP

CASE DRAIN

INLINE HTD HYDRAULIC MOTOR QUICK CONNECT COUPLERS

INTEGRAL STUFFING BOX

Figure 3: Weatherford Hydraulic Power Skid PRIME MOVER 260/360L TANK w / REMOVABLE LID TANK BREATHER DUAL FILTER HEAD W/BUILT IN 25-PSI BYPASS

HYDRAULIC PUMP OIL LEVEL SWITCH

3 MICRON FILTERS MOTOR CASE DRAIN MOTOR QUICK CONNECTORS DRAIN PORT (PLUGGED) FLOW CONTROL SUPPORT STAND

BALL VALVE

6

SUCTION HOSE

ENVIRO SKID W/DRIP PAN

®

Table 3 : Variable Displacement Hydraulic Pump Specifications FRAME SIZE

SUNSTRAND L38

SUNSTRAND V45-74CC

Delivery at 1800 rpm, gpm (I/min) Displacement in3/rev (cc/rev) Maximum Input Speed, rpm Input Mounting Flange Size Input Shaft Size (in) Maximum Operating Pressure, psi (bar) Maximum Operating Temperature, °F (°C)

17.9 (67.8) 2.3 (38) 1800 SAE B 7/8 Keyed 3000 (210) 180 (82)

35.2 (133.2) 4.52 (74) 2400 SAE C 1 1/4 Keyed 4000 (276) 180 (82)

Optimum Oil Viscosity

VICKERS PVH74

VICKERS PVH98

45 33 (170) (125) 6.0 4.5 (98) (73.7) 2100 2200 SAE C SAE C 1 1/4 Keyed 1 1/4 Keyed 3625 3625 (250) (250) 200 200 (93) (93) 40 to 16 cst at operating temperature

KAWASAKI K3VL80 38 (144) 4.88 (80) 3000 SAE C 1 1/4 Keyed 4000 (276) 203 (95)

Table 4 : Fixed Displacement Hydraulic Motor Specifications MOTOR DESIGNATION Displacement in3/rev (cc/rev) Peak Operating Pressure, psi (bar) Maximum Continuous Pressure, psi (bar) Operating Speed (rpm) Maximum Maximum Continuous Minimum Continuous Maximum Output Power, Hp (kW) Continuous Output Power, Hp (kW) Maximum Operating Temperature °F (°C)

VOLVO F12-60

VOLVO F12-80

KAWASAKI K3X112S

VOLVO F12-110

Inline HTD

3.65 (59.8) 6000 (420) 6000 (420)

4.91 (80.5) 6000 (420) 6000 (420)

6.77 (110.9) 5000 (350) 4570 (250)

6.92 (113.4) 6000 (420) 6000 (420)

39.30 (644) 7000 (483) 5000 (350)

5600 4300 50 235 (175) 145 (107) 175 (80)

5200 4000 50 295 (220) 180 (134) 175 (80)

3000 3000 50 257 (192) 234 (175) 194 (90)

4700 3600 50 362 (270) 221 (165) 175 (80)

890 710 20 337 (251) 168 (125) 194 (90)

7

Table 5 : Weatherford Gas Engine Prime Mover Specifications MODEL

DISPLACEMENT

4.3 Litre GM Industrial Engine 5.7 Litre GM Industrial Engine 7.4 Litre GM Industrial Engine 8.1 Litre GM Industrial Engine

4294.18 cc (262 cid) 5736.50 cc (350 cid) 7441.06 cc (454 cid) 8127 cc (496 cid)

COMPRESSION RATIO 9.05:1 9.1:1 9.3:1 9.1:1

BORE AND STROKE

TORQUE

101.60-88.39 mm (4.00 - 3.48 in) 101.60-88.39 mm (4.00 - 3.48 in) 107.95-101.60 mm (4.25 - 4.00 in) 107.95-111 mm (4.25 - 4.37 in)

235 ft-lb @ 2000 rpm 340 ft-lb @ 3200 rpm 400 ft-lb @ 2800 rpm 462 ft-lb @ 3000 rpm

Hp @ 1800 rpm 52 71 98 112

Table 6 : Electric Prime Movers - Totally Enclosed Fan Cooled HORSEPOWER 25 30 40 25/30/40 50 40/50/60 30/40/50 60 75 100 125

SPEED (RPM)

NEMA FRAME

SHAFT DIA (IN)

1200 1800 1200 1800 1200 1800 1130 1200 1800 1800 1200 1200 1800 1200 1800 1200 1800 1200 1800

324T 284T 326T 286T 364T 324T 365T 365T 326T 404T 404T 364T 404T 405T 365T 444T 405T 445T 444TS

2-1/8 1-7/8 2-1/8 1-7/8 2-3/8 2-1/8 2-3/8 2-3/8 2-1/8 2-7/8 2-7/8 2-3/8 2-7/8 2-7/8 2-3/8 3-3/8 2-7/8 3-3/8 2-3/8

8

SHAFT LENGTH BASE TO CENTRE (IN) LINE (IN) 5-1/4 4-5/8 5-1/4 4-5/8 5-7/8 5-1/4 5-7/8 5-7/8 5-1/4 7-1/4 7-1/4 5-7/8 7-1/4 7-1/4 5-7/8 8-1/2 7-1/4 8-1/2 4-3/4

8 7 8 7 9 8 9 9 8 10 10 9 10 10 9 11 10 11 11

®

Hydraulic Drive Calculations To calculate the polished rod torque: 1. Hydraulic motor designation (indicated by the surface drive name). 2. Operating system pressure. 3. Wellhead drive ratio. For example, use an F12-110 operating at 2000 psi with a 4:1 ratio:

To calculate the maximum allowable polished rod speed and torque values for ratios other than 4:1: 1. Hydraulic pump pressure (from Table 3). 2. Hydraulic pump displacement (from Table 3). 3. Hydraulic pump speed (from Table 3). 4. Hydraulic motor displacement (from Table 4). 5. Wellhead drive ratio. For example:

From Table 1, polished rod torque with a 4:1 drive = 36.7 lb-ft per 100 psi Polished rod torque = 36.7 lb-ft / 100 psi x 2000 psi = 734 lb-ft

1. Sunstrand V45-74cc displaces 4.52 in3 / rev with a maximum pressure of 4000 psi at 1800 rpm (maximum prime mover speed) 2. Volvo F12-110 motor displaces 6.92 in3 / rev 3. 5.14:1 Wellhead drive ratio

To calculate the expected polished rod speed: 1. Hydraulic motor displacement in in3 / rev (from Table 4). 2. Hydraulic pump displacement in in3 /rev (from Table 3). 3. Hydraulic pump shaft speed. 4. Wellhead drive ratio.

The formula to calculate the maximum allowable polished rod speed is as follows: Maximum Polished Rod Speed = (Pump Displacement x Pump Speed) / Motor Displacement / Ratio

For example, use the following information:

For example:

1. Volvo F12-110 displaces 6.92 in3 / rev. 2. Sunstrand V45-74cc displaces 4.52 in3 / rev. 3. 1800 rpm (maximum speed). 4. 4:1 Wellhead Drive Ratio.

Max. P.R. Speed = (4.52 in3/rev x 1800 rpm)/ 6.92 in3/rev/5.14 = 229 rpm

The formula to calculate polished rod speed is as follows: (Pump Shaft Speed x Pump Displacement) / Motor Displacement / Wellhead Drive Ratio For example: Polished Rod Speed = (1800 x 4.52) / 6.92 / 4 = 294 rpm To calculate horsepower used by the hydraulic system:

The formula to calculate the maximum allowable polished rod torque is as follows: Maximum Polished Rod Torque = (Motor Displacement x Pump Pressure) / 75.398 x Ratio For example: Max. P.R. Torque = (6.92 in3/rev x 4000 psi)/ 75.398 x 5.14 = 1887 lb-ft The formula to calculate the system maximum torque per 100 psi is as follows:

The formula to calculate horsepower is as follows: hp = Pressure x Pump Displacement x Pump Speed 395,934 For example: hp = (2000 psi) ( 4.52 in3 / rev) (1800 rpm) 395,934 = 41.1 hp

Maximum System Torque / 100 psi = (Max. Polished Rod Torque / Pump Pressure) x 100 For example: Maximum System Torque / 100 psi = (1887 lb-ft / 4000 psi) x 100 = 47.2 lb-ft / 100 psi

9

Figure 4: Hydraulic Pump Details PUMP CASE DRAIN

SUCTION (FROM TANK)

DELIVERY ADJUSTMENT SCREW

HYDRAULIC PUMP

PRESSURE COMPENSATOR ADJUSTMENT SCREW

TO TANK

SYSTEM PRESSURE GAUGE

MOTOR CASE DRAIN

BALL VALVE (SHOWN OPEN)

FROM MOTOR (RETURN)

TO MOTOR (PRESSURE)

Top View DELIVERY ADJUSTMENT SCREW PUMP CASE DRAIN

SYSTEM PRESSURE GAUGE

PRIME MOVER BALL VALVE (SHOWN OPEN)

TO TANK PRESSURE COMPENSATOR ADJUSTMENT SCREW

FROM MOTOR (RETURN)

HYDRAULIC PUMP

TO MOTOR (PRESSURE)

Front View 10

SUCTION (FROM TANK)

®

Variable Displacement Hydraulic Pump Setup Procedures: Gas Engine Startup Procedure: 1. Check engine and hydraulic system oil levels. 2. Make sure the 2" ball valve on the pump suction line is open. 3. Make sure the ball valve in the 1" line is open. 4. Open the fuel valve. 5. Open the throttle 3 to 4 turns. 6. Hold the Murphy Switch button and the ignition button or key until the engine starts. Release the ignition while holding the Murphy Switch for 2-3 seconds more. 7. Adjust fuel valve and throttle to maintain engine speed.

To Safely Shut Down the Drive and Skid

To Change Polished Rod Speed: Change the speed of the motor by moving the delivery adjustment screw on the pump: 1. Loosen the lock nut on the delivery adjustment screw or knob. 2. Turn the hex head screw or speed adjustment knob to adjust speed. CW direction slows the polished rod speed. CCW direction increases speed. Adjust upward to the final desired speed. 3. Tighten the lock nut on the delivery adjustment screw or knob.

Damage can occur in the pump and motor if operated under load while oil is cold and viscous. During cold weather (when tank temperature is below -30˚C):

1. If you need to stop the system, slowly open the ball valve. 2. Allow the well to backspin and then shut off the power. Apply a safety clamp before working on the drive. 3. Shutting down the prime mover (particularly a gas engine) can cause torque to be locked in the rod string. Always open the ball valve before working on the drive. To Start the Drive Skid in Cold Weather:

1. Before you start the system, open the ball valve. Disconnect the pressure and return lines from the motor and connect them together. Start the prime mover to circulate the oil. Circulating in this manner allows the pump to warm the fluid before putting a load on the system. 2. Reconnect hoses to the motor only after the fluid temperature has reached -10˚C.

Setting the Torque Limit (Pressure Compensator) at the Hydraulic Pump: 1. With skid power unit running slowly open the ball valve to bypass hydraulic motor. 2. Uncouple hoses from hydraulic motor at wellhead drive. 3. Slowly close the ball valve, loosen the lock nut, and adjust pressure compensation screw at hydraulic pump. To give the best control when making adjustments to the pressure setting, always approach the desired pressure from a lower pressure. Tighten the lock nut. 4. Slowly open the ball valve. 5. Reconnect hoses to hydraulic motor. 6 Slowly close the ball valve to resume. Pressure should not exceed maximum allowable rod torque to prevent damage to rods. Maximum allowable rod torque is a function of the rod size and grade, and the amount of axial load on the rod. See calculation example on page 9 to calculate polished rod torque from system pressure.

11

Hydraulic System Preventive Maintenance: Hydraulic Fluid Viscosity:

Hydraulic Fluid Cleanliness:

Use anti-wear hydraulic oil, or automotive type crankcase oil. Select a viscosity grade that will allow optimum viscosity between 40cSt (80 SUS) to be achieved at normal operating temperatures. Viscosity levels of 1000 cSt or higher are damaging to hydraulic equipment, therefore use a grade with good low temperature viscosity characteristics for winter application. Fluid with very low viscosity will not provide adequate lubrication during hot weather.

Fluid should be filtered adequately to meet ISO 17/15/13 cleanliness specification for variable displacement pumps and axial piston motor systems. This means, in a one ml sample, you are allowed:

Hydraulic fluid must have the correct balance of cleanliness, materials and additives to protect against the wear of components, elevated viscosity and inclusion of air. An ISO 32 hydraulic fluid with viscosity enhancers and anti-wear additives are recommended for use. Hydra-Blue 36 Univis N 32

640 to 1300 particles >2 microns 160 to 320 particles > 5 microns 40 to 80 particles > 15 microns

Manufacturers warranty requires that fluids be kept at these levels. A filter and oil change schedule should be determined based on operating conditions and periodic oil testing. Oil change frequency depends on amount of contaminants that have been ingested and overall system maintenance.

Contamination Causes Most Hydraulic Failures: Particulate contamination can be left over manufacturing, ingested through breather cap or worn seals, added with dirty new oil, or internally generated as rust or wear particles. Change your filters! Water contamination can occur from condensation or reservoir leakage or when opening and filling the reservoirs. A very small amount of water (200 ppm) shortens the bearing life by 50%. Make sure that the tank cover seals properly. Avoid shutting down the drive on cold days which might encourage condensation. Air contamination comes from the system leaks or pump

aeration. When air is present in the system a pump does extra work to compress the air. There is a loss of lubrication, and the air accelerates corrosion of metal parts. Oxidation of additives may also occur. Backspin braking effectiveness could be compromised. Inspect for and repair leaks that might occur in the system.

12

®

Table 7 : Maintenance Schedule - Hydraulic Power Unit (Skid) SERVICING FREQUENCY

DESCRIPTION

SPECIFICATIONS

MAINTENANCE

System Pressure Gauge

0 - 5000 psi

Replace when gauge won't zero.

As required

Top up as required.

Weekly

Hydraulic Oil Tanks

260 or 360 Litres HydraBlue MG36 or equivalent

Replace oil and clean out hydraulic tank.

Annually

Hose and Filter Connections

Hydraulic pump, filters, and quick couplers

Check for leaks and repair as necessary. Use Loctite PST Pipe Sealant (#56765).

As required

Return Filters

3 micron, 25 psi by-pass

Check plugged filter indicators and gauges. - Replace the filter if red indicator is showing or pressure on gauge is 25 psi.

Weekly*

Low Hydraulic Oil Level Shutdown

Murphy Switch

Make sure the switch is connected and in working order.

Weekly

Hydraulic Pump

Sunstrand, Vickers or If the pump or motor fails the hydraulic oil will be Kawasaki contaminated. Flush the tank and hoses. Install new filters and oil before restarting.

Prime Mover

Gas or Electric

As per the manufacturers specifications.

As required As required

* Filters and oil are typically changed annually.

Table 8 : Maintenance Schedule - Hydraulic Wellhead Drives DESCRIPTION

SPECIFICATIONS

MAINTENANCE

Stuffing Box

7 rings

Use EP Lithium Grease, follow directions as itemized in the Weatherford Stuffing Box Operators Manual

Belt Tension

Locking push bolt

Bearing Box Hydraulic Leaks

EP Lithium Grease Quick Connects and motor ports

SERVICING FREQUENCY

Per field experience To adjust belt tension: loosen 2 bolts holding Check and tighten motor mount plate to subframe, loosen locking after the first 3 weeks nut on push bolts, adjust push bolts. then as required. Do Retighten locking nuts. not overtighten. Grease the bearing box with two shots of Once per Week grease when greasing the stuffing box. Check for leaks at the hose connections.

13

Once per Week

Table 9 : Maintenance Schedule - Weatherford Supplied Gas Engine Prime Movers MAINTENANCE

SPECIFICATIONS

CAPACITY

SERVICING FREQUENCY

Change Engine Oil1,2

4.3 litre GM Industrial Engine 6.7 litre GM Industrial Engine 7.4 litre GM Industrial Engine 8.1 litre GM Industrial Engine

4.8 litres 5.3 litres 8.5 litres 8.5 litres

First change after 50 hours, then every 200 hours.

Check Coolant System

50/50 water/antifreeze

Check Governor Oil

ESSO Extra XD-3 0W30

Inspect air cleaner, belts, fuel regulator, for system leaks, etc. 3

1

250 ml

Check level weekly. Check concentration seasonally. Flush system annually. Check frequently for leaks. Check monthly. Replace as needed.

The industrial engine is supplied with a lightweight, high detergent cleaning oil. It should be changed after a 50 hour break-in period. Subsequent oil changes should be made every 200 hours with an API SJ approved motor oil, weight appropriate for the season. 3 Fur further maintenance reference, refer to API Recommended Practise 7C-11F Recommended Practise for Installation. Maintenance and Operation of internal-Combustion Engines. 2

Safety Switches/Indicator Gauges: Weatherford Engines are supplied with these indicators: Amp meter Tachometer with hour gauge and pre-set safety switches (Do not tamper with the settings) Engine Oil Temperature Oil Pressure Switch

14

®

Troubleshooting Hydraulic Skids and Drives Problem: Gas engine prime mover won't start or has shut down. -Safety switches may have shut the unit down: Check oil pressure and temperature in gas engines. Check oil level, temperature (optional switch) in hydraulic tanks. -Check for lack of fuel, closed valve, or stuck regulator. -Check for ignition problems: wet ignition system or grounded ground wire. -Review API recommended practice 7C-11F for Installation, Maintenance, and Operation of Internal Combustion Engines for further troubleshooting and maintenance practices. Problem: Hydraulic System is operating at high temperatures.

Problem: Polished rod turns slower than expected. -Check the flow (speed) control position on the pump. -There may be a 5-10% drop in speed when the hydraulic system is hot due to inefficiency with lower oil viscosity. -Prime mover may be undersized for the application. -If the polished rod turns very slowly (40 rpm) at 1000 psi, check that the backspin control check valve is installed correctly. -Check the ball valve to ensure that it is seated properly and not worn. -If the pump is operating within 200 psi of compensation (torque limit setting), fluid may be bypassing within the pump and flow will be reduced. Problem: Polished rod does not turn.

-Eliminate restrictions in the hydraulic lines: remove hydraulic tubing rotators, replace small hoses and quick couplers with larger ones, etc. -Pump is continually compensating because it is at its torque limit. -If operating horsepower is above 20 hp (pressure x gpm / 1714), the system may be generating enough heat to require an oil cooler. -Check the ball valve to ensure that it is seated properly and not worn.

If the pressure is low: -Check that the suction line 2" ball valve is open. -Check that the 1" ball valve is closed. -Check to ensure drive belts and sprockets are intact. If the pressure is high: -Check that the quick couplers are connected properly and do a visual check of the couplers. -The prime mover may be undersized, the hydraulic pump may be compensating at its maximum pressure limit, or the downhole pump may be seized.

Problem: Prime mover is running, but the hydraulic pump is not developing pressure.

Problem: Backspin speed is higher than 50 rpm or is not consistent.

-Check that the drive coupling between the motor and the pump is intact. -Check that the ball valve is closed. -Check that the flow (speed) control on the pump is not in the neutral position (all the way in).

-Check that the check valve is on the pressure side of the pump, and oriented in the right direction (there is an arrow indicating free flow direction on the check valve. This should be pointing toward the hydraulic motor). -Check the hydraulic lines for leaks, where air could leak in. Air in the lines can cause uncontrolled or inconsistent backspin.

15

PC Pump Division of Weatherford Canada Partnership Warranty This shall be the only warranty given by PC Pump Division of Weatherford Canada Partnership ("Partnership"), and no other warranty by Partnership, Express or Implied, shall be applicable, including any implied warrant of merchantability or any implied warranty of fitness for a particular purpose. Subject to the limitations and conditions herein, Partnership warrants its products (with the exception of rotating stuffing boxes) to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of installation or eighteen (18) months from the date of shipment, whichever occurs first. Partnership warrants rotating stuffing boxes to be free from defects in workmanship and material under normal use and service for a period of three (3) months from the date of installation or nine (9) months from the date of shipment, whichever occurs first. Partnership's obligations under this warranty shall be limited to repairing, replacing or issuing credit for, at Partnership's option, any product or parts it finds to be defective in material or workmanship. Partnership must be given a reasonable opportunity to investigate. Shipping and handling in connection with this warranty will be at customer's expense. Products sold by Partnership, but manufactured by another company, will carry only the warranty of the manufacturer, and the customer will rely solely on that warranty. Services provided by Partnership are warranted for a period of ninety (90) days from the date the services are rendered. The liability of Partnership for any loss or damage resulting to the customer or user or any third party from any defect in any product or service will not, in any case, exceed the selling price that Partnership received from the customer for the product or service. The above shall be the customer's exclusive remedy with respect to products or services. In no event will partnership be liable for incidental, consequential, special, indirect or other damages of any nature. This warranty will not apply and will be void if the product fails as a result of downhole corrosion; non-compatibility of produced fluid with the stator and/or rotor; general wear and abrasion; incorrect installation, removal, use or maintenance; operation outside of the manufacturer's recommended guidelines; alteration; accident; abuse or negligence. Hydraulic wellhead drives, hydraulic power transmission units or rotating stuffing boxes sold individually for use with equipment not manufactured by Partnership will not be covered under this warranty. Partnership does not warrant that any of the products sold by it, if used or sold in combination with other equipment or used in the practice of methods or processes, will not, by virtue of such combination or use, infringe patents of other, and Partnership shall not be liable for any patent infringement arising from, or by reason of, any such use or sale. Furthermore, Partnership shall not be liable for any patent infringement arising from, or by reason of, any use or sale of any materials, equipment or products not of Partnership's manufacture or for the use or sale of any materials, equipment or products, or other goods specially made, in whole or in part, to the customer's design specifications.

16


Manufacturing Facility Weatherford Artificial Lift Systems Canada PC Pump Products & Services 4604 - 62nd Avenue Lloydminster, Alberta T9V 2G2 Canada 780/875-0103 Telephone 780/875-0963 Fax

Canada Weatherford Artificial Lift Systems Canada PC Pump Products & Services 2801 - 84th Avenue Edmonton, Alberta T6P 1K1 Canada 780/417-4800 Telephone 780/464-5198 Fax


®

www.weatherford.com


®

GM 4.3L, 5.7L & 8.1L Engine Operators Manual

Version 1.0

®

Foreword The information, specifications and illustrations in this publication are up to date at the time of printing. Our policy is one of continued development and therefore we reserve the right to amend any of the information contained in this manual or binder without prior notice.

Disclaimer This manual is intended to give our customer basic information regarding the design, installation and operation of the GM Industrial Engine. It is not intended to be a complete source of information on these matters. The customer is responsible for using this information in a correct and safe manner. For assistance, contact your nearest Weatherford representative. Operating the engine beyond the parameters outlined in this manual without factory approval may be damaging to the equipment and/or personnel in which case Weatherford PC Pump cannot accept any responsibility whatsoever and disclaims all liability thereof.

8.1L Engine Operators Manual

Table of Contents General Specifications

Pg. 4-5

Operating Instruction

Pg. 6

Installation Setup Data

Pg. 7

Engine Operating System Maintenance

Pg. 8

Maintenance Schedule

Pg. 9

Appendix A

Pg. 10

Weatherford Progressing Cavity Pump Ltd. Warranty

Pg. 11

®

Specifications Engine ENGINE Type Rating

4.3L

5.7L

Spark Ignition, Gaseous Fuel V6 52 BHP @ 1800 RPM

8.1L

Spark Ignition, Gaseous Fuel V8 71 BHP @ 1800 RPM 120 BHP @ 1800 RPM 5.7L (350 c.i.d.) 8.1L (496 c.i.d.)

4.3L (262 c.i.d.)

Displacement Bore

101.6 mm (4.00 in.)

101.6 mm (4.00 in.)

107.950 mm (4.250 in.)

Stroke Compression Ratio

88.39 mm (3.48 in.) 9.2:1

88.39 mm (3.48 in.) 9.1:1

111.00 mm (4.370 in.) 9.1:1

Delco EST

Delco EST

N/A

10-12° BTDC (Natural Gas, Gasoline)

12° BTDC @ 700 RPM (HEI Distributor), LPG

N/A

AC 41-932 (0.027" gap)

AC 41-932 (0.027" gap)

1-6-5-4-3-2

1-8-4-3-6-5-7-2

1-8-7-2-6-5-4-3

700 RPM

800 RPM

Ignition System Timing Spark Plugs Firing Order Idle

700 RPM

Denso # TJ 14R-P15 (0.032' gap)

* Calculations in this chart are based on running propane fuel at 2000ft elevation.

Lubrication System OIL PRESSURE

4.3L

5.7L

8.1L

@ 2000 RPM

124 kPa (18 PSI)

124 kPa (18 PSI)

365 kPa (53 PSI)

@ Idle Minimum

41 kPa (6 PSI)

41 kPa (6 PSI)

41 kPa (6 PSI)

Oil Type All Temperatures 5°C - 27°C

SAE 10W30 SG/SH (40° - 80°F)

SAE 30 SG/SH

Above 27°C (80°F ) Above -18°C (0°F)

SAE 40 SG/SH SAE 15W40

Oil Filter

AC - PF52

Oil Capacity W/O Filter

4.26L (4.5 Qts.)

AC-PF25 5.7L (6 Qts.)

Fill to dipstick FULL Mark

1

AC-PF54 7.6L (8 Qts.)

Engine Operating System Maintenance The recommended maintenance schedule is a guideline to ensure the engine remains in good operating condition. However, depending on operating practices more frequent maintenance inspections and/or replacements may be required. For further inquiries for engine maintenance contact your distributor. Keep all maintenance records and receipts to qualify the engine for warranty repairs.

SAFETY WARNING: to avoid personal injury a qualified technician should perform all engine maintenance and repairs.

Engine Oil Requirements Turn off engine and allow a few minutes for the oil to drain back into the oil pan to ensure the oil indicator gauge accurately reads the fluid level.

Note: Using oil without this designation can cause engine damage and may void warranty coverage.

Engine Oil Additives Do not add any type of Engine Oil Additives. Contact your representative for further information or clarification.

Synthetic Oils Weatherford does not approve or disapprove the use of synthetic engine oils. Synthetics may offer advantages in cold temperature pumpability and high temperature oxidation resistance. However, synthetic oils have not been proven to provide operational or economic benefits over conventional petroleum-based oils in engines. The use of synthetic oil does not permit the extension of oil change intervals.

ALWAYS use "SH" QUALITY ENERGY CONSERVING OILS of proper viscosity. The "SH" designation may be shown alone or in combination with other designations such as SH/CD, SH/SG, etc. These letters show American Petroleum Institute (API) levels of quality.

2

®

Installation Setup Data The following information lists the changes required when operating engines on fuels other than Natural Gas as supplied by the manufacturer. To operate engine with Propane setup must be changed (as noted below) to prevent premature engine failure.

Natural Gas (NG) Operation ENGINE

4.3L

Mixer Assembly

IMPCO Model 200/225 Series

Fuel Regulator

IMPCO Model IMP-53

Fuel Inlet Pressure to Mixer

5.7L

8.1L

IMPCO Model 200/225 Series (Air Valve CV1-12)

IMPCO Model C200M

IMPCO Model IMP-61

N/A

139.7 mm Wg ± 12.7 mm

139.7 mm Wg ± 12.7 mm

139.7 mm Wg ± 12.7 mm

(+ 5.5 in. WC ± 0.5 in. at idle)

(+ 5.5 in. WC ± 0.5 in. at idle)

(+ 5.5 in. WC ± 0.5 in. at idle)

16° BTDC @ 700 RPM (HEI Distributor)

N/A

Base Timing

10° BTDC @ 700 RPM

Maiximum Total Timing Advance

36° BTDC @ 2600 RPM

N/A

N/A

Air / Fuel Mixture

2% O❏(Exhaust) @ Rated Speed and Power



10° BTDC @ 700 RPM (EST Distributor)

Fuel Supply Inlet Pressure (Ng): Inlet fuel pressure (natural gas) to the regulator must be maintained between (7-14" WC) during full power operation.

All fuel system installations must meet all federal, state, and local codes along with applicable NFPA regulations. Specifications revised 3/28/95

3

Propane Gas (LPG) Operation ENGINE

Mixer Assembly

Vapour Fuel

Liquid Fuel

4.3L

5.7L

8.1L



IMPCO Model IMP-53

IMPCO Model IMP-61

N/A

IMPCO Model EB

N/A

IMPCO Model EB

IMPCO Model C200M

NOTE: A balanced line should be installed between the gas mixer and the regulator when operating this engine in a dusty or dirty environment. NOTE: When operating engines on propane it will be necessary to retard engine base timing.

Fuel Inlet Pressure to Mixer

Base Timing

Maiximum Total Timing Advance

Air / Fuel Mixture

-50.8 ± 12.7 mm Wg (-2.0 ± 0.5in. WC at idle)

-50.8 ± 12.7 mm Wg (-2.0 ± 0.5in. WC at idle)

-50.8 ± 12.7 mm Wg (-2.0 ± 0.5in. WC at idle)

12° BTDC @ 700 RPM (HEI Distributor)

6° BTDC @ 700 RPM

6° BTDC @ 700 RPM (EST Distributor)

36° BTDC @ 2600 RPM

N/A

0.5 to 1.5% CO (Exhaust) at Rated Speed and Power


Fuel Supply Inlet Pressure (LPG) With engines operating on LPG vapour, the fuel pressure at the regulator inlet must be maintained between 177-356 mm WG (7-14" WC) during full operation. The low pressure regulator (LPR) is designed to supply the correct gas pressure to the mixer. Regulators must not be mounted further than 18" from the mixer for best operation. With engines operating on liquid LPG, require full tank pressure to both VFF30 Fuel Lockoff Valve and EB model regulator during full power operation.

Refer to Appendix "A" for Pressure Conversion Chart

4

N/A


®

FUEL SYSTEM

4.3L

5.7L

8.1L

Propane

IMPCO

IMPCO 200/225 Series

IMPCO

Natural Gas

IMPCO

IMPCO 200/225 Series c/w CV1-12 Air Valve

IMPCO

Gas Mixer

AIR INDUCTION SYSTEM

Air Filter Element

COOLING SYSTEM Thermostat

STARTING SYSTEM Type Battery Requirement

4.3L

5.7L

8.1L

71°C (160°F)

71°C (160°F)

90°C (195°F)

4.3L

5.7L

8.1L

12 Volt Negative Ground 550 CCA Minimum

650 CCA Minimum

485 CCA Minimum

Delco PG260

Starter

CHARGING SYSTEM Alternator Rating

4.3L Delco 12 Volt

5.7L

8.1L

Delco 12 Volt

Delco 12 Volt

42 Amps

42 Amps

Operating Instructions Engine Warm - Up Allow an engine that is below normal operating temperatures to idle for approximately five (5) minutes prior to applying a load.

Stopping the Engine 1. Decrease engine speed back to normal idle speed. Disengage the load from the engine. 2. Allow the engine to idle for four (4) to five (5) minutes at no load to cool down. After four or five minutes, stop the engine by turning the key to the OFF position.

5

42 Amps

Maintenance Schedule Maintenance Items

Interval (Hours) DAILY

Check engine oil level

XX

Check engine for obvious water, oil, fuel, or exhaust leaks

X

Check engine for loose, missing, or damaged parts and/or fasteners

X

Change engine oil and filter Check accessory drive belts for cracks, fraying, wear, and tension Inspect hoses for cracks, swelling, weather checking, or deterioration Inspect electrical system - check for loose, dirty, or damaged wires Inspect battery-check for case damage or corrosion on cables

250

500

750

1000

1200

1500

1750

2000

Change engine oil and filter after first 50 hours of operation and every 200 hours thereafter.

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Inspect Ignition system

X

X

Replace spark plugs Check air cleaner element

X X

X

X

Replace air cleaner element

X

X

X

X

X

Check fuel mixer - adjust as necessary Check coolant level (self contained cooling system models only)

X X

X

6

X

X

X

X

X

®

Appendix "A" PRESSURE CONVERSION CHART 1 IN. WATER = 0.0735 IN. MERCURY 1 IN. WATER = 0.0361 PSI 1 IN. MERCURY = 13.6000 IN. WATER 1 IN. MERCURY = 0.4910 PSI

1 PSI = 27.7000 IN. WATER 1 PSI = 2.0360 IN. MERCURY 1 PSI = 6.895 kPa 1 kPa = 0.145 PSI

PC Pump Division of Weatherford Canada Partnership Warranty This shall be the only warranty given by PC Pump Division of Weatherford Canada Partnership ("Partnership"), and no other warranty by Partnership, Express or Implied, shall be applicable, including any implied warrant of merchantability or any implied warranty of fitness for a particular purpose. Subject to the limitations and conditions herein, Partnership warrants its products (with the exception of rotating stuffing boxes) to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of installation or eighteen (18) months from the date of shipment, whichever occurs first. Partnership warrants rotating stuffing boxes to be free from defects in workmanship and material under normal use and service for a period of three (3) months from the date of installation or nine (9) months from the date of shipment, whichever occurs first. Partnership's obligations under this warranty shall be limited to repairing, replacing or issuing credit for, at Partnership's option, any product or parts it finds to be defective in material or workmanship. Partnership must be given a reasonable opportunity to investigate. Shipping and handling in connection with this warranty will be at customer's expense. Products sold by Partnership, but manufactured by another company, will carry only the warranty of the manufacturer, and the customer will rely solely on that warranty. Services provided by Partnership are warranted for a period of ninety (90) days from the date the services are rendered. The liability of Partnership for any loss or damage resulting to the customer or user or any third party from any defect in any product or service will not, in any case, exceed the selling price that Partnership received from the customer for the product or service. The above shall be the customer's exclusive remedy with respect to products or services. In no event will partnership be liable for incidental, consequential, special, indirect or other damages of any nature. This warranty will not apply and will be void if the product fails as a result of down hole corrosion; non-compatibility of produced fluid with the stator and/or rotor; general wear and abrasion; incorrect installation, removal, use or maintenance; operation outside of the manufacturer's recommended guidelines; alteration; accident; abuse or negligence. Hydraulic wellhead drives, hydraulic power transmission units or rotating stuffing boxes sold individually for use with equipment not manufactured by Partnership will not be covered under this warranty. Partnership does not warrant that any of the products sold by it, if used or sold in combination with other equipment or used in the practice of methods or processes, will not, by virtue of such combination or use, infringe patents of other, and Partnership shall not be liable for any patent infringement arising from, or by reason of, any such use or sale. Furthermore, Partnership shall not be liable for any patent infringement arising from, or by reason of, any use or sale of any materials, equipment or products not of Partnership's manufacture or for the use or sale of any materials, equipment or products, or other goods specially made, in whole or in part, to the customer's design specifications.


Canada Weather eatherfor ford d Artificial Artificial Lift Systems Canada PC Pump Products & Services Avenue 4604 - 62nd Avenue Lloydminster,, Alberta Lloydminster Alberta T9V 2G2 Canada 780/875-0103 Telephone Telephone 780/875-0963 Fax

Manufacturing Facility Weatherford Artificial Lift Systems Canada PC Pump Products & Services Avenue 2801 - 84th Avenue Edmonton, Alberta Alberta T6P 1K1 Canada 780/417-4800 Telephone Telephone 780/417-3146 Fax

Worldwide Customer Service Service Weather eatherfor ford d Artificial Artificial Lift Systems Inc. 515 Post Oak Blvd. Houston, Texas Texas 77027 United States 713/693-4800 Telephone Telephone 713/693-4323 Fax als@weatherfor als@weather ford.com d.com

®

www.weatherford.com


®

Weatherford Stuffing Box Operators Manual

Version 1.2

®


Disclaimer This manual is intended to give our customers basic information regarding the design, installation and operation of PC Pump Products & Services wellhead stuffing boxes. It is not intended to be a complete source of information on these matters. The customer is responsible for using this information in a correct and safe manner. For assistance, contact your nearest Weatherford representative. The operation of any Weatherford wellhead stuffing boxes beyond the parameters outlined in this manual without factory approval may be damaging to the equipment and/or personnel in which case Weatherford Canada Partnership cannot accept any responsibility whatsoever and disclaims all liability thereof.

Weatherford Stuffing Box Operators Manual

Table of Contents

Introduction

Pg. 1

Availability

Pg. 1

Applications

Pg. 1

Figure 1: Conventional Stuffing Box and Wellhead Frame

Pg. 2

Stuffing Box Installation Instructions

Pg. 3-4

Conventional Units

Pg. 3

Retrofit Version

Pg. 4

Polished Rod Removal

Pg. 4

Integral Version

Pg. 4

Jampak Version

Pg. 4

Stuffing Box Maintenance

Pg. 5

Conventional Units

Pg. 5

Rotating Stuffing Boxes (Retrofit and Integral)

Pg. 6

Jampak Maintenance

Pg. 6

Jampak Injection Procedure

Pg. 6-7

Stuffing Box Troubleshooting

Pg. 8

PC Pump Products & Services Weatherford Canada Partnership Warranty

Pg. 10

®

Introduction All Progressing Cavity Drives require a stuffing box to seal between the polished rod and tubing. Weatherford PC Pump manufactures three stuffing boxes: • Conventional • Retrofit • Integral Prior to 1997 the Conventional Stuffing Box was the only one available (Figure 1). Numerous combinations of rope and/or metallic packing are available for these. With PC applications continuing to expand a Retrofit (rotating) Stuffing Box was introduced for more difficult operating conditions. The "Retrofit" internals were placed into a flanged case to become the Integral Stuffing Box.

Availability The following table demonstrates which stuffing boxes are available with which drives:

HTD

HTD

HTD-I

M2

M2-I

M4/MC4

M4-I

MG

Conventional

YES

NO

YES

N0

YES

NO

YES

Retrofit

YES

NO

YES

NO

YES

NO

YES

Integral

YES

YES

NO

YES

NO

YES

YES

Applications The following is a guideline of the applications each stuffing box was designed for: Conventional • all vertical low to medium speed wells • all low to medium abrasive wells Retrofit

• slant or horizontal wells • high speed wells • environmentally sensitive areas

Integral

• same applications as the "retrofit" but is an integral part of the drive, therefore eliminating the booth (wellhead frame)

1

Figure 1 : Conventional Stuffing Box and Wellhead Frame

1/2" PACKING (1) TOP BUSHING STUFFING BOX CAP

1/2" PACKING (6)

WELLHEAD FRAME SPRING GREASE ZERK BOTTOM BUSHING

3 1/8" 3000 PSI Flange (Optional)

2 7/8" EUE PIN

2

®

Stuffing Box Installation Instructions

Conventional Units With the rod string and polished rod installed and supported from the flow tee, follow this procedure: 1. 2. 3.

4.

5.

6. 7. 8. 9.

10.

11.

12. 13. 14.

Pump a few shots of grease into the wellhead drive stuffing box. File off burrs and rough spots on the polished rod or you may damage the bushings in the drive shaft. Spray lubricating oil on the polished rod to clean and lubricate it. This important step will prevent the polished rod from being caught in the tight tolerances of the shaft and stuffing box. Never leave pipe wrench marks on polished rods. With the stuffing box mounted on the wellhead drive place this unit onto the polished rod with a picker truck or a winch line. Use a polished rod alignment tool (bullet) to keep threads from damaging stuffing box packing. If the polished rod does not go through the stuffing box easily, loosen the three Allen screws (1/4") holding the top brass to the stuffing box cap and try again. Tighten the top brass to the stuffing box cap after the polished rod is installed. Remove the polished rod alignment tool and install the polished rod clamp; then a pony rod. Support the wellhead drive with the picker truck or winch line. Support the rod string weight from the pony rod using rod elevators, and remove the polished rod clamp that was supporting the rod weight. Connect the wellhead drive to the flow tee with a hammer union or directly with flange mount. Ensure proper alignment of the drive to the flow tee to avoid premature wear of drive components. Tighten all wellhead fittings to maximum torque specifications. Remove the picker truck or the winch line. Tighten the polished rod clamp on the polished rod. Do not leave more than one foot of polished rod sticking up above the wellhead drive. Longer stickup presents a safety hazard in the event of high-speed backspin. Some stickup is necessary to be able to grasp the polished rod with the elevator when pulling the rod string. Tightly wrap the safety chain on the wellhead frame around the flow tee to prevent the wellhead drive from backing off during recoil. (On pinned mounts only. Safety chain not required with flange mount.) Grease the conventional style stuffing box prior to startup. Check and tighten all nuts and bolts on the wellhead drive and check and tighten belt tension. Turn power back on to the site, and start the drive.

3

Rotating Stuffing Box Installation Instructions Retrofit Version: Polished Rod Removal Instructions:

1. Follow normal drive installation procedures. Ensure that the polished rod is free from burrs and wrench marks. Use a bullet on the polished rod. There are tight tolerances between the polished rod and the rotating sleeve, so keep alignment of the drive to the polished rod as true as possible.

To remove the polished rod, you must loosen the cap from the rotating sleeve. This will take about two to three revolutions. A backup wrench must be used on the sleeve.

2. Bleed pressure from the flow line to make the installation easier. Pressure in the flow line will make it more difficult to tighten down the cap. 3. Position the rotating sleeve so that it will be between 1/4" and 3/4" above the stationary parts. The sleeve will lift as the cap is tightened. (Refer to photograph)

Integral Version: Follow normal drive installation procedures. Ensure that the polished rod is free from burrs and wrench marks. Use a bullet on the polished rod. There are tight tolerances between the polished rod and the rotating sleeve, so keep alignment of the drive to the polished rod as true as possible.

4. Firmly tighten the cap with a wrench, while backing up the rotating sleeve with a pipe wrench. This cap locks the rotating sleeve to the polished rod and must be tight. Damage to the assembly will result if the cap is not tight. 5. When operating properly, the red cap should turn with the polished rod. There should be a space of 1/4" to 3/4" between the rotating sleeve and the stationary parts below it.

JAMPAK Stuffing Box Installation Instructions • Follow normal drive installation procedures which can be found on Page 9 of the Weatherford Progressive Cavity Drive Manual Version 1.1 (ALS3003.01). • Ensure that polished rod is free from burrs and wrench marks. • Use a bullet or an alignment tool on polished rod to protect JAMPAK from threads. • When installing stuffing box care must be taken to protect the JAMPAK from being damaged. • Tighten stuffing box cap hand tight only. This will maintain constant pressure on the stuffing box spring, which will ensure complete JAMPAK compression. • Do not over tighten the stuffing box cap, as this will cause over heating and accelerate JAMPAK wear, inevitably leading to a premature failure.

4

®

Stuffing Box Maintenance Conventional Units Stuffing box maintenance procedures vary by well application. Some fields have success with daily greasing, some are better left untouched. Some operators find our stuffing box packing materials adequate, others prefer to use beeswax, V-ring packing or other packing types. The following procedure is an example of a recommended maintenance program: After start up, grease once a day for the next two days, then once a week after that. Always wipe away any excess grease and dirt from around the fitting before greasing. To apply grease: 1. Loosen the cap about half a turn. 2. Pump stuffing box full of grease. 3. Tighten down the cap - hand tight only. To Change Packing Rings: 1. Stop the unit and secure the polished rod. 2. Close the rod BOP's 3. Loosen the cap and inspect surface condition of the polished rod. If the polished rod is worn in the stuffing box chamber, reposition or replace the polished rod. Replace packing rings, replace the cap (loosely) and grease stuffing box, tighten the stuffing box cap, and open the rod BOP's. The stuffing box has a brass bushing in the body and another in the cap that centralize the polished rod. Every time that the drive is off the well the brass bushings should be checked for any wear. Use a bushing driver to remove and install the bushings. Do not add packing rings. Replace the entire set every six months or sooner if required. If leaking is a chronic problem, check tolerance on the bushings. Worn bushings will cause leakage. If the brass bushings become worn and oblong shaped; replace them. Do not over tighten the stuffing box cap - this will cause overheating of the stuffing box packing and accelerate wear on the polished rod. Prior to any service, allow the polished rod to backspin completely then LOCK OUT THE POLISHED ROD with a safety clamp.

Standard packing configuration from the top of the stuffing box down: 1 2 3 4 5 6 7

One ring Teflon/Graphite (black) - between the top brass and the stuffing box cap Top brass bushing (attached to stuffing box cap) One ring Teflon/Graphite (black) Four rings of Kevlar/Teflon (yellow) One ring Teflon/Graphite (black) Grease reservoir spring Bottom brass bushing

5

Rotating Stuffing Boxes (Retrofit and Integral) Check for seal wear on a weekly basis. Open the lowest sampling valve on the body of the seal assembly. Some grease may leak out, which is normal. If excessive production fluid comes out, the lower seal may be worn out. Close the sampling valve and call for service to replace the seal assembly before the final seal fails. Grease the assembly weekly with lithium based low-temp. EP grease. Open the lowest sampling valve and apply grease from the other side. Purge out all the old grease. Repeat the process on the upper chamber.

JAMPAK Maintenance • When inspecting the stuffing box, ensure that the cap is still snug. • If cap is loose or production fluid starts to leak, tighten down stuffing box cap to reform JAMPAK to the polished rod.

• When cap has bottomed out on stuffing box body, JAMPAK should be reinjected into stuffing box.

JAMPAK Injection Procedure • Shut down drive. • Back cap off until you have approximately 2-3 threads holding cap on. • Connect injecting gun to the 3/8” fitting on the stuffing box. • Open air bleeder on back of gun.

6

®

JAMPAK Injection Procedure, con’d.

• Inject JAMPAK until the cap starts to feel snug (this will indicate the JAMPAK cavity is full). Caution: Do not over fill stuffing box! • Tighten cap one more complete turn or until snug. • Start-up drive.

Stuffing Box Maintenance Summary TYPE OF STUFFING BOX

Conventional

Rotating

MAINTENANCE

FREQUENCY

Stuffing Box

Grease once a day for two days, then weekly, or per your particular field experience.

Packing

Replace every 6 months or as required.

Grease Type

EP Lithium

Packing Ring Quantity

7 Rings ( 1 is in cap).

Stuffing Box

Purge clean grease through weekly.

Poly Seals

Poly Seals are static so should outlive stuffing box but replace as required.

Grease Type

Lithium based low-temp. EP grease.

Packing Ring Quantity

None required, 2 Poly Seals in cap.

7

Stuffing Box Troubleshooting Conventional Stuffing Box Leaks: Stuffing box leaks are affected by the following conditions: 1. Packing worn or too tight. 2. Bushings worn from misalignment. 3. Drive may be misaligned relative to the equipment below. An indication of misalignment is that the cap will not thread on and off easily. Adjust the position of the drive with support arms to minimize leakage or to minimize current load on motor. Temperature is also an indicator of how much friction is in the stuffing box. 4. Sometimes using a more rigid frame or attachment system will reduce the severity of stuffing box problems. For best results, use a flanged mount with Weatherford's standard heavy duty wellhead frame.

Drive seizes to the polished rod, making it difficult to remove: Shafts and stuffing boxes are designed with tight inside diameter tolerances which could cause them to get caught if the polished rod is scored with wrench marks or has other damage. Always file off wrench marks when handling the polished rod.

0120A027 REV A

Rotating Stuffing Box:

0120A023 REV A

Cap

If the inside sleeve pushes up too high as the cap is tightened:

Rotating Sleeve

1. Make sure there is no pressure in the flow line. 1/4" to 3/4" Space

Stationary Housing

0120A029 REV A

2. Make sure the tapered bushing is seated properly. It may have come out of its seat if the cap was loosened and polished rod was pulled. Push the sleeve downward with a wedge or a hammer, and continue to tighten the cap. If threads are showing under the cap, continue to force the sleeve downward. 3. Make sure polished rod is clean

If assistance with installation or maintenance is required, please contact your nearest Weatherford ALS Service Department

8

REV A

Tapered Bushing

0120A024

If the red cap does not turn with the polished rod, it must be tightened down. Review installation instructions and tighten the cap.

®

Figure 2 : Jampak Stuffing Box CAP

SCREWS

TOP BRASS STUFFING BOX SPRING PINNED STUFFING BOX HOUSING

TOP BRASS SPACER

PACKING RING

BRASS WASHERS JAMPAK O-RING BOTTOM BRASS WITH SEAL GROOVE

WIPER SEALS

BOTTOM BRASS

JAMPAK STUFFING BOX

JAMPAK Troubleshooting Stuffing Box Leaks: Stuffing box leaks are affected by the following conditions: • Stuffing box cap too tight. • Worn bushings/ components from misalignment • Drive may be misaligned relative to the equipment below. An indication of misalignment is that the cap will not thread on and off easily. Adjust the position of the drive with support arms to minimize current load on motor. Temperature is also an indicator of how much friction is in the stuffing box. If assistance with installation or maintenance is required, please contact your local Weatherford representative.

9

PC Pump Products & Services Weatherford Canada Partnership Warranty This shall be the only warranty given by PC Pump Products & Services Weatherford Canada Partnership ("Partnership"), and no other warranty by Partnership, express or implied, shall be applicable, including any implied warrant of merchantability or any implied warranty of fitness for a particular purpose. Subject to the limitations and conditions herein, Partnership warrants its products (with the exception of rotating stuffing boxes) to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of installation or eighteen (18) months from the date of shipment, whichever occurs first. Company warrants rotating stuffing boxes to be free from defects in workmanship and material under normal use and service for a period of three (3) months from the date of installation or nine (9) months from the date of shipment, whichever occurs first. Partnership's obligations under this warranty shall be limited to repairing, replacing or issuing credit for, at Partnership's option, any product or parts it finds to be defective in material or workmanship. Partnership must be given a reasonable opportunity to investigate. Shipping and handling in connection with this warranty will be at customer's expense. Products sold by Partnership, but manufactured by another company, will carry only the warranty of the manufacturer, and the customer will rely solely on that warranty. Services provided by Partnership are warranted for a period of ninety (90) days from the date the services are rendered. The liability of Partnership for any loss or damage resulting to the customer or user or any third party from any defect in any product or service will not, in any case, exceed the selling price that Partnership received from the customer for the product or service. The above shall be the customer's exclusive remedy with respect to products or services. In no event will Partnership be liable for incidental, consequential, special, indirect or other damages of any nature. This warranty will not apply and will be void if the product fails as a result of down hole corrosion; non-compatibility of produced fluid with the stator and/or rotor; general wear and abrasion; incorrect installation, removal, use or maintenance; operation outside of the manufacturer's recommended guidelines; alteration; accident; abuse or negligence. Hydraulic wellhead drives, hydraulic power transmission units or rotating stuffing boxes sold individually for use with equipment not manufactured by Partnership will not be covered under this warranty. Partnership does not warrant that any of the products sold by it, if used or sold in combination with other equipment or used in the practice of methods or processes, will not, by virtue of such combination or use, infringe patents of other, and Partnership shall not be liable for any patent infringement arising from, or by reason of, any such use or sale. Furthermore, Partnership shall not be liable for any patent infringement arising from, or by reason of, any use or sale of any materials, equipment or products not of Partnership's manufacture or for the use or sale of any materials, equipment or products, or other goods specially made, in whole or in part, to the customer's design specifications.

10


Sold & Serviced by:

Worldwide Customer Service 515 Post Oak Blvd. Houston, Texas 77027 Phone: (713) 693-4800 [email protected] [email protected] www.weatherford.com

WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Calgary Sales: (403) 269-7788 Lloydminster: (780) 875-2730






Technical Literature

Technical Literature Available from your PC Pump Representative

PC Pump Detailed Specifications Sheets PC Pump Test Report PC Pump Inspection Report


PC Pump Detailed Specifications Sheet Pump Info: Pump Name - Metric/Imperial:

BMW 56-1000

BMW 350-3200

Operating Style:

Standard

Standard

Geometry Style:

Single Lobe

Single Lobe

Rotor Connection: Rotor Length:

25.4mm API Pin m 6.96

1" API Pin

Rotor Contour Length:

6.83

Rotor Drift Diameter: Rotor Total Weight:

Stator Top Connection:

88.9mm EUE Box

3 1/2" EUE Box

Optional Stator Top Connection:

n/a

n/a

Stator Bottom Connection:

88.9mm EUE Box

3 1/2" EUE Box

Optional Stator Bottom Connection:

n/a

n/a

Max Pump Outside Diameter:

104.9

mm

4.130

Stator Outside Diameter:

100.0

mm

3.937

in

Brand Name:

Rotor Info:

m

274 269

in in

57.66

mm

2.270

in

82

kg

181

lbs

Stator Info:

Stator Length:

in

6.91

m

272

in

Stator Total Weight:

147

kg

325

lbs

Tagbar Distance:

373

mm

14.7

in

© Copyright Weatherford • All rights reserved • Printed August 30, 2002

Page 1 of 1

Weatherford PC Pump Test Report Weatherford PC Pump Inc., Lloydminster, Alberta, Canada Pump ID: W.O.# : Test Temp (C): Stator Run #: Date Tested: Date Installed:

Placed In Stock:

Company: ABC Company Pulled From:

Installed Into:

ABC Field One

Field:

01-01-31-42-25 W3

Location:

7018 7220 30.0 4632 07-Mar-96 01-Apr-96

UWI:

PC PUMP: 56

1000

821

Stator Condition: New

Type: Standard

HN HS

Elastomer Type: G60

Rotor Condition: New

Top #

Rotor Coating: Chrome

PC PUMP TEST DATA: Distributor:

6404

Diff. Press. (psi)

BMW Mack

0

Bott. #

Test Time (sec) 60.2

Hyd. Press. (psi) 270

Pump Eff. (%) 99.7

Torque (ft-lbs) 101.4

CC

300

63.4

505

94.6

189.6

Rotor Major Diameter:

2.261

600

66.8

715

89.8

268.4

Rotor Minor Diameter:

1.712

900

70.8

970

84.7

364.1

300 553

1100

75.6

1170

79.4

439.2

1400

85.6

1475

70.1

553.7

70

1800

112.2

1805

53.5

677.6

2400+

2200

BMW Pump

2600

Tested By:

Test Speed RPM: Torque (100 psi/stage) Eff. (100 psi/stage): Maximum Pressure: Test Bench:

Efficiency & Torque VS Differential Pressure

800

100 90

700

80

600

70

500

60 50

400

40

300

30

200

20 100

10 0

0 0

200

400

600

Pump Efficiency (%)

800

1000

1200

Torque (ft-lbs)

Comments:

Weatherford PC Pump Inc. Registered to: BMW Pump Inc

September 18, 2002

Weatherford PC Pump Inspection Report Weatherford PC Pump Inc., Lloydminster, Alberta, Canada WELL AND PUMP DATA

Company: ABC Company Field: ABC Field One Location: 01-01-31-42-25 W3

WO# : 7220 Date Received: 01-Apr-97 Date Inspected: 02-Apr-97 Inspected By: Roland Distributor: BMW Mack

UWI: Report ID#: 825 PC PUMP: 56 Pump Type:

1000

821

HN

6404

HS

Standard

ROTOR CONDITION Good

Rotor Threads:

Fair

Poor

Top Base Metal : Scored: Checking: Flat Spots:

Middle

Bottom

Top General Wear:

Blank = No Blank = No Blank = No Blank = No

Dull Grey (Acid): Pitting: Broken:

Middle

Bottom

Blank = No Blank = No Blank = No Blank = No

STATOR CONDITION Foreign Material:

None

Top Hot Spots:

Blank = No

Missing Rubber:

Blank = No Pieces:

Middle

Large

Blank = No Blank = No Blank = No Blank = No Blank = No Blank = No

Hard/Cracked: Elastomer Torn: Swollen: Worn: Hardened: Grooved:

Bottom

Small

TAG BAR CONDITION Knocked Out: Rotor Wear Bottom:

Blank = No 6

(inches)

Bent:

Blank = No Above

Pin Shows Wear:

Blank = No

Below

PUMP CONDITION SUMMARY Blank = No Rotor Seized in Stator: (% at 100 psi/stage) Re-Test Efficiency: 70 Pump Install Date: 01-Apr-96 Pump Out: 02-Apr-97 366 Days Current Run: 366 Days Total Run:

Reason For Work Over: Rotor Will Be: Rotor Condition: Stator Will Be: Stator Condition:

Work Over Rechromed General Wear Reused Worn

New Pump Number: Comments:

Weatherford PC Pump Inc.

Registered to: BMW Pump Inc

September 18, 2002


Related Products

Other Equipment to Assist you in Your Pumping Needs.

Progressing Cavity Pumping System Accessories COROD Continuous Sucker Rod Weatherford Sucker Rod PC Surface Transfer Pump Torque Limiter Model M1 VSH2 Nitrogen-Over-Hydraulic Pumping Unit VSH2 Set-Up & Operators Manual


PROGRESSING CAVITY PUMPING SYSTEMS ACCESSORIES Key Features Chemical Injectors Coated Couplings - Urethane-Super 'E' Electric Motors Engines Flanged B.O.P. / Flow Tee Combinations Gas Separators Modified Seat Nipples Modified Tag Bars Northlander™ N0-Turn Tools P.C. Drive Rods P.C. Polished Rods P.C. Union Flow Tees Pony Rods Pup Joints Recycle Pumps Rotating Stuffing Boxes

Key Features

Rupture Burst Joints

Continuous Sucker Rod

Sucker Rod Couplings

P.C. Drive Safety Guards

Torque Limiters

TRICO Products

Tubing Couplings


Tubing Drains

Remote P.R. Speed Indicator,

Tubing Rotators

CSA Approved Class I, Div II

Weld Extensions

Open/Close Tagbar (OCT)

API Sucker Rods

Custom Tagbars Stealth Shack Stealth Wrap


WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Phone: (403) 269-7788





Continuous Sucker Rod Technical Excellence by Design

T

he unique design characteristics of the COROD® continuous sucker rod offer distinct production enhancement and cost saving advantages to rod string applications. Unlike conventional sucker rods that are coupled every 25 or 30 feet (7.6 or 9.1 meters), continuous sucker rods require couplings only at the top and bottom of the rod string - regardless of well depth. With fewer joints, this solid length of steel is lighter and enhances tubing life due to a more uniform contact between the tubing and sucker rod. It also addresses many premature tubing wear challenges, especially in directional and horizontal wells. Corod continuous sucker rods are manufactured in multiple round and semi-elliptical sizes for high system efficiency in various downhole environments.

Minimal Pin and Coupling Failures With only two threaded connections — one at the polished rod and one at the pump, pin and coupling failures that commonly occur in conventional threaded rod strings are dramatically reduced. Fewer failures mean wells can

stay on production for longer periods and costs associated with retrieval, repair and replacement of rod string components are minimized.

Extended Tubing Life The protruding diameter of threaded couplings often become a bearing or concentrated point on the tubing ID that can eventually erode the tubing wall, especially in deviated wells. Because COROD systems do not point-load the ID of the tubing with couplings, the uniformly distributed side load of a continuous sucker rod means reduced tubing wear rates and prolonged tubing life.

Minimal Rod and Tubing Wear In tubing less than 3-inch (7.7-centimeter) ID, the semi-elliptical crosssection rod designs contact the tubing wall at two points rather than one point observed with conventional sucker rods. For every 25 feet (7.6 meters) of tubing, there is 50 feet (15.2 meters) of line contact versus the 4 to 4 ½ inch (10.2 to 11.4 centimeters) of coupling OD contact of

threaded rods. The load-bearing contact area of the COROD string on the tubing wall is 100 to 150 times less for semi-elliptical rod and 50 to 75 times less for round rod compared with other rod systems. The consequent redistribution of the load-bearing area minimizes wear and potential failure, especially in directional or slant wells.

Minimal Torque and Power Requirement COROD strings lower torque and power requirements of primary drivers by eliminating the restrictions or flow losses associated with couplings, centralizers and rod guides. COROD systems are subject to reduced loads and run more efficiently for extended periods in rotary (PCP) applications. Continuous sucker rod strings also lower stress since they can be made in larger sizes than conventional rod strings for the same tubing size.

Enhanced Pump Efficiency COROD continuous sucker rods eliminate the rod-coupling piston effect, resulting in longer net plunger travel and higher pump efficiency.

Designed and manufactured for optimum performance, COROD continuous sucker rod combines industry-leading innovative design with quality materials and manufacturing excellence. Every rod is manufactured to exacting specifications under the highest degree of quality control. Rigid manufacturing processes, plus skilled operators and specially designed equipment, monitor each phase to ensure the integrity of every design and finished product. COROD sucker rods are manufactured from API Grade D carbon steel, chrome-moly, and special-service alloys. COROD systems made of ENDURA™ material are used in wells

where chlorides and carbon dioxide may be present or in more corrosive environments where a corrosion inhibitor is present. ENDURA material is also used in high-strength continuous rod strings for high loading applications. Available in three round and seven semi-elliptical configurations, rod sizes range from 12/16 in. to 18/16 in. (19 to 28.5 mm.) tapered to any length. Both type configurations are ideally suited for reciprocating rodpumping applications. The round rod configurations have also proven extremely effective in rotary-type rod pumping methods.

D, DE and SE COROD products are successfully used in H2 S Environments when the wells are effectively inhibited.

Continuous Sucker Rod Technical Excellence by Design

SIMPLE, QUICK INSTALLATION AND FIELD SERVICE By nature of its unique design, COROD continuous sucker rod is transported and installed at the wellsite by our custom-built service rig and welder. Stored on an 18-ft. (5.4-m.) diameter reel, the rod is deployed into the well at rates of 90 to 100 ft/min (27 to 30 m/min) by a variable-speed, hydraulically driven gripper mechanism. With the rod installed directly off the reel and through the gripper system, damage often associated with makeup equipment and human handling is minimized. Installation is simple, fast and conducted by highly trained rig crews. Since COROD strings only require top and bottom connections, the top connection can be welded onsite during installation. This welding procedure produces topquality, long-lasting joints on the string. These techniques can also be used to perform field repairs, if necessary, or to transfer a continuous rod string from one well to another.

THE RIGHT SOLUTION FOR MULTIPLE APPLICATIONS COROD continuous rod is ideally suited to both reciprocating and rotary pumping applications. Backed by a wealth of experience and technical expertise in each of these applications, Weatherford Specialists help operators select the right solution for optimum performance and production enhancement.

Reciprocating Rod Pumping Both semi-elliptical and round crosssection COROD systems work effectively in reciprocating rod lift applications. Properly selecting the applicable crosssection can reduce internal tensile, compressive, and bending stresses in the rod, minimize the load imposed on the pump and enhance pump efficiency. All the advantages translate to increased cost savings and enhanced production from the well.

Rotary Rod Pumping Round cross-section COROD systems function efficiently in rotating rod-pump applications. In a rotating (PCP) system, COROD strings can reduce the torque placed on motors and pumps, decrease the power requirements, and in turn, decrease the required size of the progressing cavity pump. The reduced load and stresses on system components can result in operational cost savings through fewer tubing leaks, lower flow losses, and higher system efficiency.

Special Applications Special applications such as highly deviated wells and heavy, high-viscosity oil production are prime opportunities for the high-strength, high-torque capabilities of the COROD systems.

A recent case history published by Stocker Resources, Inc. in California reported that the performance of the COROD system saved approximately $350,000 (US) through reduced operational costs and improved overall system efficiency.

When selecting a sucker-rod system for your artificial lift application, whether for ease of installation, longer run life or operating cost reduction, choose Weatherford COROD continuous sucker rod. ®

COROD continuous sucker rod is an integral part of Weatherford's comprehensive portfolio of artificial lift systems, products and services for optimum performance and production enhancement. Its unique design characteristics reflect Weatherford's ongoing commitment to providing customers more efficient and cost-effective solutions to reservoir production problems. Contact your Weatherford Artificial Lift representative for an in-depth analysis of your rod string applications. US & International 713-693-4000

515 Post Oak Blvd. S Houston, Texas 77027 www.weatherford.com

Canada 403-571-2424

Weatherford products and services are subject to Weatherford’s standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford.

© Copyright 1999 Weatherford • All rights reserved • ALS7500 • 0699/7000 • Printed in U.S.A.

Choices in Technology For Your Sucker Rod Needs

Weatherford Sucker Rods

High-Strength Sucker Rods

PC Pumping Torque Limits

Weatherford Artificial Lift Systems offers premium quality, high-strength sucker rods with high and ultra-high load ratings plus highly corrosion-resistant properties. These special chrome-moly/chrome-nickel alloy steel sucker rods are available in 5/8, 3/4, 7/8, 1 and 1-1/8 inch diameters. All sizes are offered in 25 and 30 foot lengths. Each rod is heat treated, and has pin ends machined, with API rolled threads. ®

Grade

Rod Size (inch)

Yield Strength (psi)

Elastic torque Limit (ft-lbs)

Specified Torque Limit (ft-lbs)

Grade MD 56

3/4"

85

362

430

Grade MD 56

7/8"

85

568

675

Grade MD 56

1"

85

850

1000

EL ULTRA-HIGH-STRENGTH SUCKER RODS

QUENCHED AND TEMPERED SUCKER RODS

Designed to provide an ultra-high load rating and successful corrosionresistant qualities, EL rods are Weatherford's premium line of highstrength coupled sucker rods. The exclusive induction case hardening process incorporated into the manufacturing of these rods makes them the ultimate fatigue-resistant sucker rod.

Designed for high strength and fatigue performance, the S88 rod provides an intermediate step between the normalized Grade D and ultra-high strength EL rod. These rods are manufactured with 3130M Nickel-Chrome steel; they are quenched and tempered which results in higher toughness and a finer grain structure, making them capable of better fatigue resistance. For example, the quenched and tempered rods typically have charpy impact results in the +70 ft. lb. range, while normalized and tempered rods are typically in the 20 ft. lb. range. This added toughness of the quenched and tempered rod provides the added fatigue resistance needed in extreme applications.

Grade D

3/4"

85

362

460

Grade D

7/8"

85

568

735

Grade D

1"

85

850

1100

Grade D

1 1/8"

85

1214

1570

S67

7/8"

110

696

780

S67

1"

110

1039

1165

S67

1 1/8"

110

1480

1660

S88 sucker rods are available in 5/8"*, 3/4", 7/8", 1" and 1 1/8"* diameters. All sizes are available in 25-foot and 30-foot* lengths.

Grade KD63

3/4"

85

362

450

Grade KD63

7/8"

85

568

700

Grade KD63

1"

85

850

1000

Grade KD63

1 1/8"

85

1214

1500

S87

7/8"

115

728

815

S87

1"

115

1086

1220

S87

1 1/8"

115

1551

1740

Special Alloy T-66/XD

3/4"

115

462

500


7/8"

115

725

800


1"

115

1086

1200


1 1/8"

115

1551

1700


1 1/4 X 1"

115

2100

1600*


1 1/4 X 1 1/8"

115

2100

2500*

S88

7/8"

130

823

920

S88

1"

130

1228

1380

S88

1 1/8"

130

1749

1965

EL

7/8"

-

-

1000*

EL

1"

-

-

1600*

EL

1 1/8"

-

-

2500*

Ordinary sucker rods tend to fail from fatigue originating at the surface under tension. The unique engineering of the EL rod puts it in a class by itself. It has a thin compression layer at its surface that remains under compression even under normal operating tensile loads. Since the compressive pre-stress protects the surface from tensile stresses, the chances of developing fatique cracks are greatly reduced. Additionally, stringent quality control procedures employed with these rods promote reliable and long service life.

Maximum Stress Allowable Sa = (T/2.8 + 0.375 Smin) SF

Key Benefits • Energy saving through pumping with a lighter string with no compromise in production • Higher fluid production with existing pumping unit • Reduction in the size of pumping unit with no reduction in production • Use of smaller, more economical tubing • Increased pump speeds for additional production • Avoidance of more unconventional and expensive recovery techniques • Extended service life Applications Super high-load capacity in mild sweet (CO2) and sour (H2S) corrosive environments. Satisfactory corrosion-inhibiting practices must be followed. Specifications • Special chrome-moly alloy steel • Normalized, tempered, and induction case hardened • Pin ends machined with API rolled threads Maximum Stress Allowable Sa = (55,000 PSI = 0.2143 Smin) SF

S87 API D rod is recommended for mild corrosive or inhibited wells; also recommended for CO2 wells (sweet corrosive environments). Manufactured with 3130 modified alloy steel. S67 API Grade D rod is recommended for heavy duty pumping in non-corrosive or inhibited wells. This economical high strength rod is manufactured with 1029 modified alloy steel. Applications Deep, highly loaded wells in mildly corrosive environments provided satisfactory corrosion inhibiting practices are followed. Specifications • Special chrome-nickel alloy steel (S88 and S87) • Quenched and tempered • Pin ends machined with API rolled threads *These sizes are available with minimum order quantities.

*Special High Torque Coupling and Make-up Procedures Required.

Weatherford Couplings Weatherford Grade “T” and “SM” sucker rod couplings are manufactured to strict quality control standards from high strength alloy steel and conform to API Specification 11B. The threads of these couplings are cold form-rolled produced by displacement of material rather than by removal of material as in the cut thread. Rolling the thread results in a compressive stress at the root of the thread, giving maximum strength to the traditional weak point of cut thread couplings.

Weatherford sprayed metal couplings have a corrosion resistant surface with a low coefficient of friction that reduces wear on the tubing and the coupling. This coupling is recommended for deviated wells. Weatherford couplings are available in Standard O.D., oversized and Slim Hole configurations in sizes of 5⁄8” through 1-1⁄8”.

T66/XD SUCKER RODS

API GRADE RODS

The T66/XD is an extremely dependable rod designed for high-strength service and provides an intermediate step between the Grade D and ultra-high-strength EL rod.

Weatherford API sucker rods are manufactured to API 11B specifications and ISO 9001/API Q1 certified in one of the most modern facilities of its type within the industry. These rods feature fully rolled, cold-formed threads designed to provided a precise, smooth, reinforced thread structure not attainable by normal machine-cut threads. Metal is displaced rather than removed, and the resultant cold working strengthens the thread root. Weatherford rods are cleaned by shot blasting to remove any scale and oxidation, then liberally coated with rust inhibitors and carefully palletized in bundles for safe transport and handling.

These rods are manufactured with 4138M chrome-moly steel, making them capable of handling the toughest stresses. The special alloy steel provides more resistance to sulfide stress cracking than AISI 4337 nickel-chrome-moly steel used in older generation high-strength sucker rods. The metallurgical makeup of the T66/XD sucker rods is checked continually for quality assurance. Rods are forged, normalized, and tempered, shot blasted, and pins precision machined and roll-threaded. This continuous in-process inspection confirms that only the finest sucker rods bear the Weatherford name. Applications Deep, highly loaded wells in mildly corrosive environments provided satisfactory corrosion inhibiting practices are followed.

Weatherford Couplings

Specifications

COUPLING SELECTION CHART HARDNESS

COUPLING

O. D. 56-62 HRA

API Grade “SM” Coated

( 14 )-23 HRC

( 14 )-23 HRC

595 HV200 ( min )

56-62 HRA

56-62 HRC

( 14 )-23 HRC

APPROXIMATE WEIGHT OF A 25-FOOT SUCKER ROD API SIZE (INCHES)

WEIGHT IN POUNDS WITHOUT COUPLING

Tensile Minimum

High Strength Alloy Steel

90,000 psi

110,000 psi


75,000 psi

100,000 psi

Core 56-62 HRA

WITH STANDARD WITH SLIM HOLE COUPLING COUPLING

• Normalized and tempered

Yield Minimum

Material

API Grade “T”

• Special chrome-moly alloy steel

API COUPLED SUCKER RODS A complete line of API grade sucker rods is available from Weatherford. Each rod manufactured from Special Quality (SBQ) bar stock and held to the same stringent quality control measures and careful handling as our high-strength rods.

COUPLING SIZES AND WEIGHTS API SIZE (INCHES)

OUTSIDE DIAMETER (INCHES)

WEIGHT(POUNDS)

STANDARD

SLIM HOLE

STANDARD

SLIM HOLE

27.2

28.5

28.2

5/8

1-1/2

1-1/4

1.30

1.00

3/4

38.5

40.0

39.8

3/4

1-5/8

1-1/2

1.50

1.26

7/8

52.0

53.8

53.5

7/8

1-13/16

1-5/8

1.80

1.50

1

69.9

72.5

71.9

1

2-3/16

2

2.58

2.01

88.7

91.8

–


5/8

1-1/8

• Pin ends machined with API rolled threads

1-1/8

2-3/8

–

3.13

Grade C Rods Light-to-medium load applications in non-corrosive wells. AISI 1536 carbon-manganese alloy steel. Grade K Rods Light-to-medium load applications in corrosive wells. AISI 4623 nickel-molybdenum alloy steel. Grade MD56 Rods Medium-to-heavy loads in non-corrosive wells. AISI 1541 carbon-manganese alloy steel. Grade D Rods Heavy loads in non-corrosive or effectively inhibited wells. AISI 4142 chromium-molybdenum alloy steel. Grade KD63 Rods (normally API Grade D Service) Heavy loads in effectively inhibited corrosive wells. AISI 4720 nickel-chromium-molybdenum alloy steel. API Pony Rods Pony Rods from Weatherford conform to appropriate API classifications. They are manufactured under strict quality standards and from the same alloy steels as COROD® Continuous Sucker Rods sucker rods.

–

Recommended Makeup from Hand Tight Positions for EL & T66/XD Rods Only Rod Size (in.)

Wrench Square (in.)

5/8" 3/4"

API - 7/8" API - 1"

7/8" (EL rod)

Non API 1-1/8" to match sucker rod strength

7/8"

API - 1"

1"

API - 1-5/16"

1-1/8"

API - 1-1/2"

Coupling

Full Size, Slim Hole, API Grade T Couplings and Grade SM Couplings

New Rods Rerun Coupling Box OD (in.) Min (in.) Max (in.) Max (in.) Max (in.) 1-1/2" 1-5/8"

21/64" 26/64"

25/64" 30/64"

20/64" 23/64"

22/64" 25/64"

1-13/16"

29/64"

33/64"

28/64"

31/64"

1-13/16"

29/64"

33/64"

28/64"

31/64"

2-3/16"

37/64"

43/64"

36/64"

40/64"

2-3/8"

45/64"

52/64"

43/64"

50/64"

Weatherford manufactures the COROD ® continous sucker rod for distinct production enhancement and cost saving advantages to various rod string applications. Unlike conventional sucker rods that are coupled every 25 or 30 feet, continuous sucker rods require couplings only at the top and bottom of the rod string-regardless of well depth. With fewer joints, this solid length of steel is lighter and enhances tubing life due to a more uniform contact between the tubing and sucker rod. It also addresses many premature tubing wear challenges, especially in directional and horizontal wells. SPECIAL APPLICATIONS Special applications such as highly deviated wells and heavy, highviscosity oil production, are prime opportunities for the high-strength, high-torque capabilities of the COROD® system.

Corod is ideally suited to both reciprocating and rotary pumping applications. For more information contact your nearest Weatherford Representative

Sucker Rod Comparison Chart Mechanical Properties

Sucker Rod Comparison Chart Chemical Analyses

Based On API Specifications 11B


Manufacturer

Type

Yield Strength 1,000 PSI

Color Code

Tensile Strength 1,000 PSI

API GRADE C

Elongation Reduction % in 8” of Area, %

Brinell Hardness

Heat Treatment

White

90/105

100/115

13Mn

55Mn

207-235

Quenched & Tempered

Weatherford

C

White

60Mn

90/115

18Mn

50Mn

185-240

Normalized

Norris

30

White

60Mn

90/115

15Mn

45Mn

185-239

Normalized

Upco

35

White

60Mn

90/115

14Mn

45Mn

187-238

Normalized & Tempered

S-59

Blue

90/105

100/115

13Mn

55Mn

207-235

Quenched & Tempered

Weatherford

K

Blue

60Mn

90/115

16Mn

60Mn

185-231


Norris

40

Blue

60Mn

90/115

16Mn

55Mn

174-239


Upco

45

Blue

60Mn

90/115

16Mn

40Mn

174-238


S-67

CARBON STEEL, CHROME-MOLY ALLOY AND SPECIAL ALLOY

Brown

110/125

120/140

% Carbon

11Mn

% Mang.

% Phos.

% Sulphur

55Mn

248-277

S-87

Orange

115/130

125/140

12Mn

55Mn

248-280

Quenched & Tempered

Weatherford

D

Yellow

85Mn

115/140

10Mn

45Mn

240-294


Weatherford

MD56

Brown

85Mn

115/140

14Mn

45Mn

240-294


Weatherford

KD63

Orange

85Mn

115/140

14Mn

45Mn

240-294


Norris

54

Brown

85Mn

115/140

15Mn

50Mn

239-290


Norris

78

Yellow

85Mn

115/140

10Mn

45Mn

239-290


Norris

90

Orange

85Mn

115/140

12Mn

40Mn

239-290


Upco

75

Yellow

85Mn

115/140

10Mn

40Mn

234-289


Upco

75A

Green

85Mn

115/140

10Mn

40Mn

238-289


Upco

95

Orange

85Mn

115/140

10Mn

40Mn

238-289


% % Nickel Chromium

% Moly

% Other

CARBON STEEL

S-60

1029Md

.22-.29

1.00-1.32

.025Mx

.04Mx

.15-.30

.15Mx

.20Mx

.05Mx

Weatherford

C

1536SR

.30-.37

1.20-1.50

.04Mx

.04Mx

.20-.30

.25Mx

.25Mx

.05Mx

.35 Cu Mx

Norris

30

1536M

.30-.39

1.10-1.40

.04Mx

.04Mx

.15-.35

.35Mx

.30Mx

.06Mx

.02-.07 Va, .35Mx Cu

Upco

35

1536M

.30-.37

1.20-1.50

.04Mx

.04Mx

.20-.30

.25Mx

.25Mx

.05Mx

.01-.38 (Cu, N, Va)

API GRADE K

NICKEL MOLY ALLOY

Weatherford

S-59

46XX

.14-.21

.55-.75

.025Mx

.035Mx

.15-.35

1.65-2.00

Weatherford

K

4623

.20-.25

.75-1.00

.035Mx

.04Mx

.20-.35

1.65-2.00

Norris

40

4621M

.18-.25

.60-.80

.035Mx

.035Mx

.15-.35

1.65-2.00

.20Mx

.15-.25

.03-.07Va, .35Mx Cu

Upco

45

4623

.20-.24

.75-1.00

.035Mx

.04Mx

.20-.35

1.65-2.00

.25Mx

.20-.28

.015-.43 (Cu, N, Va)

API GRADE D

Quenched & Tempered

Weatherford

% Silicon

Weatherford

NICKEL MOLY ALLOY

Weatherford

Weatherford

Steel Type

API GRADE C

S-60

API GRADE D

Type

CARBON STEEL

Weatherford

API GRADE K

Manufacturer

.20-.30 .25Mx

.20-.30


Weatherford

S-67

1029Md

.22-.29

1.00-1.32

.025Mx

.04Mx

.15-.30

.15Mx

.20Mx

.05Mx

.35Mx Cu

Weatherford

S-87

3130Md

.22-.29

.71-1.00

.025Mx

.035Mx

.15-.35

.70-1.00

Weatherford

D

4142SR

.40-.45

.75-1.00

.035Mx

.04Mx

.15-.30

.25Mx

.41-.65

.05Mx

.35Mx Cu

.80-1.10

.15-.25

Weatherford

MD56

1541MV

.40-.44

1.35-1.55

.035

.04Mx

.15-.30

.25Mx

.25Mx

.05Mx

Weatherford

KD63

4720SR

.19-.23

.85-1.05

.035Mx

.04Mx

.15-.35

.90-1.20

.80-1.05

.22-.30

Norris

54

541VM

.36-.45

1.35-1.65

.040Mx

.040Mx

.15-.35

.35Mx

.30Mx

.06Mx

.04-.09Va, .35Mx Cu

Norris

78

4142HM

.38-.45

.80-1.00

.035Mx

.035Mx

.15-.35

.45Mx

.80-1.10

.15-.25

.03-.07Va, .35Mx Cu

Norris

90

4320M

.18-.24

.80-1.00

.025Mx

.025Mx

.15-.35

1.15-1.50

.70-.90

.20-.30

.03-.07Va, .35Mx Cu

Upco

75

Special

.40-.44

1.35-1.55

.035Mx

.035Mx

.20-.30

.25Mx

.25Mx

.05Mx

.05-.41 (Cu, N, Va)

Upco

75A

4142M

.40-.45

.75-1.00

.035Mx

.040Mx

.15-.30

.25Mx

.80-1.10

.15-.25

.02-.49 (Cu, N, Va)

Upco

95

4720

.19-.23

.35Cu Mx

MISCELLANEOUS / SPECIAL SERVICE

MISCELLANEOUS / SPECIAL SERVICE

Weatherford

S-88

Red

130/145

140/155

11Mn

50Mn

285-311

Quenched & Tempered

Weatherford

S-88

3130Md

.22-.29

.71-1.00

.025Mx

.035Mx

.15-.35

.70-1.00

.41-.65

.05Mx

Weatherford

EL

Lavender

Proprietary

Proprietary

Proprietary

Proprietary

Proprietary

Induction Case Hardened

Weatherford

EL

Special

.38-.42

1.00-1.30

.035Mx

.040Mx

.20-.35

.30Mx

.55-.85

.24-.55

Weatherford

T66/XD

Green

115Mn

140/150

10Mn

40Mn

286-319


Weatherford

T66/XD

4138Md

.38-.42

1.00-1.30

.035Mx

.040Mx

.20-.35

.30Mx

.55-.85

.24-.32

Norris

97

Green

115/125Mn

140/150

10Mn

45Mn

290-311


Norris

97

4330MI

.28-.35

.70-.90

.035Mx

.040Mx

.20-.35

1.65-2.00

.70-.90

.20-.35

.05-.07Va, .35Mx Cu

Upco

50

Silver

105Mn

140/160

8Mn

40Mn

289-333


Upco

50

4337

.35-.39

.75-.95

.025Mx

.035Mx

.15-.30

1.45-1.75

.80-1.00

.20-.30

.03-.035 (Cu, N, Va)

M or Md = Modified Mn = Minimum Mx = Maximum T= Typical NOTES: 1. Information Sources API Specification 11B. 24th Edition 2. Color codes according to API Specification 11B. 24th Edition World Oil Sucker Rod Tables, July 1997 Grade C - White Grade K - Blue Grade D - (Carbon Steel) -Brown; (Chrome-Moly) -Yellow; (Special) -Orange

These properties are subject to change without notice (E. & O.E.)



Sucker Rod Comparison Chart Mechanical Properties

Sucker Rod Comparison Chart Chemical Analyses



Manufacturer

Type

Yield Strength 1,000 PSI

Color Code

Tensile Strength 1,000 PSI

API GRADE C

Elongation Reduction % in 8” of Area, %

Brinell Hardness

Heat Treatment

White

90/105

100/115

13Mn

55Mn

207-235

Quenched & Tempered

Weatherford

C

White

60Mn

90/115

18Mn

50Mn

185-240

Normalized

Norris

30

White

60Mn

90/115

15Mn

45Mn

185-239

Normalized

Upco

35

White

60Mn

90/115

14Mn

45Mn

187-238


S-59

Blue

90/105

100/115

13Mn

55Mn

207-235

Quenched & Tempered

Weatherford

K

Blue

60Mn

90/115

16Mn

60Mn

185-231


Norris

40

Blue

60Mn

90/115

16Mn

55Mn

174-239


Upco

45

Blue

60Mn

90/115

16Mn

40Mn

174-238


S-67


Brown

110/125

120/140

11Mn

55Mn

248-277

S-87

Orange

115/130

125/140

12Mn

55Mn

248-280

Quenched & Tempered

Weatherford

D

Yellow

85Mn

115/140

10Mn

45Mn

240-294


Weatherford

MD56

Brown

85Mn

115/140

14Mn

45Mn

240-294


Weatherford

KD63

Orange

85Mn

115/140

14Mn

45Mn

240-294


Norris

54

Brown

85Mn

115/140

15Mn

50Mn

239-290


Norris

78

Yellow

85Mn

115/140

10Mn

45Mn

239-290


Norris

90

Orange

85Mn

115/140

12Mn

40Mn

239-290


Upco

75

Yellow

85Mn

115/140

10Mn

40Mn

234-289


Upco

75A

Green

85Mn

115/140

10Mn

40Mn

238-289


Upco

95

Orange

85Mn

115/140

10Mn

40Mn

238-289


S-88

Red

140/155

11Mn

50Mn

Weatherford

EL

Lavender

Weatherford

T66/XD

Green

115Mn

140/150

10Mn

40Mn

Norris

97

Green

115/125Mn

140/150

10Mn

Upco

50

Silver

105Mn

140/160

8Mn

% Sulphur

% Silicon

% % Nickel Chromium

% Moly

% Other

CARBON STEEL

S-60

1029Md

.22-.29

1.00-1.32

.025Mx

.04Mx

.15-.30

.15Mx

.20Mx

.05Mx

C

1536SR

.30-.37

1.20-1.50

.04Mx

.04Mx

.20-.30

.25Mx

.25Mx

.05Mx

Norris

30

1536M

.30-.39

1.10-1.40

.04Mx

.04Mx

.15-.35

.35Mx

.30Mx

.06Mx

.02-.07 Va, .35Mx Cu

Upco

35

1536M

.30-.37

1.20-1.50

.04Mx

.04Mx

.20-.30

.25Mx

.25Mx

.05Mx

.01-.38 (Cu, N, Va)

API GRADE K

.35 Cu Mx

NICKEL MOLY ALLOY

Weatherford

S-59

46XX

.14-.21

.55-.75

.025Mx

.035Mx

.15-.35

1.65-2.00

Weatherford

K

4623

.20-.25

.75-1.00

.035Mx

.04Mx

.20-.35

1.65-2.00

Norris

40

4621M

.18-.25

.60-.80

.035Mx

.035Mx

.15-.35

1.65-2.00

.20Mx

.15-.25

.03-.07Va, .35Mx Cu

Upco

45

4623

.20-.24

.75-1.00

.035Mx

.04Mx

.20-.35

1.65-2.00

.25Mx

.20-.28

.015-.43 (Cu, N, Va)

API GRADE D

.20-.30 .25Mx

.20-.30


Weatherford

S-67

1029Md

.22-.29

1.00-1.32

.025Mx

.04Mx

.15-.30

.15Mx

.20Mx

.05Mx

.35Mx Cu

Weatherford

S-87

3130Md

.22-.29

.71-1.00

.025Mx

.035Mx

.15-.35

.70-1.00

Weatherford

D

4142SR

.40-.45

.75-1.00

.035Mx

.04Mx

.15-.30

.25Mx

.41-.65

.05Mx

.35Mx Cu

.80-1.10

.15-.25

Weatherford

MD56

1541MV

.40-.44

1.35-1.55

.035

.04Mx

.15-.30

.25Mx

.25Mx

.05Mx

Weatherford

KD63

4720SR

.19-.23

.85-1.05

.035Mx

.04Mx

.15-.35

.90-1.20

.80-1.05

.22-.30

Norris

54

541VM

.36-.45

1.35-1.65

.040Mx

.040Mx

.15-.35

.35Mx

.30Mx

.06Mx

.04-.09Va, .35Mx Cu

Norris

78

4142HM

.38-.45

.80-1.00

.035Mx

.035Mx

.15-.35

.45Mx

.80-1.10

.15-.25

.03-.07Va, .35Mx Cu

Norris

90

4320M

.18-.24

.80-1.00

.025Mx

.025Mx

.15-.35

1.15-1.50

.70-.90

.20-.30

.03-.07Va, .35Mx Cu

Upco

75

Special

.40-.44

1.35-1.55

.035Mx

.035Mx

.20-.30

.25Mx

.25Mx

.05Mx

.05-.41 (Cu, N, Va)

Upco

75A

4142M

.40-.45

.75-1.00

.035Mx

.040Mx

.15-.30

.25Mx

.80-1.10

.15-.25

.02-.49 (Cu, N, Va)

Upco

95

4720

.19-.23

.35Cu Mx

MISCELLANEOUS / SPECIAL SERVICE 285-311

Quenched & Tempered

Weatherford

S-88

3130Md

.22-.29

.71-1.00

.025Mx

.035Mx

.15-.35

.70-1.00

.41-.65

.05Mx

Induction Case Hardened

Weatherford

EL

Special

.38-.42

1.00-1.30

.035Mx

.040Mx

.20-.35

.30Mx

.55-.85

.24-.55

286-319


Weatherford

T66/XD

4138Md

.38-.42

1.00-1.30

.035Mx

.040Mx

.20-.35

.30Mx

.55-.85

.24-.32

45Mn

290-311


Norris

97

4330MI

.28-.35

.70-.90

.035Mx

.040Mx

.20-.35

1.65-2.00

.70-.90

.20-.35

.05-.07Va, .35Mx Cu

40Mn

289-333


Upco

50

4337

.35-.39

.75-.95

.025Mx

.035Mx

.15-.30

1.45-1.75

.80-1.00

.20-.30

.03-.035 (Cu, N, Va)



% Phos.

Weatherford

MISCELLANEOUS / SPECIAL SERVICE Weatherford

% Mang.

Weatherford

Quenched & Tempered

Weatherford

130/145

% Carbon

NICKEL MOLY ALLOY

Weatherford

Weatherford

Steel Type

API GRADE C

S-60

API GRADE D

Type

CARBON STEEL

Weatherford

API GRADE K

Manufacturer



Weatherford Couplings Weatherford Grade “T” and “SM” sucker rod couplings are manufactured to strict quality control standards from high strength alloy steel and conform to API Specification 11B. The threads of these couplings are cold form-rolled produced by displacement of material rather than by removal of material as in the cut thread. Rolling the thread results in a compressive stress at the root of the thread, giving maximum strength to the traditional weak point of cut thread couplings.

Weatherford sprayed metal couplings have a corrosion resistant surface with a low coefficient of friction that reduces wear on the tubing and the coupling. This coupling is recommended for deviated wells. Weatherford couplings are available in Standard O.D., oversized and Slim Hole configurations in sizes of 5⁄8” through 1-1⁄8”.

O. D.

Core 56-62 HRA

( 14 )-23 HRC

( 14 )-23 HRC

595 HV200 ( min )

56-62 HRA

56-62 HRC

( 14 )-23 HRC

API Grade “T”

API Grade “SM” Coated

APPROXIMATE WEIGHT OF A 25-FOOT SUCKER ROD API SIZE (INCHES) 5/8

WEIGHT IN POUNDS WITHOUT COUPLING 27.2

WITH STANDARD WITH SLIM HOLE COUPLING COUPLING 28.5

28.2

These rods are manufactured with 4138M chrome-moly steel, making them capable of handling the toughest stresses. The special alloy steel provides more resistance to sulfide stress cracking than AISI 4337 nickel-chrome-moly steel used in older generation high-strength sucker rods.

Deep, highly loaded wells in mildly corrosive environments provided satisfactory corrosion inhibiting practices are followed. Specifications

Yield Minimum

Material

56-62 HRA

Weatherford API sucker rods are manufactured to API 11B specifications and ISO 9001/API Q1 certified in one of the most modern facilities of its type within the industry. These rods feature fully rolled, cold-formed threads designed to provided a precise, smooth, reinforced thread structure not attainable by normal machine-cut threads. Metal is displaced rather than removed, and the resultant cold working strengthens the thread root. Weatherford rods are cleaned by shot blasting to remove any scale and oxidation, then liberally coated with rust inhibitors and carefully palletized in bundles for safe transport and handling.

Applications

COUPLING SELECTION CHART HARDNESS

API GRADE RODS

The T66/XD is an extremely dependable rod designed for high-strength service and provides an intermediate step between the Grade D and ultra-high-strength EL rod.

The metallurgical makeup of the T66/XD sucker rods is checked continually for quality assurance. Rods are forged, normalized, and tempered, shot blasted, and pins precision machined and roll-threaded. This continuous in-process inspection confirms that only the finest sucker rods bear the Weatherford name.

Weatherford Couplings

COUPLING

T66/XD SUCKER RODS

Tensile Minimum

• Special chrome-moly alloy steel • Normalized and tempered • Pin ends machined with API rolled threads


90,000 psi


75,000 psi

Maximum Stress Allowable

110,000 psi

Sa = (T/2.8 + 0.375 Smin) SF 100,000 psi

API COUPLED SUCKER RODS

COUPLING SIZES AND WEIGHTS API SIZE (INCHES) 5/8

OUTSIDE DIAMETER (INCHES)

Grade C Rods Light-to-medium load applications in non-corrosive wells. AISI 1536 carbon-manganese alloy steel. Grade K Rods Light-to-medium load applications in corrosive wells. AISI 4623 nickel-molybdenum alloy steel. Grade MD56 Rods Medium-to-heavy loads in non-corrosive wells. AISI 1541 carbon-manganese alloy steel. Grade D Rods Heavy loads in non-corrosive or effectively inhibited wells. AISI 4142 chromium-molybdenum alloy steel. Grade KD63 Rods (normally API Grade D Service) Heavy loads in effectively inhibited corrosive wells. AISI 4720 nickel-chromium-molybdenum alloy steel. API Pony Rods Pony Rods from Weatherford conform to appropriate API classifications. They are manufactured under strict quality standards and from the same alloy steels as COROD® Continuous Sucker Rods sucker rods.

A complete line of API grade sucker rods is available from Weatherford. Each rod manufactured from Special Quality (SBQ) bar stock and held to the same stringent quality control measures and careful handling as our high-strength rods.

WEIGHT(POUNDS)

STANDARD

SLIM HOLE

STANDARD

SLIM HOLE

1-1/2

1-1/4

1.30

1.00

3/4

38.5

40.0

39.8

3/4

1-5/8

1-1/2

1.50

1.26

7/8

52.0

53.8

53.5

7/8

1-13/16

1-5/8

1.80

1.50

1

69.9

72.5

71.9

1

2-3/16

2

2.58

2.01

1-1/8

88.7

91.8

–

1-1/8

2-3/8

–

3.13

–

Recommended Makeup from Hand Tight Positions for EL & T66/XD Rods Only Rod Size (in.)

Wrench Square (in.)

5/8" 3/4"

API - 7/8" API - 1"

7/8" (EL rod)

Non API 1-1/8" to match sucker rod strength

7/8"

API - 1"

1"

API - 1-5/16"

1-1/8"

API - 1-1/2"

Coupling

Full Size, Slim Hole, API Grade T Couplings and Grade SM Couplings

New Rods Rerun Coupling Box OD (in.) Min (in.) Max (in.) Max (in.) Max (in.) 1-1/2" 1-5/8"

21/64" 26/64"

25/64" 30/64"

20/64" 23/64"

22/64" 25/64"

1-13/16"

29/64"

33/64"

28/64"

31/64"

1-13/16"

29/64"

33/64"

28/64"

31/64"

2-3/16"

37/64"

43/64"

36/64"

40/64"

2-3/8"

45/64"

52/64"

43/64"

50/64"

Weatherford manufactures the COROD ® continous sucker rod for distinct production enhancement and cost saving advantages to various rod string applications. Unlike conventional sucker rods that are coupled every 25 or 30 feet, continuous sucker rods require couplings only at the top and bottom of the rod string-regardless of well depth. With fewer joints, this solid length of steel is lighter and enhances tubing life due to a more uniform contact between the tubing and sucker rod. It also addresses many premature tubing wear challenges, especially in directional and horizontal wells. SPECIAL APPLICATIONS Special applications such as highly deviated wells and heavy, highviscosity oil production, are prime opportunities for the high-strength, high-torque capabilities of the COROD® system.

Corod is ideally suited to both reciprocating and rotary pumping applications. For more information contact your nearest Weatherford Representative

Choices in Technology For Your Sucker Rod Needs


High-Strength Sucker Rods

PC Pumping Torque Limits

Weatherford Artificial Lift Systems offers premium quality, high-strength sucker rods with high and ultra-high load ratings plus highly corrosion-resistant properties. These special chrome-moly/chrome-nickel alloy steel sucker rods are available in 5/8, 3/4, 7/8, 1 and 1-1/8 inch diameters. All sizes are offered in 25 and 30 foot lengths. Each rod is heat treated, and has pin ends machined, with API rolled threads. ®

Grade

Rod Size (inch)

Yield Strength (psi)

Elastic torque Limit (ft-lbs)

Specified Torque Limit (ft-lbs)

Grade MD 56

3/4"

85

362

430

Grade MD 56

7/8"

85

568

675

Grade MD 56

1"

85

850

1000

EL ULTRA-HIGH-STRENGTH SUCKER RODS

QUENCHED AND TEMPERED SUCKER RODS

Designed to provide an ultra-high load rating and successful corrosionresistant qualities, EL rods are Weatherford's premium line of highstrength coupled sucker rods. The exclusive induction case hardening process incorporated into the manufacturing of these rods makes them the ultimate fatigue-resistant sucker rod.

Designed for high strength and fatigue performance, the S88 rod provides an intermediate step between the normalized Grade D and ultra-high strength EL rod. These rods are manufactured with 3130M Nickel-Chrome steel; they are quenched and tempered which results in higher toughness and a finer grain structure, making them capable of better fatigue resistance. For example, the quenched and tempered rods typically have charpy impact results in the +70 ft. lb. range, while normalized and tempered rods are typically in the 20 ft. lb. range. This added toughness of the quenched and tempered rod provides the added fatigue resistance needed in extreme applications.

Grade D

3/4"

85

362

460

Grade D

7/8"

85

568

735

Grade D

1"

85

850

1100

Grade D

1 1/8"

85

1214

1570

S67

7/8"

110

696

780

S67

1"

110

1039

1165

S67

1 1/8"

110

1480

1660

S88 sucker rods are available in 5/8"*, 3/4", 7/8", 1" and 1 1/8"* diameters. All sizes are available in 25-foot and 30-foot* lengths.

Grade KD63

3/4"

85

362

450

Grade KD63

7/8"

85

568

700

Grade KD63

1"

85

850

1000

Grade KD63

1 1/8"

85

1214

1500

S87

7/8"

115

728

815

S87

1"

115

1086

1220

S87

1 1/8"

115

1551

1740


3/4"

115

462

500


7/8"

115

725

800


1"

115

1086

1200


1 1/8"

115

1551

1700


1 1/4 X 1"

115

2100

1600*


1 1/4 X 1 1/8"

115

2100

2500*

S88

7/8"

130

823

920

S88

1"

130

1228

1380

S88

1 1/8"

130

1749

1965

EL

7/8"

-

-

1000*

EL

1"

-

-

1600*

EL

1 1/8"

-

-

2500*

Ordinary sucker rods tend to fail from fatigue originating at the surface under tension. The unique engineering of the EL rod puts it in a class by itself. It has a thin compression layer at its surface that remains under compression even under normal operating tensile loads. Since the compressive pre-stress protects the surface from tensile stresses, the chances of developing fatique cracks are greatly reduced. Additionally, stringent quality control procedures employed with these rods promote reliable and long service life.


Key Benefits • Energy saving through pumping with a lighter string with no compromise in production • Higher fluid production with existing pumping unit • Reduction in the size of pumping unit with no reduction in production • Use of smaller, more economical tubing • Increased pump speeds for additional production • Avoidance of more unconventional and expensive recovery techniques • Extended service life Applications Super high-load capacity in mild sweet (CO2) and sour (H2S) corrosive environments. Satisfactory corrosion-inhibiting practices must be followed. Specifications • Special chrome-moly alloy steel • Normalized, tempered, and induction case hardened • Pin ends machined with API rolled threads Maximum Stress Allowable Sa = (55,000 PSI = 0.2143 Smin) SF

S87 API D rod is recommended for mild corrosive or inhibited wells; also recommended for CO2 wells (sweet corrosive environments). Manufactured with 3130 modified alloy steel. S67 API Grade D rod is recommended for heavy duty pumping in non-corrosive or inhibited wells. This economical high strength rod is manufactured with 1029 modified alloy steel. Applications Deep, highly loaded wells in mildly corrosive environments provided satisfactory corrosion inhibiting practices are followed. Specifications • Special chrome-nickel alloy steel (S88 and S87) • Quenched and tempered • Pin ends machined with API rolled threads *These sizes are available with minimum order quantities.

*Special High Torque Coupling and Make-up Procedures Required.

WEATHERFORD SUCKER RODS Another Production Enhancement Solution from Weatherford


WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Phone: (780) 417-4800




Weatherford products and services are subject to Weatherford's standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford. © Copyright 2003 Weatherford • All rights reserved • ALS7501.01


TORQUE LIMITER MODEL M1 For Progressing Cavity Pumping Systems To optimize production by loading your rotary equipment to the limits, without damaging your downhole equipment, you need to accurately control torque. Weatherford's M1 Torque Limiter provides torque S/D, monitoring and data logging for all electric-driven rotary (PCP) artificial lift systems. Features include accurate torque and low power shutdown, automatic well restart, data logging and a random startup timer. The M1 Torque Limiter download includes 4 separate text logs to assist with well optimization and failure analysis.

TORQUE LIMITER™ PACKAGE Another Production Enhancement Solution from Weatherford

Key Features The Weatherford M1 Torque Limiter displays real polished rod torque in ft-lbs. by measuring both actual electric power (not amperage) and actual polished rod speed.

High torque shutdown. Low power shutdown. Excessive belt slip shutdown. After shutdown, drive will automatically restart after backspin is complete. Operator interface displays polished rod RPM, torque and motor HP HP during operation. RPM, HP and torque values at shutdown retained and displayed. Maximum polished rod speed during last recoil retained and recorded. recorded. Download software allowing user to view, view, graph, retrieve and process data logs. Comprehensive data logging which includes: total number of recoils, recoils, 30 day torque log (1 sample every every 11 minutes), RPM & HP log for 2 hours prior to shutdown (1 sample sample every every 4 seconds), time and date of last 16 drive startups recorded, time time and date stamp of last 32 torque and/or HP limits reprogrammed, time and date stamp of download. "Bump Start" drive starting for added brake reliability. reliability. Basic self diagnostics for easy installation and troubleshooting. troubleshooting.

Samples of actual Weatherford M1 Torque Limiter tracking Torque & speed history in minutes

Torque history in days

If the task at hand is to optimize production without overloading your sucker rod, then you need The Weatherford M1 Torque Limiter... The Intelligent Solution for Today's Demanding Rotary Applications.


BLK YELL MAG CYAN BLK


MAG

YELL

BLK

CYAN

MAG

YELL

Surface Transfer Pump

The Weatherford Progressing Cavity Surface Transfer Pump System (PCSTP) is a field proven design that is suitable of transferring many fluids including oil, formation water and entrained solids - either in separate states or as a mixture. This innovative design is a cost-effective solution that provides great flexibility for fluid movement applications.

Applications

YELL

BLK

CYAN

Fluid transfer Fluid disposal

Key Features Customer-focused designs Ability to pump a wide range of fluids

MAG

Electric driven systems Hydraulic/gas driven systems - ideal for remote locations

CYAN

Available in numerous displacements/pressures Designed to adapt to different drive and/ or pump configurations with minimal cost

BLK

Very versatile Minimal site preparation

CYAN

MAG

YELL

BLK

CYAN

MAG

YELL

Utilization of surplus customer inventory Low maintenance Low operating costs

2 Piece Frame (21' Base & 8' Extension) With M4 Electric Drive Head Shown

CYAN

MAG

YELL

BLK

CYAN

MAG

YELL

BLK

CYAN

MAG

YELL

BLK

CYAN

MAG

YELL

PROGRESSING CAVITY SURFACE TRANSFER PUMP Another Production Enhancement Solution from Weatherford

Hydraulic or Electric Drive Head

Operation The pump is operated in the counter clockwise direction placing the fluid intake directly below the drive and discharge at the opposite end, extending stuffing box life.

Optional Polished Rod Guard

Booth Optional Booth Guards

Fluid must be delivered to the pump inlet by either gravity feed or another pump. This system requires a small amount of inlet pressure, not exceeding 500psi.

Stuffing Box Fluid Inlet 3"-300# Flange

The frame works ability to be lengthened or shortened by adding or removing extensions to the base gives the user the ability to move the complete unit and/or change pumps at will, with minimal cost.

4" - 600# Flanges Top & Bottom Of Pump Optional CSA Approved Digital Tachometer

Adjustable Pump Clamps

Optional Oil Pan PC Pump

Fluid Discharge 4" - 600# Flange Frame

Operational Boundaries Anchoring Locations

Maximum Fluid Temperature - +65°C or +150°F Maximum Discharge Pressure - 1350psi or 9300 kPa Maximum Inlet Pressure - 500psi or 3400 kPa Stator Tube Sizes - 3 1/4" to 5 1/4" OD or 82mm to 134mm OD Standard frame components - 21' Base, & 8', 16', or 24' Extensions The specifications listed above represent the limits of the standard PCSTP system; if different operational parameters are required please contact your Weatherford representative for assistance.

Attach Frame Extentions

1 Piece Frame (21' Base) With HTD Drive Head Shown


WESTERN HEMISPHERE

EASTERN HEMISPHERE

Canada Phone: (403) 269-7788

Europe Phone: (44) 1224 331 331




VSH2 NITROGEN-OVER-HYDRAULIC PUMPING UNIT This unique reciprocating rod pump was specifically developed for fields with heavy crude oil and wells with rod fall problems. Due to its nitrogenover-hydraulic technology, it can lift greater loads using less energy. The VSH2 can handle Polished Rod loads up to 40,000 lbs. and change SPM with a turn of a knob.

1

1

Nitrogen gas pushes down on the accumulator piston. Hydraulic fluid under the piston is forced into the upper stage of the cylinder and pushes up on the cylinder piston.

2

The Servo Valve routes pressurized fluid from the pump, to the lower stage of the cylinder. This cycles the cylinder rod up and down, using less horsepower as nitrogen furnishes approximately two-thirds of the lifting power.

3

The proximity switches activate the Electric Displacement Control that operates the Servo Valve, changing the direction of the stroke.

4

SPM can be changed by merely turning the knob up or down on the control panel switches.

Advantages Low maintenance Low operating pressures Minimal freight and setup charges Minimal site preparation Versatility to pump a wide range of wells Variable speed control Adjustable stroke lengths

Applications Heavy crude oil (Pump to surface applications) Poor rod fall Testing wells, new and reentry Short term repairs Use large bore pumps

2

M

3 4

VSH2 NITROGEN-OVER-HYDRAULIC PUMPING UNIT Another Production Enhancement Solution from Weatherford

Performance Data Maximum stroke Minimum stroke Maximum SPM* Max. rod loads (lbs.)** Cylinder size

60

Unit Model 120

150

60 24" 9 35,000 4"

120 52" 8 40,000 4"

150 72" 7 40,000 4"

*Maximum SPM can vary depending on PPRL. **PPRL loads can vary depending on SPM.

D

Overall Dimensions A = width B = length C = shipping ht. C = working ht. 90° C = working ht. Vertical D = cylinder E = pedestal F = mast width (shipping) G = mast width

60

Unit Model 120

150

61" 102" 57" 62" 83" 157" 144" 26" 18.5"

61" 102" 57" 74" 115" 277" 215.5" 26" 18.5"

61" 102" 57" 74" 115" 255" 254.5" 26" 18.5"

F

E

C

A

B

•Polished Rod loads to 40,000 lbs

G

•SPM with a turn of a knob Distributed By

515 Post Oak Blvd. Houston, Texas 77027 www.weatherford.com

Worldwide Customer Service Phone: (713) 693-4000 Fax: (713) 693-4323 [email protected] Canadian Manufacturing & Service Phone: (780) 871-2333 Fax: (780) 871-2393

Weatherford products and services are subject to Weatherford's standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford. © Copyright 2002 Weatherford • All rights reserved • ALS7004 • Printed in U.S.A.

®

VSH2 Set-Up & Operating Manual

Version 1.0

®


Disclaimer This manual is intended to give our customers basic information regarding the design, installation and operation of the VSH2 unit. It is not intended to be a complete source of information on these matters. The customer is responsible for using this information in a correct and safe manner. For assistance, contact your nearest Weatherford representative. The operation of any Weatherford VSH2 unit beyond the parameters outlined in this manual without factory approval may be damaging to the equipment and/or personnel in which case Weatherford Canada Partnership cannot accept any responsibility whatsoever and disclaims all liability thereof.

Date Sold Serial Number Model

VSH2 Set-Up & Operating Manual

Table of Contents Theory of Operation

Pg. 1

Base Plate Installation

Pg. 2

VSH2 Polish Rod Spacing

Pg. 3

Accumulator Working Position

Pg. 4

Set-Up Procedures with Picker/Crane

Pg. 5-6

Caution Using Pole Truck

Pg. 7

Bridle Separation Plate Adjustment

Pg. 8

Set-Up Procedures with Pole Truck

Pg. 9-10

Accumulator Fill Procedures

Pg. 11

Torque and High Pressure Light Setting

Pg. 12

Maintenance

Pg.13-14

Speed Increaser Information

Pg. 15

VSH2 Take Down Procedures

Pg 16

Troubleshooting Guide

Pg 17-18

VSH2 Parts List & Blow Up - Mast

Pg 19-21

VSH2 Parts List & Blow Up - Power Unit

Pg 22-26

Electrical Trouble Shooting guide

Pg 27-40

Contact List

Pg 41

Note Page

Pg 42

VSH2 Daily Log

Pg 43

Weatherford Canada Partnership Ltd. Warranty

Pg 44

®

Theory of Operation Unit has a two stage double acting cylinder and utilizes a piston style accumulator, nitrogen over hydraulic oil: • Nitrogen pressure pushes down on the accumulator piston; hydraulic fluid under the piston is forced into the upper chamber of the cylinder forcing the cylinder piston to rise from the pressurized fluid. • Proximity switches activate the EDC valve to change direction of the pressurized fluid. • Servo valve routes pressurized fluid to the lower stages, which cycles the cylinder up or down depending on the chamber being filled. • Turning the speed switch can change stroke speed. This in turn changes the angle of the swashplate in the pump, changing the amount of fluid released to the upper or lower chamber. This unit comes completely assembled,with the exception of hook up of the four hoses from the powerpack to the pedestal and the electrical cable from the pedestal to the electrical box. All connections for the hoses are matched with quick disconnect couplings. The accumulator hose connection is painted red and will connect to the "B" hose connection. Install on the accumulator pipe. Prior to installation of the unit make sure all personnel have read this manual.

CAUTION - when standing pedestal, always have guy wires manned by two or more people and locate truck winch cable directly over the wellhead or behind, never in front of the wellhead (refer to diagram Caution Using Pole Truck). When stroking the unit, be aware of the after travel of the target plate to proximity switch. The faster the SPM the more after travel, make sure to adjust for this after travel when speeding the unit up or down.

1

Base Plate Installation

Supplied with Hydraulic Unit: Base Plate (2 7/8" eue) CUSTOMER WILL SPECIFY ROD SIZE

Optional: Pumping Tee • Preventer • Adapter Flange • Valves • Nipples • Tee • Tubing Nipple • Stuffing Box • Elbow Polish Rod Clamp - 3 bolt (1 1/4" or 1 1/2") • Hammer Union • Studs • Ring Gasket • Gauges • Needle Valves • Swages

2

®

VSH2 Polish Rod Spacing 4" Cylinder

Cylinder Rod

Clevis Tee

Rod Clamp Bridal Block Polish Rod

44" - 65"

Rig Positioned Rod Clamp Stuffing Box Bottom Plate Tubing Nipple Pump Tee

CAUTION Space polish rod out, including rod stretch in the down stroke From the top of the base plate to the tip of the polish rod or coupling, leave the following: • 60", 120" or 150" Unit Min. Rod sticking up - 44" • 60" unit - Max. Rod sticking up - 58" including coupling • 120", 150" Unit - Max. Rod sticking up - 60" including coupling

3

Accumulator Working Position

4

®

Set-Up Procedures with Picker/Crane Before leaving for the lease or setting the unit, be sure to instruct the operator in the proper spacing of the polish rod in relation to the length of rod extending above the plate (refer to spacing requirements in the manual). The polish rod should be set in the down stroke with all the rod stretch calculated. Depending on the means of installation, (pole truck, picker or work-over), position the trailer to unload the pedestal and cylinder assembly. • Release and remove all straps and tie-downs. • Attach winch cable to the pedestal-lifting eye using a safety hook and raise the pedestal and cylinder from the trailer. • Caution - if unloading the pedestal with a forklift, do not put forks underneath the pedestal, this could cause damage to the proximity switch adjustment tubing. • Set the pedestal on the ground with the bottom near the wellhead. Remove the safety hook from the pedestal and fasten to the cylinder eye at the top of the cylinder (attach small rope to safety latch for easy removal of sling or hook). • Attach all guy wires to the pedestal eyes at the top of the pedestal. • Attach all switch wires to switches and remove all wire-ties as needed. • Remove bridle carrier bar from bridle assembly. • Caution - Loosen the bridle separation wire bracket, adjust to clear the pedestal support bracket before lowering bridle assembly. • Check all hydraulic hoses and connections for tightness. • Slowly start lifting the cylinder and pedestal in the vertical position, place directly on the base plate. • Align the pedestal hinge plate with the well base plate, install the hinge pin with cotter pins and the four (4) 3/4" x 4" bolts in the plate. • Space the guy wires approximately 15' - 20' from the wellhead out using the stakes supplied or anchors; drive these at a 45degree angle. • Attach all guy wires to the stakes and remove the slack. • Using a safety line, disengage the safety hook and remove from the cylinder eye. • Back-up trailer to well, approx. 20' from wellhead or position skid on sills. • Attach all hoses (4) and electrical cable to powerpack and pedestal (do not use wrenches on quick disconnect couplings; hand tighten only to tighten line on coupling). • Raise the accumulator from the shipping position, to the 30 or 90-degree angle (90 is best so the piston floats vertically). Caution - loosen the connection at the bottom prior to standing the accumulator and then tighten with the elbow facing the wellhead. • Space powerpack to wellhead and stretch hoses as needed. • Open oil suction valve to pump (failure to operate pump without oil could cause damage to pump). • Hook up nitrogen charging kit and pre-charge accumulator and bottles with 150# of nitrogen. • Hook up energy sources (wellhead gas to scrubber or energy to control box). • Turn on the motor and allow oil to circulate for a couple of minutes (Rpm's at 1500 to start if gas). • Adjust stroke length switches approx. 60" from top and bottom at start up. • Unit speeds should be slow at the start up, this allows for visual inspections prior to incidents. • Switch to manual, and jog in the down direction slowly, making sure not to hit switches on the down stroke or allowing the polish rod and cylinder rod to meet. • With the bridle in the down position and the cylinder rod fully extended, install polish rod to bridle assembly, reinstall bridle carrier bar and install polish rod clamp. • Place separation plate on top of the rod clamp and adjust the switch to within 1/8-1/4" of the plate. • Release the lower clamp and raise the clamp 4" from the cylinder bottoming position. • Plumb the pedestal using a level with the rod weight on the cylinder. • Mark oil level on the level gauge and add 2-1/2" - 3" in the accumulator (check accumulator fill procedures).

5

Set-Up Procedures with Picker/Crane cont'd. • Turn the remote pressure relief valve in to gain maximum press at the beginning. Using the jog up and jog down switch, run the unit for one stroke making sure all is correct, stop the bridle in the middle of the stroke and then turn to auto, press auto and unit should change directions automatically. • Check the up and down pressure gauge; At the beginning the up pressure will be higher, and nitrogen will be needed to increase life. Add nitrogen until the down pressure is 100 lbs. more than the up pressure, (as the fluid levels drop, the rod & fluid weight increases, thus revering the balance). • Reset the pressure relief valve, this must be done in the up direction. Adjust this valve to 300 lbs. more than the operating pressure, also adjust the high pressure alarm light to 200 lbs. more than the operating pressure. • Adjust stroke lengths with desired speeds (when adjusting stroke lengths, allow for after travel depending on speed. DO NOT STRIKE TOP OR BOTTOM STROKE CONTINUOUSLY). • CHECK ALL FITTINGS, CONNECTIONS and BALANCE AS NEEDED.

REMEMBER: • • • • • •

Read this manual prior to operating. Always have guy wires manned when standing the pedestal. Make sure that when operating, all safety functions are in operation. Set the pressure relief valve and high-pressure alarm light. Keep system clean and free of dirt and pollution. Keep records of daily operating pressures, accumulator pressure and temperatures (this information will be needed if assistance is required by the agent). • Hand tighten quick disconnect couplings to line only, NO WRENCHES. • SAVE - All tank, hose and coupling caps and plugs for future use, when moving unit. • Prior to working on unit, notify your local Weatherford ALS agent. Sometimes the problem is only an adjustment.

6

®

Caution Using Pole Truck

CAUTION CENTER LINE OF WELL CASING

"YES" Proper position, cable is directly over the well casing "CAUTION" make sure personnel are clear of the area around the casing before attempting to lift the pedestal into position!

CENTER LINE OF WELL CASING

"NO"

Improper position!! cable is not plumb over well casing

Always make sure that at least two guy wires are manned when raising or lowering the pedestal (opposite sides). Make sure the truck is positioned directly over the well and NOT in front, this could cause the pedestal to swing. Always use a safety hook when raising or lowering the pedestal.

7

Bridle Separation Plate Adjustment

Direction proximity switches should have between 1/8 - 1/4" clearance betwen the target plate. Rod separation switch should be adjusted approximately 1/8 - 1/4" from separation plate.

8

®

Set-Up Procedures with Pole Truck Before leaving for the lease or setting the unit, make sure that you have instructed the operator in the proper spacing of the polish rod in relation to the length of rod extending above the plate (refer to spacing requirements in the manual). The polish rod should be set in the down stroke with all rod stretch calculated. Depending on the means of installing, pole truck, picker or work-over, position the trailer to unload the pedestal and cylinder assembly. • Release and remove all straps and tie-downs. • Attach winch cable to the pedestal-lifting eye using a safety hook and raise the pedestal from the trailer. • Caution - If unloading the pedestal with a forklift, do not put the forks underneath the pedestal; this could cause damage to the proximity switch adjustment tubing. • Align the pedestal hinge plate with the well base plate and install the hinge pin with cotter pins. • Support the cylinder using the cylinder support bracket just forward of the center of the cylinder. • Release the safety hook and position the pole truck opposite the pedestal direction. • Attach all guy wires to the pedestal eyes at the top of the pedestal. • Attach all switch wires to switches and remove all wire-tie as needed. • Remove bridle carrier bar from bridle assembly. • Caution - Loosen bridle separation wire bracket, adjust to clear pedestal before lowering bridle assembly. • Check all hydraulic hoses and connections for tightness. • Attach the winch cable to the pedestal-lifting eye (using a safety hook). When lifting the pedestal, make sure the cable is positioned directly over the wellhead, as this will eliminate some possibility of the cylinder swinging and have guy wires manned. • Slowly start raising the cylinder using people to hold the guy wires; this will help keep the cylinder from swinging. Once the cylinder is stood up and in ther vertical position secure with the four (4) 3/4" x 4" bolts. • Space the guy wires approximately 15' to 20' from the wellhead out using the stakes supplied or anchors, drive these at a 45-degree angle. • Attach all guy wires to the stakes and remove the slack. • Release the safety hook from the pedestal eye. • Back-up trailer to well, approx. 20' from wellhead or position skid on sills (position on the pipe side). • Attach all hoses (4) and electrical cable to powerpack and pedestal (do not use wrenches on quick disconnect couplings, hand tighten only to tighten line on coupling). • Raise the accumulator from the shipping position, to the 30 or 90-degree angle (90 is best so the piston floats vertically). Caution - Loosen the connection at the bottom prior to standing the accumulator and then tighten with the elbow facing the well head. • Space powerpack to wellhead and stretch hoses as needed. • Open oil suction valve to pump (failure to operate pump without oil could cause damage to pump). • Hook up nitrogen charging kit and pre-charge accumulator and bottle with 150# of nitrogen. • Hook up energy sources (wellhead gas to scrubber or energy to control box). • Caution - Open the hydraulic oil suction valve to the pump (failure to do so could cause damage). • Start the motor and allow oil to circulate for a couple of minutes (Rpm's at 1500 to start if gas). • Adjust stroke length switches approx. 60" from top and bottom at start up. • Unit speeds should be slow at the start up, this allows for visual inspections prior to incidents. • Turn power switch on, switch to manual, and jog in the down direction slowly, Caution - making sure not to hit switches on the down stroke or allowing the polish rod and bridle block to hit. • With the bridle in the down position, cylinder rod fully extended, now install polish rod to bridle assembly, reinstall bridle carrier bar and install polish rod clamp. • Place separation plate on top of the rod clamp and adjust the switch to within 1/8 - 1/4" of the plate. • Plumb pedestal using turnbuckles and boomers.

9

Set-up Procedures with Pole Truck cont'd. • Mark oil level on the level gauge and add 2-1/2" - 3" in the accumulator (check accumulator fill procedures). • Turn the remote pressure relief valve in to gain maximum press at the beginning. Using the jog up and jog down switch, run the unit for one stroke making sure all is correct, stop the bridle in the middle of the stroke and then turn to auto, press re-set and unit should change directions automatically. • Check the up and down pressure gauge, at the beginning the up pressure will be higher, and nitrogen will be needed to increase lift. Add nitrogen until the down pressure is 100 lbs. more than the up pressure, (as the fluid levels drop, the rod & fluid weight increases, thus revering the balance). • Reset the pressure relief valve, this must be done in the up direction. Adjust this valve to 300 lbs. more than the operating pressure, also adjust the high pressure alarm light to 200 lbs. more than the operating pressure. • Adjust stroke lengths with desired speeds. (when adjusting stroke lengths, allow for the after travel depending on speeds. DO NOT STRIKE TOP OR BOTTOM STROKE CONTINUOUSLY) • CHECK ALL FITTINGS, CONNECTIONS and BALANCE AS NEEDED.

REMEMBER: • • • • • •

Read this manual prior to operating. Always have guy wires manned when standing the pedestal. Make sure that when operating, all safety functions are in operation. Set the pressure relief valve and high-pressure alarm light. Keep system clean and free of dirt and pollution. Keep records of daily operating pressures, accumulator pressure and temperatures. (This information will be needed if you phone your agent). • Hand tighten quick disconnect couplings to line only, NO WRENCHES. • Save - All tank, hose and coupling caps and plugs for future use. • Prior to working on unit, notify your local Weatherford ALS agent. Sometimes the problem is only an adjustment.

10

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Accumulator Fill Procedures • Turn speed control to lowest setting (up, down). • Put selector switch in the manual position. • Using the jog switch, extend the cylinder rod in the full down stroke position. • Open fill valve. • Mark level on sightglass. • If the initial start-up, put 2-1/2" - 3" of oil into the accumulator. • Hold the jog switch in the down position and slowly turn the down speed dial (clockwise) to increase the pressure while filling accumulator (it might take a moment to see the oil level start to drop). • Once the desired oil level is obtained, close the fill valve and release the jog switch.

REMEMBER: • If the accumulator has been over filled, then the cylinder cannot complete the down stroke when the unit is in operation. • If the accumulator does not have enough hydraulic oil, then the cylinder will use more pressure at the top of the up stroke.

11

Torque & High Pressure Light Setting To Set the Light • The pressure light switch is located on the right side of the tank (looking at control box). • Use the procedure below, only after setting the torque valve back off the pressure 100 lbs. • Keep the jog switch manually in the up position and turn the high pressure light switch clockwise to increase the pressure or counter clockwise to decrease the pressure. • When the high pressure light comes on, hit the red re-set button, do this until this light is set 300 lbs. more than the operating pressure and the light does not come on. • After light is set, then set the torque valve to 100 lbs. above the light setting.

Setting the Torque Valve • • • • •

Observe the OPERATING pressures. Stop the unit in mid stroke by turning to the manual position. Turn the up speed to a slower position on the speed dial. Using the jog up switch, turn to manually jog up holding the switch. As the cylinder is going up, use the up speed dial to slow the cylinder down as it reaches the top of the stroke, still holding the jog switch in jog position (do not hit the bottom of the cyl. at full speed). • When the cylinder bottoms out, slowly turn the speed dial clockwise to a faster speed; this increases the gauge pressure, it should read what the torque pressure is set at. • If the operating pressure was 1000 lbs. on either gauge (example) then set the TORQUE at 400 lbs. more than the highest operating pressure.

REMEMBER - Always JOG the unit in the mid-position, to ensure that the unit will go up and down when the auto-start button is pushed. If operator is above or below the proximity switches when the button is pressed, the target plate will not contact the switch to change direction automatically. The unit will then continue to run until monitored.

12

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Maintenance VSH2 with ELECTRIC motor • After the first 60 days of operation - change the hydraulic pump filter; Then replace every 5 months thereafter. • Visually check all connections, nuts and bolts periodically. • Hydraulic oil level should be 1/2 of level gauge when operating. DO NOT OVERFILL, remember that when the accumulator is drained, this fluid raises the tank level about 3" or by whatever oil is in the accumulator. • Hydraulic oil should be analyzed once per year for oil condition, and filtered if possible. • Grease motor every 150 days (one or two shots of grease). • Check Increaser oil monthly. • Speed Increaser - change oil every 90 days (see Speed Increaser lubrication section).

VSH2 unit with GAS engine • Drain gas volume pot daily. • After the first 60 days of operation - change the hydraulic pump filter and then replace very 5 months thereafter. • Change engine oil, engine filter and luberfiner filter after the first 200 hours of operation and then every 350 hours thereafter. (Recommend API - "SJ") If you have luberfiner system, change engine oil every 30 days. • Visually check all connections, nuts and bolts periodically. • Hydraulic oil level should be 1/2 of level gauge when operating. DO NOT OVERFILL, remember that when you drain the accumulator, this fluid raises the tank level about 3". • Hydraulic oil level should be analyzed once per year for oil condition, and filtered if possible. • Oil Change every 30 days (see speed increaser lubrication section). NOTE: If the unit has a speed increaser• DO NOT EXCEED 1800 RPM'S during operation of engine. THIS WILL EXCEED THE RECOMMENDED REQUIREMENTS OF PUMP RPM'S FOR CONTINUOUS OPERATION.

Filter Change When changing the filter, always follow the procedures below. • • • • • • • • •

Turn engine / motor off. Shut suction hose valve to pump. Place a drip pan underneath the filter to be changed (filter will drip some oil from the filter and pump). Remove filter and replace with new filter (always put small amount of oil on filter seal prior to installing). Hand tighten filter only. Open suction valve to pump (failure to do so could result in damage to pump). Turn engine / motor on and allow running for 1 minute prior to operating cylinder. Check filter for leaks prior to removing drip pan. Check tank levels and do not over fill.

13

Maintenance Cont'd. REMEMBER: • When adding oil, always make sure the pump, hose and oil is clean prior to pouring into the tank. • Make sure breather assembly is tight on tank lid. • Check connections and do not over tighten the quick disconnect couplings past the tighten line on the coupling (this could result in damage to the coupling seal). • Do not use wrenches on the quick disconnect couplings.

14

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Speed Increaser Information Lubrication (Oil) Fill with MIL-L-2105C or API-GL-5. Always use clean oil do not overfill. This will result in overheating and possible malfunction of the unit. It is recommended that the oil be changed after the first 500 hours of service and thereafter changed after six months or 2000 hours of operation, whichever comes first. Always drain oil when the unit is warm and clean all magnetic drain plugs before replacing. Maximum Operating Oil Temperature is 210° F (98.8° C)

Lubricant Grade Below - 10° F (-23° C) Ambient use 40W Above -10° F and up to 100° F (37.8° C) Ambient use 80W-90 or EP90 Above 100° F (37.8° C) Ambient use 85W-140 Optional: Mobil SHC 635 synthetic or equivalent (All temperature ranges) The use of grease, hydraulic fluid, or other substitute compounds is not recommended as a substitute to a good grade MIL-L-2105C or APL-GL-5 gear oil.

Oil Capacity The following is an approximate amount: always fill to level plugs or dipstick level. KF89 Series: (1 pad) Vertical Mounting 2 12 Qts./ 2.37 Liters

Wet Spline Pump Pads Add the specified amount of oil through the oil cap in the top of the pump pad. This amount of oil will cover the entire spline diameter. Do not fill the pump pad completely full of oil.

15

VSH2 Take Down Procedures • Stop the unit in the center of the pedestal and switch to the manual position. • Using the jog switch lower the cylinder to within 3" of the complete down stroke. • Release the jog switch. • Place a rod clamp on the top of the stuffing box and tighten. • Open the fill valve to relieve the accumulator pressure to 0 lbs. (DO NOT RELEASE NITROGEN). • Remove the polish rod coupling at the end of the polish rod. • Remove the separation plate. • Loosen the rod clamp on the bridle assembly slowly and then remove. • Using the jog switch, slowly raise the cylinder rod to the top completely. • Turn unit off. • Remove all hoses and electrical lines from the pedestal and secure on powerpack or trailer. • INSTALL ALL HOSE CAPS AND PROTECTORS IMMEDIATELY. • Attach crane or pole truck cables to lifting eye and secure cylinder. • Release guy wires from anchors. • Remove plate bolts and hinge pin (IF USING A POLE TRUCK OR LOWERING FROM THE CENTER EYE, DO NOT REMOVE PIN UNLESS THE PEDESTAL IS IN THE HORIZONTAL POSITION). • Slowly remove pedestal from base plate and position as needed. • If using a pole truck, position the cable directly over the wellhead (AS IN THE CAUTION SECTION). • When re-installing on another well, you might find that you need to release some nitrogen, due to differences between the well conditions and rod loads. • Caution - when setting pedestal on the ground or any trailer so as not to damage switch adjustment tubing.

16

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Troubleshooting Guide 1. Up pressure is higher: • Add nitrogen (using charge kit, add nitrogen to bottles). • Add oil to accumulator (in the down stroke using the jog switch, open the fill valve). 2. Down pressure is higher: • Reduce accumulator oil (open bleed valve). • Reduce accumulator nitrogen pressure (bleed nitrogen by opening nitrogen needle valve). 3. Loss of accumulator pressure: • Accumulator bleed valve open (close bleed valve). • Possible Nitrogen loss (check connections for leaks). • Upper cylinder chamber seal leaking (check oil return line to tank or switch hoses). • Accumulator seal leaking (possible oil in bottles). 4. High oil temperature: • Low oil level (add oil). • Cooler needs cleaning. 5. Cylinder will not cycle: • Rod separation switch tripped or faulty (re-set light). • SPM speed turned to stop position (turn switch to faster speed). 6. Cylinder will not change direction: • Faulty proximity switch. • Faulty electrical board. 7. Cylinder bottoms out before switching: • Too much after travel (move switches closer to center of pedestal) • Switches not spaced correctly. 8. Cylinder will not lift weight: • Torque relief valve not set correctly (turn clockwise for more pressure). • Low accumulator pressure (add oil or nitrogen).

17

Troubleshooting Guide cont'd. .9. Rod separation light on: • Pump (plunger) sticking in down stroke. • Possible energy failure during the day or night (re-set). • Stroke bottoming out (adjust switches). •

Check relay.

10. High pressure light on: • Improper torque adjustment (re-set light switch). • Pump (plunger) sticking in up stroke. 11. Bridle proximity switch plate passes switch and bottoms out: • Excessive pressure in the up or down stroke (reduce pressure by bleeding nitrogen). • Check distance of switch to plate. 12. Unable to fill accumulator: • Put in manual and hold jog down switch. • Open fill valve. • Nitrogen pressure exceeds set pump operating pressure (Contact a Weatherford Representative). 13. Separation plate will not function: • Check separation switch. • Check separation switch cables. • Check relay.

18

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VSH2 Parts List - Mast

19

VSH2 Parts List - Mast Cont'd. (c/w optional switch adapter bracket)

125-46-5177

Fab Part Par Part Fab Par

Part Fab Par

2 54-1053

125-46-5010

*

125-46-2084 * 125-46-2084 * 125-46-2084 Fab Part

20

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VSH2 Parts List - Mast Cont'd Item No Qnty.

Part Number

Description

11

2 1 Fab Part Fab Part Fab Part

1 125-46-5119

1

125-46-2015

Replacement Cylinder Seal Kits for 60, 120, 150

21

VSH2 Parts List - Power Unit

22

®

VSH2 Parts List - Power Unit Cont'd.

23

VSH2 Parts List - Power Unit Cont'd.

Item No 1

Qnty. 1

2

1

3 4 5 6 7 8 9 10

2 1 1 1 1 1 1 1 1 1 1 4 2 1

11 12 13

Part Number 125-46-7269 125-46-7270

125-46-7250 125-46-7271 56-0498 125-46-2001 125-46-2012 125-46-2010 125-46-7291 125-46--4000 125-46-1995

Description 5 x 8 VSH2 Skid 6 x 10 VSH2 Skid 15gal Accumulator Tilting Carrier Fab Part 21gal Accumulator Tilting Carrier Fab Part Lower Nitrogen Cylinder Rack Fab Part Uppler Nigrogen Cylinder Rack Fab Part Upper Nitrogen Cylinder Rack w/ Arm Mount Fab Part Accumulator Support Arm Fab Part 360L VSH2 Hydraulic Tank Nitrogen Bottle Guard Battery Box 15 Gal Accumulator 15 Gal Accumulator Seal Kit 21 Gal Accumulator 21 Gal Accumulator Seal Kit Nitrogen Cylinder Motor Mount Rails Fab Part Control Panel Gas, 125-46-1996 Electric

24

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VSH2 Parts List - Power Unit Cont'd. Item No

Qnty.

Part Number

Description

Fab Part

4.3 L or 5.7 L

54-1172

125-135-4576 125-46-5005

Fab Part Series 90, 130cc or 750c 2x 1" NPT Stnd Black Pipe

6290-24-20 #24Jic x #20 Fl 90 Fab Part

4 3

54-1654

125-46-2082

4

125-135-3229 125-46-2083

-24 1 1/2" x 25' Hose Assy, c/w 1 1/2" FJIC, Both Ends

2024-24-24 1 1/2" Mpt x #24 Jic GH793-24 1 1/2" X 25' Hose Assy, c/w 1 1/2" Fjic X BT 90 One End Fab Part of Tank

125-46-7272

3

55-1026

1/4' MPT x 1/4" FPT90, 2089-04-04

8

25

VSH2 Parts List - Power Unit Cont... Item No

Qnty.

Part Number

Description

1

125-135-4518 54-1121

1 1/4" x 1' Blk Reducer Bushing 2024-16-16, #16 Jic x 1" MPT 90

41

54-1121 117-135-3210 117-02-1001

1 1/4" Run Tee, 2092-4-4

4

1 7 54-1316

54-1026

54-1078 Fab Part 54-1725

54-1334

54-1586

4

125-135-0212 125-135-0212 125-135-5406 3/8" Half Coupling Fab Part

105

1

125-02-1012

1 1/4" X 1/4" Blk Reducer Bushing

26

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VSH2 Electrical Troubleshooting Procedure Gas VSH2 tools required:

Testlight or multimeter capable of measuring 12VDC Small blade terminating screwdriver

Electric VSH2 tools required:

Testlight or multimeter capable of measuring 12VDC Multimeter capable of measuring up to 480VAC Small blade terminating screwdriver Confirm that Hydraulic system is working, this can be done as follows: 1) 2) 3) 4)

Start engine or electric motor. On the EDC located on the hydraulic pump is a small toggle. Moving the toggle in one direction then the other, should result in the stroking of the cylinder. If cylinder does not stroke with the movement of the toggle, replace pump.

Once Hydraulics are confirmed to be working, step through following procedure to troubleshoot control problem. 1) Make sure 12vdc is present in control panel and fuse is good. 12vdc should be present on both sides of fused terminal, lower right hand corner of VSH2 control panel. If 12 vdc only present on 1 side of fuse change fuse. 1.1)

Gas VSH2 requires that the engine be running and Murphy run tattletale must be closed allowing 12vdc to get to control panel. 1.1.1)

1.2)

Low hydraulic oil level and/or high hydraulic oil temperature are both direct engine shutdowns and are both indicated on Murphy tattletales.

Electric VSH2 requires the utility supply be on and electric motor must run.

27

Electrical Troubleshooting Procedure Cont'd. Confirm all power supplies (using multimeter) 1.2.1)

Ensure 480 vac/380vac 3 phase is present and main breaker is on.

1.2.2)

480vac/120vac control transformer fuse is good and 120vac is present.

1.2.3)

120vac/12vdc power supply has 12vdc present.

Confirm electric motor runs (using multimeter) 1.2.4)

Ensure 480vac/380vac 3 phase is present and main breaker is on.

1.2.5)

480vac/120vac control transformer fuse is good and 120vac is present on terminal #1.

1.2.6)

Check to see if motor will run in hand position on selector.

1.2.7)

If motor will not run in hand position, check for 120vac on terminal #3 in no power check HOA switch.

1.2.8)

Check for 120vac on terminal A1; if no power, check hydraulic oil level is not low as indicated on tank site If oil level not low and no power on terminal A1, check level switch.

1.2.9)

Check for 120vac on terminal A2; if no power, check hydraulic oil temperature is not high as indicated by indicating lamp on control panel door. If temperature is not high and no power on terminal A2, check high temp relay is properly inserted in base. If in base and still no power on terminal A2; change relay.

1.2.10)

If 120vac on terminal A2 and motor does not run, check thermal overloads by pushing reset button on door of controller.

1.2.11)

If 120vac is measured across coil of magnetic starter but starter does not pull in, change starter coil. If starter does pull in (listen for loud snap when starter pulls in) and motor does not start, check electric motor.

glass.

If electric motor runs in hand position but not in auto (using multimeter) 1.2.12)

Check terminal 2 for 120vac. If no power, check remote shutdown device (e.g. Presco high pressure switch).

28

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Electrical Troubleshooting Procedure Cont'd. If 12vdc is present in control panel proceed with following: (Note the control system creates a voltage drop on the 12vdc supply but should always be a minimum of 9vdc)

Visually check all wiring for wires that appear to have fallen off and ensure all terminations are tight. 2) Put control system into manual with selector on door, turn the jog button in either the up or down direction depending on what cylinder position is and increase corresponding speed potentiometer. Try both directions again being sure to increase the proper speed potentiometer. This will verify the electrical operation of the EDC coil on the pump for both directions.

If 12vdc is present and VSH2 will not jog in manual (using test light or multimeter):

2.1)

Check to make sure separation relay is energized. 2.1.1)

This is a white 11 pin relay that is on the right when looking at the bank of relays in the bottom left corner of control panel. This relay has a small window on the top of it and when energized an orange flag is visible through the window. While in manual the separation proximity switch is out of circuit and not a factor at this time. If not energized when in manual and 12vdc is present at terminals 2 and 10 of relay, change relay. If not energized when in manual and 12vdc not present at terminals 2 and 10 or relay, change printed circuit board.

If all checks out in manual, change to auto (using test light or multimeter):

2.2)

Ensure bridle is somewhere between upper and lower proximity switches and bridle is in contact with rod block. Move into position while in manual. On a gas VSH2, press reset button, power on light should come on and stay on. If it does not, check latching relay to be energized. Movement of contacts is visible through clear relay cover and 12 vdc should be present on terminals 7 and 8 or relay. An electric VSH2 power light comes on with the closing of the on/off switch and latching relay is energized with start button or will start automatically without the press of the start button after time delay has expired. This time delay circuit does not affect the operation of the control system, it's only used to restart system in the event of a power failure. 2.2.1)

This relay in a gas VSH2 is a clear 8 pin relay that is on the left when looking at the bank of relays in the bottom left corner of control panel.

2.2.2)

This relay in an electric VSH2 is a clear 8 pin relay that is in the center when looking at the bank of relays in the bottom left corner of control panel.

If not energized when in auto after reset button (gas) or start button (electric) has been pressed and 12vdc is present at terminals 7 and 8 or relay, change relay.

29

Electrical Troubleshooting Procedure Cont'd. If latching relay does pull in but system does not start (using test light or multimeter);

2.3)

Check LED's on circuit board, down LED should be lit. If not, check proximity switches.

2.3.1)

Visually inspect all mast wiring and main wiring harness for integrity and damage.

2.3.2)

Ensure main wiring harness is plugged and tightened correctly into control panel.

2.3.3)

Ensure proximity switch harnesses are plugged and tightened correctly into each switch.

2.3.4)

Check on terminal block in control panels at wires marked upper and lower proximity switch N/C for 12vdc (again, ensure bridle is somewhere in mid position). Unit will always start down unless resting at lower proximity switch.

2.3.5)

Each switch can be manually jogged to ensure sensor plate is within 1/4" or 5mm. The proximity switches have an indicating LED on them to signal when the target is in range. At this point you can ensure the 12vdc switches from the wire marked N/C are to the one marked N/O on the proximity being tested. If no inputs from proximitys, change proximity switch.

2.3.6)

If 12vdc is not present on any of the wires marked N/O or N/C then proximity power supplies must be checked, This requires taking the cover off the black box in the upper right hand corner of control panel.

2.3.7)

Check the input and output of the barrier, should have between 9vdc and 12vdc. If no power off barrier output, change barrier.

2.3.8)

If power present at output from barrier and still no response from proximity switches, check all connections within mast termination boxes.

2.3.9)

If have all inputs from mast proximity switches as described but system does not operate, change printed circuit board.

If unit does start and run but seems to have some intermittent operation;

2.4)

Place a 400 to 700 ohm 1/4 watt resistor across the up and down speed potentiometers' positive and negative terminals. These would be the outer terminals on the potentiometer with red and black wires. If unit still operates intermittently, change printed circuit board.

2.5)

If separation light comes on check that the bridle is in contact with rod blocks and sensor plate is within 1/4" or 5mm of sensor plate.

30

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Electrical Troubleshooting Procedure Cont'd. If hydraulic oil high pressure light is on, check pressure at gauge. 2.6) this is just indication only and does not affect the operation of the control system.

VSH2 Tandem units have a stroke delay option, this delays the transition from up to down and down to up without affecting stroke speed.

2.7) If printed circuit board indicates direction change (up and down LED's change state) but there is no response from the hydraulics; 2.7.1)

Check for 12vdc at stroke direction potentiometer, if no power present, center terminal orange wire. Check for 12vdc both at terminal 1 and 3 of stroke delay timers (these are the red cubes affixed to the cover of the black plastic box that houses the barrier). 2.7.1.1) If power present at terminal 1 but not 3 and time delay has expired (5 seconds max), change timer. 2.7.1.2) If no power present at terminal 1 or 3, change printed circuit board.

If all steps in procedure have been followed and unit still does not operate properly then change printed circuit board.

31

Electrical Troubleshooting Schematics

VSH2 Direct Drive Hydraulic System Panel Cover Layout 01/08/09

32

DWG:04

REV:1

®

Electrical Troubleshooting Schematics Cont'd.

VSH2 Direct Drive Hydraulic System Amphenol Pin Out 00/03/01

33

DWG:09

REV:2

VSH2 Hydraulic System 12 Vdc Control Engine Drive

VSH2 Hydraulic System 12Vdc Control Engine Drive 01/03/09 DWG:03 REV:2

34

®

VSH2 Direct Drive Hydraulic System Control Schematic Electric Tandem

VSH2 Direct Drive Hydraulic System Control Schematic Electric Tandem 01/08/09

35

DWG:15

REV:1

Electrical Drawings VSH2 Hydraulic System 12Vdc Control Electric Motor Drive

VSH2 Direct Drive Hydraulic System 12Vdc Control Electric Motor Drive 01/03/09

36

DWG:03

REV:2

®

Electrical Drawings cont'd. VSH2 Direct Drive Hydraulic System Control Schematic Electric

VSH2 Direct Drive Hydraulic System Control Schematic Electric 01/08/09 DWG:14 REV:1

37

Electrical Drawings cont'd. VSH2 Hydraulic System 480V Motor Schematics

VSH2 Hydraulic System 480 Motor Schematics 01/06/01 DWG:VSH2-100

38

REV:1

®

Electrical Drawings cont'd. VSH2 Direct Drive Hydraulic System Control Schematic Gas

VSH2 Direct Drive Hydraulic System Control Schematic Gas 01/08/09

39

DWG:16

REV:1

VSH2 Direct Drive Hydraulic System Control Schematic Gas Tandem

VSH2 Direct Drive Hydraulic System Control Schematic Gas Tandem 01/08/09 DWG:17 REV:1

40

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VSH2 Contact List Global Product Manager:

Jim Trapani Weatherford ALS 515 Post Oak Blvd, Suite 600 Houston, TX 77027 USA (713) 693-4528 Direct (713) 693-4323 Fax (281) 380-1963 Cellular [email protected]

Manufacturing Plant:

Wade King Weatherford BMW Products & Services 4604 - 62 Avenue Lloydminster, Alberta T9V 2G2 Canada (780) 871-2333 Office (780) 875-2393 Fax (780) 808-1233 Cellular [email protected]

International Part Orders:

Mike Burton Weatherford ALS 515 Post Oak Blvd., Suite 600 Houston, TX 77027 (713) 693-4000 Main Switchboard (713) 693-4068 Direct (713) 693-4098 Fax [email protected]

Domestic Part Orders

Call (713) 693-4000 Ask for nearest agent or Weatherford Service Center

`

Local Agent: Phone Number: Motor Service:

41

VSH2 Notes

42

®

VSH2 Daily Log DATE

Up#

Down #

Accum.#

Oil Temp.

43

SPM

Relief #

Light #

Stroke In.

Weatherford Canada Partnership Ltd. (WCP) Warranty This shall be the only warranty given by WCP, and no other warranty by WCP, express or implied, shall be applicable, including any implied warrant of merchantability or any implied warranty of fitness for a particular purpose. Subject to the limitations and conditions herein, WCP warrants its products to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of delivery. WCP obilgations under this warranty shall be limited to repairing, replacing or issuing credit for, at WCP option any products or parts it finds to be defective in material or workmanship. WCP must be given a reasonable opportunity to investigate. Shipping and handling in connection with this warranty will be at the customer's expense. Products sold by WCP out manufactured by another company, will carry only the warranty of the manufacturer and the customer will rely on that warranty. Services provided by WCP are warranted for a period of thirty (30) days from the date the services are rendered. The liability of WCP for any loss or damage resulting to the customer or user or any third party from any defect in any product or service will not, in any case, exceed the selling price that WCP received from the customer for the product or service. In no event will WCP be liable for incidental, consequential, special, indirect or other damages of any nature. WCP personnel will attempt to perform the services requested; however, because of the nature of the work to be accomplished and unpredictable conditions, the results of such services cannot be and are not guaranteed. WCP uses its best efforts to ensure that all service personnel furnished are competent and rental equipment is in good condition. NO WARRANTY IS GIVEN WITH RESPECT TO ENGINEERING AND TECHNICAL INFORMATION FURNISHED BY WCP OR WITH RESPECT TO THE RESULTS OF SERVICES PROVIDED BY WCP. WCP MAKES NO WARRANTY OR REPRESENTATION, EXPRESSED OR IMPLIED, AS TO THE DESIGN OR OPERATION OF RENTAL EQUIPMENT DELIVERED OR THE RESULTS OF SERVICES PROVIDED TO COMPANY HEREUNDER, AND WCP MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS OF THE EUIQPMENT FOR ANY PARTICULAR PURPOSE OR ANY OTHER REPRESENTATION OR WARRANTY WHATSOEVER. This warranty will not apply and will be void if the product fails as a result of general wear, abrasion, incorrect installation and removal, use of maintenance, operation outside of the manufacture's recommended guide lines, alteration, accident and abuse or negligence. WCP does not warrant that any of the products sold by it, if used or sold in combination with other equipment or used in the practice of methods or processes, will not, by virtue of such combination or use, infringe patents of other, and WCP shall not be liable for any patent infringement arising from, or by reason of, any such use or sale. furthermore WCP shall not be liable for any patent infringement arising from, or by reason of any use or sale of the materials, equipment or products not of WCP's manufacture or for the use or sale of any materials, equipment or products, or other goods specially made in whole or part, to the customer's design specifications.

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®

www.weatherford.com

Manufacturing Facility 4604 - 62nd Avenue Lloydminster, Alberta T9V 2G2 Canada 780/875-0103 Telephone 780/875-0963 Fax

Canadian Customer Service 2801 - 84th Avenue Edmonton, Alberta T6P 1K1 Canada 780/417-4800 Telephone 780/417-3146 Fax

Worldwide Customer Service 515 Post Oak Blvd. Houston, Texas 77027 United States 713/693-4000 Telephone 713/693-4323 Fax [email protected]

Weatherford products and services are subject to Weatherford's standard terms and conditions. For more information concerning the full line of Weatherford products and services, please contact your authorized Weatherford representative. Unless noted otherwise, trademarks and service names noted herein are the property of Weatherford. © Copyright 2000 Weatherford • All rights reserved • ALS7013 • 02/02/400 • Printed in Canada


Bulletins & Published Articles

Additional Information & Reviews About or Line our Line of PC Pumping Products

2004 2003-2000



Bulletins & Published Articles 2003-2000

Additional Information & Reviews About or Line our Line of PC Pumping Products

Oil Lift Distribution Agreement JAMPAK Stuffing Box Stealth Shack & Stealth Wrap JAMPAK Stuffing Box ~ Oil & Gas Network Weatherford Edmonton ~ Uniform PC Pumps ~

Magazine Magazine


PC Pump Stuffing Box Successfully Incorporates Injectable Packing

Weatherford’s ability to think “outside the box” into other industry opportunities propels our customers to success with leading-edge technology, backed by

® 2003 Weatherford Canada Partnership

Weatherford’s years of design, field and repair experience.

Weatherford has introduced the most innovative solution to Conventional Stuffing Box sealing available today. The JAMPAK™ Stuffing Box from Weatherford increases overall fluid retention while decreasing down time for packing adjustment or replacement. This unit adapts the complete sealing, no-leak requirements of the marine industry along with the ability to seal the highly caustic and abrasive particles found in pulp and paper industry fluids.

Key Features / Benefits Injectable “putty-like” packing Self lubricating & self cooling to ensure minimal friction No need to replace packing Improves sealing in worn areas or slight misalignments -“will conform to fit the void” Extend the life of the stuffing box Significant time and production savings Cost effective Simple, effective maintenance procedure Can be retro-fitted to nearly all existing conventional PC Pump stuffing boxes

For more information on this or any other Weatherford product, please contact your local Weatherford Representative. Turning Ideas Into Results...Call the Experts

Canadian Sales - Calgary: (403) 269-7788 Canadian Distribution - Lloydminster: (780) 875-2730

Worldwide Customer Service: (713) 693-4800

www.weatherford.com [email protected]

Weatherford Artificial Lift Systems has signed an exclusive worldwide distribution agreement with Oil Lift Technology of Calgary, Alberta, Canada. Under the agreement, Weatherford's existing product line will be complimented by the addition of the Oil Lift wellhead drives, and will be sold and serviced throughout its global distribution Oil Lift Technology has developed a line of gear driven electric and hydraulic wellhead drives with a unique top mounted zero spill stuffing box that has proven to outlast any other stuffing box on the market. Oil Lift drives were developed to emulate the reliability of a pump jack. Since introducing the prototype in May 2000, the product has been refined and improved based on extensive fieldtesting. Reliability has been well established with over 300 drives currently operating. The success of the stuffing box, the quiet gear drive, and other low maintenance features have many companies selecting the Oil Lift drive as their preferred drive of choice. Oil Lift has also developed “The BOP that Clamps”. This is a polished rod lock out clamp that seals and holds onto the polished rod to allow wellhead drives to be serviced or replaced without a rig. The product reduces operating cost and enhances safety. Vern Hult, the President of Oil Lift is excited to have Weatherford as its exclusive distributor. Weatherford, with worldwide sales and service, is ideally positioned to take the Oil Lift products to the next level of commercialization.

WPCP# 020303BW

A Serious Solution For Serious Problems

Turning Ideas Into Results... Call the Experts Introducing the new Stealth Shack & Stealth Wrap

® 2002 Weatherford Canada Partnership

Weatherford has Engineered two products to meet today's stringent Oil Field Noise Level Requirements by reducing noise from Gas Powered Hydraulic Skid Units and Hydraulic Driveheads: The Stealth Shack and Stealth Wrap. A Serious Solution For Serious Problems.

Weatherford. The Lift Experts.™

Canadian Headquarters & Sales Calgary Canadian Distribution Headquarters Lloydminster

Ph: (403) 269-7788 • Fax: (403) 266-1837 Ph: (780) 875-2730 • Fax: (780) 875-6005

[email protected] www.weatherford.com

Technology - November 2002 Introducing the Weatherford JAMPAK™ Weatherford has introduced the most innovative solution to conventional stuffing box sealing available today. The JAMPAK Stuffing Box from Weatherford increases overall fluid retention while decreasing down time for packing adjustment or replacement. This unit adapts the complete sealing, no-leak requirements of the marine industry along with the ability to seal the highly caustic and abrasive particles found in pulp and paper industry fluids. The Weatherford Jam Pak design is a conventional Weatherford progressing cavity (PC) pump stuffing box, which uses “injectable packing” contained between 2 conventional packing rings. While a typical stuffing box containing rings of packing requires the leaking of some produced fluid for lubricating the packing, the internal lubricants and the malleable putty-like consistency of Weatherford’s injectable packing does not require any leakage. This flowing capability allows improved sealing over worn areas or slight misalignments as it will conform to fit the void, unlike solid packing rings. The injectable packing used in the Weatherford JAMPAK can be injected into the stuffing box without removing the internal components. Similar to a conventional stuffing box, the Weatherford unit has a cap, which can be tightened to increase the sealing capabilities of the packing. In the event that the JAMPAK is tightened to its maximum instead of requiring the cap to be removed and all the internal sealing components replaced, the new injectable packing can be injected into the stuffing box using the Weatherford JAMPAK injection pump quickly with minimal down time. Field tests have shown significant time and production savings by operators that have used this product. The savings are determined by the ease of system conformity and the overall sealing requirements. As an added benefit, the Weatherford JAMPAK can be retrofitted to existing stuffing boxes. This feature has led to the development of retrofit systems to modify nearly any existing rotating shaft stuffing box. By making several small off-well modifications to the stuffing box housing, then inserting the internal components, a conventional stuffing box can quickly and cost effectively be converted to operate as a Weatherford JAMPAK unit. To date, this injectable packing retrofit system has been used in over 700 stuffing boxes already in field service. Weatherford’s ability to think “outside the box” into other industry opportunities propels our customers to success with leading-edge technology, backed by Weatherford’s years of design, field and repair experience. M Canadian Sales • Calgary: (403) 269-7788 • Lloydminster: (780) 875-2730

ARTIFICIAL LIFT SYSTEMS

W E AT H E R F O R D E D M O N T O N C A N A D A FAC I L I T Y E N A B L E S QU I C K R E S P O N S E

PC Pump Project Forges Seamless Customer Link

C

USTOMIZED PUMPING UNITS FROM

WEATHERFORD’S

NEW FOCUSED DESIGN-RESEARCH-MANUFACTURING FACILITY ARE PROVIDING LIFTING SOLUTIONS FOR

CUSTOMERS A CONTINENT AWAY

– for Venezuelan Operadora

Cerro Negro (OCN), a partnership between PDVSA, Exxon Mobil and Veba Oel of Germany, who searched for a higher volume pump to meet production needs for their high viscosity Rotor profile marking is part of the manufacturing process at Weatherford’s Edmonton facility where PC pumping

wells. Weatherford’s new Model 130 (130 denotes nominal daily pumping capacity in cubic-meters-per-day per 100 rpm),

systems are designed to customer’s

high capacity progressing cavity pump (PC) was manufactured

specifications.

exactly to OCN’s specifications in only 4 months from design to prototype testing in the ground in Venezuela. It is now in service in Venezuela’s Orinoco heavy crude oil region with strong results.

26

Weatherford’s Model 130 Pump was manufactured to meet the customer’s specific lifting needs.

27

New PC Pump Design Creates Higher Volume Capacity WEATHERFORD ANSWERS LIFT NEEDS

A successful PC pumping solution is driven by customer input as well as engineering and manufacturing expertise. Weatherford ALS uses key strategies to help customers meet their goals. These include: • Weatherford’s business plan to meet customers’ special requirements • Strong technical support at all levels • A new state-of-the-art design center and manufacturing facility in Edmonton, Alberta, Canada • A close working relationship between Weatherford and the customer • Direct involvement by all groups in all phases of the project and open communication • Global footprint allows project management in real time on location.

The more conventional PC pump designs are designed largely to fit inside the majority of the world’s wells. For the most part, that means the stator must be able to pass through 5 1⁄2-inch casing and the rotor must be able to pass through 2 7⁄8-inch tubing. Taking into account that the amount of fluid a PC pump displaces is determined by the size of the cavity, then 5 1⁄2-inch casing and 2 7⁄8-inch tubing put definite limits on cavity geometry. High volume fluid demands that the cavity be larger. The result is, pumps with longer cavities, since they cannot be wider. That is why high volume PC pump designs are typically made with long narrow cavities. These longer pumps are known for efficiently moving large volumes of relatively low viscosity fluids, such as medium to light crude oils and for use in wells with high water cuts. PC pumps also have a very long history of successfully pumping very heavy viscous crude oils. However, the majority of these wells are relatively low volume. Because of this, they are used in Western Canadian fields successfully in both of these scenarios. OCN Volume Requirements Higher

This was not the situation for OCN in Venezuela. Although wells have similar crude oil properties as their heavy oil counterparts in Western Canada, their production differs. The wells produce an average of approximately

A SUCCESSFUL PC PUMPING SOLUTION IS DRIVEN BY CUSTOMER 5 cubic meters a day (30 BFPD). Some of the Venezuelan wells are capable of producing up to 100 times that volume. For the answer, OCN called on Weatherford and its global resources. Working Together for a Pumping System

Weatherford’s Model 130 Pump has brought about a new larger PC pump— the Model 175.

In Weatherford’s new Edmonton facility, employees focused on the project in which OCN wanted increased production with a limitation on horsepower and torque requirements. The new, larger volume pump needed to use the same horsepower motors on the surface, comparably sized drive strings and drive heads and motors to what they had been using—just add a larger pumping volume pump into the equation. Weatherford engineers had to address the problem of the high viscosity fluid traveling through the long skinny cavities of the conventional PC Pump. Weatherford began the project with close customer cooperation. The team held a meeting in Edmonton with Weatherford engineers, manufacturing, applications and distribution personnel as well as the customer. Key Protocols Speed Process

One reason for fast turnaround has been Weatherford’s use of the “Fast Prototyping” process at the Edmonton Facility to bring designs into reality quickly. This requires setting a development schedule with the customer’s input to go from conceptual design—which is visiting with an end user

28

INPUT AS WELL AS ENGINEERING AND MANUFACTURING EXPERTISE. and talking about the application—to having a product tested in-house in 8 weeks. That is approximately 2–3 times faster than results in comparable facilities. Another reason is the new Edmonton facility itself. Now there is no need for Weatherford to rely on an outside manufacturing facility. Additionally, there is a laboratory to do the elastomer development and the metallurgical work on-site, as well as full-scale testing facilities for extended-length testing of products. Weatherford can span the process from R&D, developing needed elastomers, designing and manufacturing the pump, producing full scale testing and qualifying the product before sending any prototype out to the field in house. This is unique in the PC pumping market. Customer Feedback Essential

Customer feedback from OCN after installation of the PC Pumps in Venezuela has helped Weatherford’s engineers ensure that the product performed as designed. It also answered questions for further development of higher volume pumps for these applications. New models of PC pump designs for other applications are now under development in Edmonton. In fact, the success of the Model 130 has brought about the Model 175— a new and larger PC pump also under development for Venezuela. As with the development of the Model 130, customer input has proved essential to all stages of the process.

Above: Weatherford’s Edmonton facility spans processes from R&D, design and manufacturing, and qualifying the pump. This unique facility speeds delivery to the customer.

Bruce Weir WALS International Technical Manager, PC Pumping Systems Phone: (780) 417-4849 E-mail: [email protected] Ron Lawrence, Region Manager, WALS Northern Latin America Phone: 58-281-2820044 E-mail: [email protected] For more information: www.weatherford.com/divisions/ artificiallift/pcp/pcp_index.htm

29

PCP, continuous rod sysFew artificial lift tems and ESPs better able systems use intelligent to operate in deviated and completion technology horizontal wellbores. These for automatic control. same systems also must Weatherford is working have increased capacity for on a standardized wellhigher volumes and site automation and extended run life. optimization system, Monitoring wells from a computer is one advantage of integrated production For coiled tubing and which will be able to optimization systems. These systems allow operators to gather real-time slimhole wells, we will effectively manage any of data from downhole conditions, monitor it, and control the production of focus on developing more the six artificial lift syshydrocarbons from a single bore, or multiple wells, all in real-time. Shown here are Jay Mehta of Case Services and Lee Colley of Weatherford. systems that can operate tems. The system will under thru-tubing applicainclude the combined lift, which is being combined with tions. Some of these slimhole designs strengths of Weatherford’s artificial the electric submersible pump (ESP). already exist in the case of PCP, lift equipment, proven technology in This hybrid system allows greater flow hydraulic and gas lift. downhole and surface electronics and when small casing restricts the flow innovative software solutions for area and increases the outlet pressure Life-of-the-field economics will drive optimizing production. With the of downhole ESP pumps. Research more artificial lift decisions. system, customers will be able to also is being done to define the perCapital rather than operating costs reduce costs and improve the quality formance criteria of gas lift assisted typically drive artificial lift decisions. of data collected, which in turn will hydraulic jet and PC pumping— Life-of-the-field economics analyzes the enhance decision making. the initial results are promising. wide range of technical, logistical and Weatherford also is prototype testing financial factors, along with both operHybrid systems will become an electric submersible pump comating and capital costs, to determine more prevalent. bined with a hydraulic lift system. whether a new type of ALS will further Weatherford will continue coupling optimize production. Weatherford different technologies to find ways Newer technologies needed for high will continue to work closely with around the limitations of the current temperature, horizontal and coiled operators to customize artificial lift six systems. For example, we are testtubing wells. solutions to actual reservoir changes, ing a hydraulically driven progressing For high temperature wells, we saving costs as the well matures. cavity (PC) pump that we developed currently are working on composite in Brazil for Petrobras. This system materials for PC pumps, which will requires minimum intervention by improve performance and lead to a having tandem PC pumps, one pump by E. Lee Colley, longer pump life (see related article as a driver and the second as a proPresident of Weatherford ® on Even Wall stator technology on ducer, thereby eliminating the need Artificial Lift Systems for sucker rods. It is best suited for page 23). Likewise, for electric offshore or remote land applications submersible pumps, we are searching where moving a rig out to the for new, more durable materials— location for a workover is costincluding metals and elastomers— prohibitive. It also can be used that will withstand extremely elevated where a significant amount of rod bottomhole temperatures. or tubing wear is prone to occur. For horizontal wells, we are look Other combinations include gas ing for ways to make hydraulic lift,

22

<< E M E R G I N G T E C H N O L O G Y U P D AT E >>

Tests show promise in new design of PC pump

How often have your well crews encountered problems with progressing cavity (PC) pumps that fail in aggressive applications such as heavy oil, high temperature or light oil? A new stator design is being tested by Weatherford that could reduce these costly frustrations. Called Uniform Thickness or Even Wall® stator technology, this upgrade to conventional stators is showing promise in improving the durability, reliability and flexibility of artificial lift pumps in Weatherford’s initial tests. This is the first major technology shift for downhole PC pump stators in the past two decades. Over the last five years, Weatherford has been involved in developing and testing the Uniform Thickness stator. Currently, there are six pumps undergoing field testing in heavy oil applications, with the longest run time to date of eight months. Weatherford has 100 additional Even

23

How it

In a conventional PC pump stator, the elastomer is injected into heavy-walled steel tubing forming a double internal helix. For years, this design was considered the only economical way to produce stators. However, heat building up or swelling in the portions of the elastomer that were thickest could cause premature stator failure in more aggressive applications.

Wall pumps ordered that are expected to be installed during the second quarter of 2000. The initial pump design being tested produces 60 barrels per day per 100 revolutions per minute (bpd/rpm) with a pressure rating of 1,800 pounds per square inch (psi). There are two other designs for higher volume applications that will be field tested next. The first produces 300 bpd/100 rpm and the second produces 440 bpd/100 rpm. Both pumps will have a pressure rating of 1,400 psi. Full-scale laboratory testing of the Even Wall technology has now exceeded 2000 hours at 1000 rpm and 300° F. Additional laboratory testing is scheduled for 350° F and the first field trial is in progress, with downhole temperatures between 200-250° F.

24

Weatherford’s new technology stators are manufactured with an external profile matching the internal geometry, which leads to numerous advantages including: • Improved Heat Dissipation The elastomer runs cooler, leading to improved mechanical properties. Two thousand pump inspections from five major Canadian heavy oil fields document that the majority of failures were due to stress or wear of the stator elastomer minors. By eliminating this portion of the stator, failures should be drastically reduced. • Uniform Elastomer Swell/ Uniform Thermal Expansion Having a uniform elastomer thickness means the elastomer also swells or expands

Works

The Even Wall® stator has an external profile that matches the internal geometry, enabling improved heat dissipation. This design should reduce stress to elastomer minors — a major cause of pump failure — ease proper sizing of rotors for aggressive applications, and allow PC pumps to be used in wells where this was not possible before.

in a uniform fashion. Properly sizing the rotor for aggressive applications is therefore much simpler. • Wider Applicability Applications that once pushed the envelope for PC pumps may now be within reach. These include wells with higher concentrations of aromatics, or wells with higher downhole temperatures. • Higher Pressure Rating Conventional PC pumps rely on the interference between the rotor and stator to create a seal. Uniform thickness stators are more consistent, providing a better rotor/stator fit with less interference. This enables the pump to handle more pressure, meaning a more compact pump design is possible.

WHAT’S NEXT? Field testing of the higher volume uniform thickness pumps (300 and 440 bpd/100 rpm) in light oil applications are slated for second quarter 2000. Simultaneous field testing of the second batch of low volume, uniform thickness pumps (60 bpd/100 rpm) is also scheduled for the second quarter. Field and laboratory testing of the high temperature capabilities of the Even Wall testing will continue throughout the year. While final results are not expected until 2001, early test results appear promising and commercial scale development may then proceed. If so, operators should find PC pumps more reliable—and better suited to more applications—than ever before.

25

How it

In a conventional PC pump stator, the elastomer is injected into heavy-walled steel tubing forming a double internal helix. For years, this design was considered the only economical way to produce stators. However, heat building up or swelling in the portions of the elastomer that were thickest could cause premature stator failure in more aggressive applications.

Wall pumps ordered that are expected to be installed during the second quarter of 2000. The initial pump design being tested produces 60 barrels per day per 100 revolutions per minute (bpd/rpm) with a pressure rating of 1,800 pounds per square inch (psi). There are two other designs for higher volume applications that will be field tested next. The first produces 300 bpd/100 rpm and the second produces 440 bpd/100 rpm. Both pumps will have a pressure rating of 1,400 psi. Full-scale laboratory testing of the Even Wall technology has now exceeded 2000 hours at 1000 rpm and 300° F. Additional laboratory testing is scheduled for 350° F and the first field trial is in progress, with downhole temperatures between 200-250° F.

24

Weatherford’s new technology stators are manufactured with an external profile matching the internal geometry, which leads to numerous advantages including: • Improved Heat Dissipation The elastomer runs cooler, leading to improved mechanical properties. Two thousand pump inspections from five major Canadian heavy oil fields document that the majority of failures were due to stress or wear of the stator elastomer minors. By eliminating this portion of the stator, failures should be drastically reduced. • Uniform Elastomer Swell/ Uniform Thermal Expansion Having a uniform elastomer thickness means the elastomer also swells or expands

Works

The Even Wall® stator has an external profile that matches the internal geometry, enabling improved heat dissipation. This design should reduce stress to elastomer minors — a major cause of pump failure — ease proper sizing of rotors for aggressive applications, and allow PC pumps to be used in wells where this was not possible before.

in a uniform fashion. Properly sizing the rotor for aggressive applications is therefore much simpler. • Wider Applicability Applications that once pushed the envelope for PC pumps may now be within reach. These include wells with higher concentrations of aromatics, or wells with higher downhole temperatures. • Higher Pressure Rating Conventional PC pumps rely on the interference between the rotor and stator to create a seal. Uniform thickness stators are more consistent, providing a better rotor/stator fit with less interference. This enables the pump to handle more pressure, meaning a more compact pump design is possible.

WHAT’S NEXT? Field testing of the higher volume uniform thickness pumps (300 and 440 bpd/100 rpm) in light oil applications are slated for second quarter 2000. Simultaneous field testing of the second batch of low volume, uniform thickness pumps (60 bpd/100 rpm) is also scheduled for the second quarter. Field and laboratory testing of the high temperature capabilities of the Even Wall testing will continue throughout the year. While final results are not expected until 2001, early test results appear promising and commercial scale development may then proceed. If so, operators should find PC pumps more reliable—and better suited to more applications—than ever before.

25


Multimedia & Extras

Innovation for Your Workspace

Optimizer

Make your equipment Calculations Quick & Easy

Video Clips ScreenSaver Unit Converter Wallpaper Posters



Video Clips

Bring Words and Pictures to Life

Progressing Cavity Pumping System



ScreenSaver

Innovation on Your Desktop Installation Click an icon for the Weatherford Screen Saver of your choice. Follow instructions as they appear on your screen. Once installed Screensaver settings can be adjusted in your Display Properties, under Screensaver and Setting.

If you have any questions or problems consult your Weatherford PC Pump Products & Services representative for support.

Product Images

Motivational Images


Sketch Images


Wallpaper

Innovation on Your Desktop Installation Web Browser Required Click the appropriate screen size resolution from the wallpaper choices below. Once image is loaded in your web browser, right click on image and select Set As Wallpaper.

Weatherford 1600x1200 1024x768 800x600

Rotors 1600x1200 1024x768 800x600

Pump Models (Metric) 1600x1200 1024x768 800x600

Pump Models (Imperial) 1600x1200 1024x768 800x600

Rotor Burst 1600x1200 1024x768 800x600


Drive Models 1600x1200 1024x768 800x600


Posters

Innovation on Your Workspace Click on the poster you want and print as big as you want, or just have a look. Or contact your Weatherford PC Pump Representative to enquire about a printed wall poster.

Current Pump Models - The Rotor Poster (Metric)

Current Pump Models - The Rotor Poster (Imperial)

Current Drive Models - The Drive Poster


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What’s New

Everything New or Updated Since the Previous CD Version Progressing Cavity Pumping Systems System Design PC Pump Design Form ~ Adobe PC Pump Design Form ~ Excel Weatherford Drive Head Belt Sizing Equipment Operation Weatherford Progressing Cavity Pump Specifications & Capacities Stuffing Box Manual Multimedia & Extras Optimizer ScreenSaver



Contact

How to Contact Weatherford PC Pump Products & Services

Canadian Customer Support PC Pump Products & Services 4604 – 62nd Avenue Lloydminster Alberta, T9V 2G2 Canada 780/875-0103 Office 780/875-0963 Fax

International Customer Support PC Pump Products & Services 2801 – 84th Avenue Edmonton Alberta, T6P 1K1 Canada 780/417-4800 Office 780/471-5198 Fax


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