Progressing Cavity Pump Applications

Pumps & Systems
Progressing Cavity Pump Applications
Thomas Boehme, NETZSCH Pumps & Systems GmbH,

Head Of Business Field Oil & Gas Mid- & Dowstream
www.NETZSCH.com
Technical Presentation
1. Introduction
2. Working principle Progressing Cavity Pump (PCP)
a. Hydraulic design
b. Universal joint (power transmission)
c. Mechanical seal
d. Motor and Gearboxes
e. Materials
f. System requirements
3. Applications of PCP
4. Case studies and references
Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 1

1. Introduction
a. Hydraulic design
c. Mechanical seal
e. Materials

1. Introduction
a. Hydraulic design
c. Mechanical seal
e. Materials

1. Introduction
a. Hydraulic design
c. Mechanical seal
e. Materials

Pump Classification
pumps
non positive positive

displacement pump displacement pump
venturi reciprocating rotating

rotary type
type pump pump
plunger/pis air rotary

jet ton/ operated gear progres-
screw peristaltic impeller/va lobe/
centrifugal diaphragm diaphragm pump sing cavity
pump pump pump ne pump piston
pump
pump pump pump
internal external
centrifugal pump
gear pump gear pump
centrifugal centrifugal
open closed
impeller impeller
type type

Pump Classification
Pumps
Positive
Dynamic(centrifugal)
Displacement
Positive Displacement Pumps Dynamic Pumps

displace liquid by creating a chamber or imparting velocity energy to the fluid.
cavity between the pumping elements.
API 610 and ANSI standard applies.

The chamber or cavity is moved by the
reciprocating or rotary motion.
API 676 Rotary Positive Displacement

Pumps applies to progressive cavity pumps.

PC Pumps - Operating Principles
Progressing cavity pump
API 676 Rotary Positive Displacement Pump standards apply

The Rotor
Rotating pumping element
Elongated screw shape
Single external helix geometry
Eccentrically manufactured

The Stator
Internal shape of a double screw
Screws pitches start 180 apart and opposed
Stationary pumping element

The cavity is created and carries

the process fluid.
The cavity volume is transferred through

the pump by the rotation of the rotor

Interference in the Rotor/Stator System
In order to achieve optimal efficiency and long

service life, the interference between rotor
and stator and the d/D ratio of the
interference are of vital importance.
D
Due to interference fit, a fluid film is required
to lubricate sliding surfaces.
In multiphase applications, high gas fractions

can be pumped.0.5% of a pumps volume
flow is required as liquid.

Higher pressures are achieved by

adding stages.
Adding stages increases the length

of the sealing line and therefore
increases the resistance to fluid
flowing back through the pump (slip).
UP TO 12 STAGES IN MODULAR DESIGN (72 bar)

Advantage PCP pressure stability in comparison
to centrifugal pumps
Pos. Displacement pump
Centrifugal pump
Theor. Pos. Displacement pump

Head - H
System
performance
curve
Flow rate - Q

Performance Curve:
Q and n directly proportional
Typical performance curve of

a positive displacement pump
0 bar
2 bar
4 bar
Capacity Q
Theoretical capacity PC pumps are ideal for gentle transfer of
homogenous and heterogeneous fluids

and suspensions
viscous and corrosive media
Media containing solids
Media for dosing
Speed n
4 NEMO Rotor/Stator Geometries provide
high efficiency for your application
S-Geometry
Lobes: 1/2
Double stage
Flow rate: 100%
Differential pressure: 12 bar
L-Geometry
Lobes: 1/2
Single stage
Flow rate: 200%
D-Geometry
Lobes: 2/3
Double stage
Flow rate: 150%
P-Geometry
Single stage
Lobes: 2/3
Flow rate: 300%

1. Introduction
a. Hydraulic design
c. Mechanical seal
e. Materials

PC Pumps - Universal joint
Universal joints are required to compensate between concentric motion at the

pump shaft/seal area and the eccentric motion of the rotor

PCP Pin Joints
Simple robust design

Maintenance free
High quality SM-seal
100% oil filled design (other manufacturers use grease)
The most common kind of joint
Abrasion resistant external steel sleeve to protect
against ingress of solids

PCP V Pin Joint
For longer service life in difficult applications

Strengthened by hardened bushings fitted
into boreholes in the coupling rod and the
rotor/drive shaft head
Easy to remove for maintenance purposes

PCP K-Joint
Long service life due to transmission of

torque and axial load on separate paths
Preferred for continuous operation under
high load
Double seal design, therefore optimal
chemical resistance to pumped product
and optimal joint lubricant.
Installed, patented oil grooves in the ball
cup guarantee lubrication under heavy
load conditions

PCP Z-Joint
The joint for the highest mechanical demands

Axial forces and torque are transmitted by the bearings of the pivot
Easy maintenance due to cartridge design
Double sealed design

1. Introduction
a. Hydraulic design
c. Mechanical seal
e. Materials

Mechanical seal
Mechanical seal are located in the free flowing area in the casing.
Typically mounted on the suction side (low pressure and therefore lower
loading)

Mechanical seal
Seal faces are self flushing and give very

good service life in abbrasive solids
loaded applications.
Flush plans are available, but not always

neccesary

Mechanical seal
Pre-assembled cartridge seal
Cartridge seal type
Single acting for quench Double acting for

applications with and
without sealing pressure

Mechanical seal
Quality of PC Pumps
Mechanical Seals engineered according to API 682, SAE according to API

610
Sealing Systems: Plan 02, 11, 13, 32, 53A, 53B, 53M, 62, 75

Mechanical seal
Medium: Dilute Sand Slurry

Showing: API plan 31 system (mini solid-liquid hydrocyclone
separator)

Mechanical seal
Showing: API plan 53A seal system with instruments in a heated

enclosure for extreme cold temperature environment

Mechanical seal
Solutions available
Solution for high incoming pressure or high design
pressure rating are available and in operation.
bar.g
ANSI 1500 lbs RF flanges to

handle a 90 bar(1305 psi) inlet
pressure

Mechanical seal
Delivered solution for 94 bar(1305 psi) inlet pressure.
API plan 53B

Typical installation on a pump

1. Introduction
a. Hydraulic design
c. Mechanical seal
e. Materials

PC Pumps Motor and gearboxes
Block design
Auger and wide throat hopper design for

high pasty non flowable solids (such as drill cutting)
Bearing housing

1. Introduction
a. Hydraulic design
c. Mechanical seal
e. Materials

Stator Materials
Elastomers
Hydrated Nitrile-Butadiene-Rubber
FKM Fluoro Carbone Mixture
Ethylene-Propylene-Diene-Mixture
NBR Nitrile-Butadiene-Rubber
BR Butadiene Rubber
Solid materials
Plastics
PTFE Poly-Tetra-Fluor-Ethylene
PA Poly-Amide
Metals
Grey cast iron

Rotor Materials
Standard
1.2436 hardened Hardened tool steel
1.7225 VCP Tool steel, VCP
1.4301 Stainless steel, 304
CrNiMo 17-12-2 Stainless steel, 316 L / 316 Ti
SIC/1.4462 Ceratec - Solid Ceramic
PVDF Only C.Pro
Special
1.4462 Duplex steel (20.000 ppm Cl-, 40C)
1.4410/1.4501 Super Duplex steel
1.4539 Alloy steel Ni-Cr-Mo-Cu (Corrodur)
2.4602 Hastelloy C22 (NiCr21Mo14W)
2.4617 Hastelloy B2 (NiMo28)
Coating
VCP Hard chrome plating
CRC Chromium Carbide Coating
Materials for Wetted Parts
Standard
St A570 36
0.6025 A 278 30
Cr-Ni-Mo17-12-2
(1.4404, 1.4571, 1.4401) 316L, 316Ti, 316
PP Poly-Propylene
PU Baydur Poly-Urethane
Special
0.6025 A 278 30, internally rubber lined or plastic coated
1.4462 A 182 F51, duplex stainless steel
1.4410/1.4501 A 182, A 276, A 479, super duplex stainless steel
1.4539 904L Ni-Cr-Mo-Cu (Corrodur)
2.4602 Hastelloy C22 (NiCr21Mo14W) N06022
2.4617 Hastelloy B2 (NiMo28) N 10665
Inconel 625, Inconel 825 For Very High Chlorid Content
Further materials on request
Certificates ( 3.1, NDT, PMI, WPS/PQR (ASME-Section IX) etc)

1. Introduction
a. Hydraulic design
c. Mechanical seal
e. Materials

System requirements
no piping spool available Lots of space behind the motor
Hydrocyclone feed pump on Bunga Orchid A platform
Stator removal space

System requirements
Dry Running Protection

System requirements
Over Pressure Protection
Pressure Gauge with

Contact(s) and a
Pressure Transmitter
Connection: 3/4 BSP

System requirements
Progressive cavity pumps are positive displacement pumps. Pressure relief

valves are always needed.
Relief valve sizing and piping back to suction of the pump must be sized for
full flow.
Consider back to tank relief valve routing for larger relief system system
volume.

Progressive Cavity Pumps
Quality of PC Pumps
- Capacity: 0,01 l/h (0.0026 gal/hr) to 600 m/h (2642 gal/min)
- Operation pressure of transfer pumps: up to 72 bar (1044 psi)
- Re-Injection pumps: 33 m/h (9146 gal/min) at up to 240 bar (3480 psi)
- Temperatures for elastomer stator design up to 160 C (320F)

1. Introduction
a. Hydraulic design
c. Mechanical seal
e. Materials

Downstream process applications
Progressive cavity pumps (pcp) are used successfully in offshore applications

all around the globe. The characteristics of the pump design fits well with
offshore services.
The following list show some of the services where they are applied
successfully:
- Hydrocyclone feed pump
- IGF skimmer pump
- Separator produced water transfer pump
- Compressor scrubber pump
- Closed drains pump
- LP Flare KO Drum pump
- HP Flare KO Drum pump
- Open drains pump - Drains caisson pump
- Skimmed oil pumps - Amine sump pumps
- MEG recycle and brine slurry pump - Crude oil transfer pump
- Diesel ring main pump - Low volume water injection

PC pumps in the oilfield
Application process flow chart
PC pumps for pumping multiphase liquids in oilfields, 2013 www.NETZSCH.com 46

Mid- & Downstream process applications
The fluid handling characteristics of the PCP can be summarized by the following
statements:
Low NPSH required. NPSH available as low as 0.5m (1.64 ft) can be
handled with solutions for lower NPSH available ready for application.
Low Shear pumping. The gentle way in which the fluid travel in the cavities
of the pump means PCPs never create inseparable emulsions and do least
damage to the oil droplet is conveys.
Solids handling. Capable of handling coarse or fine particle solids. Sand

can be pumped away.
Handles low to high Viscosity. Virtually any viscosity can be pumped with a
PCP.

Mid- & Downstream process applications
Stable flow. Positive displacement characteristic curve with stable flow even
against changing pressures.
Capable of frequent start/stop

- Can be started and stopped on demand. Can be started against open circuit or a
pressurized line.
- Need not be operated continually on a bypass loop circuit as some centrifugal
pumps are operated. Start up and shut down of the pump does not introduce
unwanted run-up vibration.
Does not gas lock. Can displace 100% gas in event of gas flooding of the
pump. Does not gas lock as some pump technologies do.
Capable of a wide temperature range operation. Can operate at a wide

range of operating temperatures. Some gear and sliding vane pumps are
limited in the operating range they can tolerate due to clearance fits in gear
and vanes.

Downstream process applications
Water Injection Pump in Brazil

PCP MPP in the oilfield

PCP MPP in the oilfield
Application Example in Peru
Pump NM105SY01L06K
Speed: 250 rpm
Suction pressure: 30 psig
Discharge pressure: 120 psig
Multiphase flow rate: 18.115 BFPDe

GVF:90%
Oil flow rate:1.500 BOPD
Water flow rate:310 BWPD

PC Pumps for International Projects
Multi-phase Pumps in Russia

PC Package capabilities demonstrated

PC Pumps supplied North Western Australia
Equipment list of pumps supplied:
- Pump tag OP-0923 A/B Brine pumps

- Pump tag OP-0957 MEG Slurry pump
- Pump tag OP-0963 A/B Brine pumps
- Pump tag OP-6403 A/B Oily water sump pumps
- Pump tag OP-0906 Rich MEG storage tank skimming pump
- Pump tag OP-0946 Rich MEG storage tank skimming pump
- Pump tag OP-0922 A/B Recovered MEG return pumps
- Pump tag OP-0962 A/B Recovered MEG return pumps
- Pump tag OP-0980 & OP-0980A MEG slurry export pumps
- Pump tag OP-1011 A/B Drain Pumps Gorgon
- Pump tag OP-1051 A/B Drain pumps Jansz

PC Pumps supplied for North Western Australia
Pump tag OP-0980 & OP-0980A MEG slurry export pumps

PC Pumps supplied for North Western
Australia
Pump tag OP-0963 A/B Brine pumps

Australia
Pump tag OP-1011 A/B Drain Pumps Gorgon

Australia
Pump tag OP-0963 B Brine pumps - Test house

PC High Pressure Pumps for Russia
Medium: slop/hydrocarbons containing sand and silt

Capacity: 20 m3/h
Diff. pressure: 2329 kPa g (= 23,29 bar)
Material: Duplex 1.4462
Pump size: NM063SY04S24B
Medium: Hydrocarbons/Water
Capacity: 11,4 m/h
Diff. pressure: 5619,6 kPa g (= 56,196 bar)
Material: Duplex 1.4462
Pump size: NM053SY12S72Z

Applications in multiple industries
various different industries
Environmental
Environmental& Chemical, Pulp Food & Oil & Gas Oil & Gas Dosing Systems
&Energy
Energy & Paper Pharmaceutical Upstream Downstream Technology
Presentation BU P&S, 11/2012 www.NETZSCH.com

www.netzsch.com 60
Highlights of PC Pumps
Remember pc pumps for:
Stable flow
Low shear
Viscosity is not a limitation for the pump
Ability to handle solids
Low NPSH Requirements
Can handle multiphase liquids

Your local contact of NETZSCH Canada, Inc.
Jason Balcerczyk
NETZSCH Pumpen & Systeme GmbH Cell Phone: +1 (705) 797 8426236
Geretsrieder Str. 1 E-Mail: jason.balcerczyk@netzsch.com
84478 Waldkraiburg, Germany
Phone: +49 (8638) 63-0
Fax: +49 (8638) 63-67981 Head of Business Field Oil & Gas Mid- & Downstream
www.netzsch.com Thomas Boehme
info.nps@netzsch.com Telephone: +49 8638 63 2277
Cell Phone: +49 172 6607127
E-Mail: thomas.boehme@netzsch.com

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Pumps & Systems

Progressing Cavity Pump Applications

Thomas Boehme, NETZSCH Pumps & Systems GmbH,

2. Working principle Progressing Cavity Pump (PCP)

b. Universal joint (power transmission)

d. Motor and Gearboxes

4. Case studies and references

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 1

2. Working principle Progressing Cavity Pump (PCP)

b. Universal joint (power transmission)

d. Motor and Gearboxes

4. Case studies and references

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 2

2. Working principle Progressing Cavity Pump (PCP)

b. Universal joint (power transmission)

d. Motor and Gearboxes

4. Case studies and references

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 3

2. Working principle Progressing Cavity Pump (PCP)

b. Universal joint (power transmission)

d. Motor and Gearboxes

4. Case studies and references

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 4

non positive positive

venturi reciprocating rotating

plunger/pis air rotary

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 5

Positive Displacement Pumps Dynamic Pumps

API 610 and ANSI standard applies.

API 676 Rotary Positive Displacement

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 6

Progressing cavity pump

API 676 Rotary Positive Displacement Pump standards apply

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 7

Rotating pumping element

Elongated screw shape

Single external helix geometry

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 8

Internal shape of a double screw

Screws pitches start 180 apart and opposed

Stationary pumping element

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 9

The cavity is created and carries

The cavity volume is transferred through

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 10

In order to achieve optimal efficiency and long

In multiphase applications, high gas fractions

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 11

Higher pressures are achieved by

Adding stages increases the length

UP TO 12 STAGES IN MODULAR DESIGN (72 bar)

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 12

Pos. Displacement pump

Theor. Pos. Displacement pump

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 13

Typical performance curve of

Theoretical capacity PC pumps are ideal for gentle transfer of

homogenous and heterogeneous fluids

Calgary Pump Symposium, Thomas Boehme, 2013-11 www.NETZSCH.com 15