1

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

The Geared Centrifugal Pump

• A mechanically driven centrifugal pumping system.

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

• No electrical components down hole.

• ESP capacity with better efficiency.

What is the GCP?

2

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head The Geared Centrifugal Pump

GCP Components from the Bottom up

1

1

2

2

3

3

4

4

5

5

6

6

7

7

• Pump intake stinger

• Centrifugal pump

• Lower seal section with thrust bearing

• Transmission

• Upper seal, compensator

• Receiver

• Tubing with a guided rod string

• Drive head8

8

3

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

The Geared Centrifugal Pump

• A bottom intake pump – better gas handling

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

weight so side loads are small.

– Load on drive head thrust bearing reduced

– Issue: rod rotational instability at bottom due to low string tension.

• Transmission – Multi-stage parallel shaft transmission

– Unique PHG gearing provides high power in a small diameter.

Unique Traits of the GCP

4

The Geared Centrifugal Pump Transmission

Before and after load is imposed

Before

After

Paired Helical Gearing - Operation

5

The Geared Centrifugal Pump Transmission

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

.

0

100

200

300

400

500

600

700

800

900

1000

10 11 12 13 14 15 16 17 18 19

Time, seconds

Bridge 2

Bridge 3

Bridge 4

Bridge 5

`

Torq

ue, ft-lbs

4321

1 Input, 920 ft-lbs

2

3

4 220 ft-lbs

680 ft-lbs

440 ft-lbs

6

Geared Centrifugal PumpTransmission Gear Train Layout

1st Stage (PHG)

3rd Stage5th Stage

4th Stage

2nd Stage

Input

Output

7

The Geared Centrifugal Pump

Transmission - large D-channels for fluid flow

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

8

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

The Geared Centrifugal Pump

• D-tube flow channels provide

excellent cooling of gears and

bearings

• Forced lube oil circulation reduces

oil degradation due to stagnation

• Forced oil circulation prevents

overheating during gas lock or

pump-off.

• Modular construction – allows easy

modification of transmission

Other Transmission Features

9

The Geared Centrifugal Pump

GCP Rate Potential

• Same rate potential as an ESP with

equal HP rating

• Nominal depth limit is 10,000 feetGeared Centrifugal Pump

Fluid Rate vs. Depth

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

0 1 2 3 4 5 6 7 8 9

Pump Depth, '000 feet

Flu

id R

ate

, B

FP

D

150 HP

100 HP

75 HP

200 HP

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

10

Geared Centrifugal PumpField Installation and Testing

11

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

The Geared Centrifugal Pump

• Installed May 19, 2010 in West Texas waterflood producer. Replaced ESP.

• ESP

– 450 series 60 HP, 156 stage FC1200

– 1150 BFPD, 98% WC

– 100% motor load

– ESP overall efficiency = 45 %

• GCP

– 575-100, 87 stage G17 pump

– 1550 BFPD, 98% WC

– GCP overall efficiency > 50%

– Mechanical efficiency = 79.5%

GCP Field Installation

12

Geared Centrifugal Pump - Downhole Test

13

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

The Geared Centrifugal Pump

GCP Field Trial Results

• Performance – GCP efficiency was

higher that expected.

• No problems installing or operating

the GCP.

• Unit has run 18 months at time of

writing

Second 575-100 GCP run in a well in

New Mexico, January 18, 2011. 14

GCP Rod String Test Apparatus

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

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

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

• Rod stability monitored via lasers and multiple view ports in tubing

• Rig inclination variable from 0 deg. (vertical) and 85 deg.

15

GCP Rod String Test Apparatus

16

• Over 1000 test measurements

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

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

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

• Well inclination has only a minor effect on rod stability

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

GCP Rod String TestingResults

17

High Temperature GCP

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

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

• Current 575-100 GCP has high temperature transmission, thrust bearing, and pressure compensator design.

• Conversion to high temperature service requires only changing materials (steel, elastomers, lubricant)

• Full assembly high temperature testing beginning in March. First field installation expected in 3rd quarter of this year.

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• Full GCP assembly testing, including

short rod string

• 3000 B/D rate at 3000 psi and 250º C.

• 125 HP drive motor with VSD

• Monitor input torque, RPM, inlet and

discharge pump pressures and

temperatures, and flow rate

• All principal controls and data

collection in remote location

High Temperature GCP

Test Loop

19

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

• Bottom intake pump provides better gas handling than ESP.

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

• Estimated power cost savings of 10-15% over an equivalent ESP system

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

• Utilizes the best part of a PCP system eliminates the worst – the elastomer PCP stator exposed to wellbore fluids and varying conditions.

Advantages of the GCP

20

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

• High temperature application -currently testing a 575-100 for 250º C (482º F).

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

• If a VSD is required, it is a less expensive VSD than an ESP VSD, no sine wave filter and the surface package requires no step-up transformer.

• No downhole electrical components

Advantages of the GCP

21

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

• The system can ride through a gas-lock condition no concerns with burning up a motor.

• The system can deploy low flow rate centrifugal pumps; i.e, 100-200 BPD. Again without the concern of cooling a downhole electric motor.

• Can be operated on single phase power.

• Less expensive installation; no cable spooling, no banding.

• Fewer pump changes in a dewatering cycle.

Advantages of the GCP

22

Rod String Drive

Transmission

Upper Seals and

Compensator

TransmissionLower Seals and

Thrust Bearing

Pump

Rod String Drive

Pay ZoneGas Anchor

Drive Head

Drive Rod String

Receiver Section

Upper Seals and

Compensator

LowerSeals and

Thrust Bearing

Transmission

Pump

Intake Stinger

Pay Zone

Drive Head

• Can be deployed with a standard PCP type downhole pressure/temperature gauge.

• A cost effective alternative to large mechanical pumping systems: i.e., 640/912/1280 pumping units, tubing pumps .

Advantages of the GCP

23