PROGRESSING CAVITY PUMP SYSTEMS

PROGRESSING
PR
ROGRESSING CAVITY PUMP SYSTEMS

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NOVOV®® is
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major mechanical components for land and offshore drilling rigs, complete land drilling and
well servicing rigs, tubular inspection and internal tubular coatings, drill string equipment,
extensive lifting and handling equipment, and a broad offering of downhole drilling motors,
bits and tools. NOV also provides supply chain services through its network of more than 200
distribution service centers located near major drilling and production activity worldwide.
We continue to build upon our unlimited, customer-focused solutions and are proud to
deliver our Artificial Lift Systems through the NOV Monoflo® division.
The NOV Monoflo division is a true partner and worldwide source for complete Artificial Lift
equipment and packaged solutions. Our Artificial Lift professionals collaborate with you to
properly evaluate well conditions and determine a customized artificial lift solution that will
optimize your production.
Artificial Lift Solution Packages Include:
• Professional Well Evaluation
• Surface and Subsurface Equipment
• Controllers and Production Automation
• All Production Accessories and Expendables
• Global
al Supply
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Progressing Cavity Pump Systems
NOV Monoflo is a leader in the design, manufacture and
supply of progressing cavity pumps (PC Pumps) and artificial
lift solutions worldwide. With over 75 years of experience, 8
international sites and global distribution network, we provide
a range of PC Pump solutions that fulfill many oilfield production
needs. Our line of downhole PC Pumps are designed for use
in both oil production and dewatering applications where the
economics of production demand efficiency, reliability and low
life-cycle cost from the production equipment.

Common Applications
• Heavy Crude (aggressive geometry)
• Medium Crude
• Coal Bed Methane – CBM (specialized elastomers)
• Shale Oil and Water
• High GOR Wells
Features and Benefits
• Lower Capital Cost
The lack of expensive foundations, simple construction
and the compact surface drive units reduce start-up costs
which allow for more pumps to be installed and more oil
recovered.
• Lower Running Cost
Typically, a PC pump has an overall efficiency rating of 70%
which is significantly higher than alternative lift methods
and lowers the cost per barrel of recovered fluid.
• Reliable
The simple construction consists of only one moving part
downhole and has no standing or traveling valves to block.
The pump handles gas and solids without blocking and is
more resistant to abrasive wear.
• Environmentally Acceptable Profile
The low, unobtrusive profile of the quiet running surface
drivehead makes the PC pump ideal for environmentally
sensitive areas. Also, state of the art Leak Detection
Stuffing Boxes help protect the environment from spills.

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PROGRESSING CAVITY PUMP SYSTEMS
The Pumping Principle
The progressing cavity principle is ideally suited to the demands of pumping downhole fluids.
At the heart of the downhole PC pump lay the pumping elements, consisting of a hard steel
rotor, usually in the form of a single external helix of circular section, and a stator with the
internal form of a two-start helix. The stator is manufactured from a resilient, abrasion-
resistant elastomer bonded inside an alloy steel tube that is selected to be compatible with
the specified well fluids. When the rotor is placed inside the stator a series of sealed cavities
are formed.
As the rotor turns, these cavities progress from the suction end of the progressing pump up to
the discharge end, positively transporting the well fluid through the pump and up the tubing
string to the surface, without pulsation. The fluid flow rate is directly proportional to the speed
of rotation. Therefore, the pump can be closely matched to the well inflow rate for optimum
production.
The constantly sweeping seal line between the stator and rotor prevents a build-up of solids
within the pump. Entrained gas or suspended solids can also pass through the pump without
causing gas locking or pump blockage.

Progressing Cavity Pump Specifications

Rotors, Stators and Elastomers
Rotors and Stators
Performance by Design
Rotors are available in alloy steel (4140) with hard chrome plating which provides resistance
to abrasion and wear. All pumps have 1:2 ratio lobe geometry and rotor chrome thickness
within 0.010 and 0.020 inches.
Through the use of advanced manufacturing technology and modern production techniques,
finite machining and plating of the rotor profile is maintained, ensuring that the design
performance is always achieved.

Elastomers
A range of stator elastomers is available allowing the pump to be selected for many
downhole fluid conditions as described below.
Elastomer Type General Description and Application Temperature Limit Tensile Strength Tear Strength Abrasion Resistance H2S Resistance CO2 Resistance Hardness (IRHD)
• Very soft medium acrylonitrile content with good
oil and solvent resistance and excellent abrasion
QS resistance 80°C Good Good Excellent Good Poor 48-53
(Soft Nitrile)
• Typically used in very abrasive and high water cut
applications with low aromatic content fluids
• Soft medium acrylonitrile content with good oil
and solvent resistance and excellent abrasion
OD resistance 90°C Good Excellent Excellent Good Fair 60-65
(Soft Nitrile - Buna L)
• Typically used in medium abrasive and high water
cut applications with low aromatic content fluids
• Medium acrylonitrile content with good oil and
solvent resistance
RR • Excellent abrasion resistance and mechanical
100°C Good Excellent Excellent Good Good 68-72
(Nitrile) properties
• Typically used in abrasive and high water cut
applications with low to medium aromatic content
• High acrylonitrile content with improved oil and
solvent resistance and excellent mechanical
OB properties
100°C Excellent Excellent Excellent Good Fair 70-75
(High Nitrile) • Higher acrylonitrile content provides extra
resistance to oils with medium to high aromatic
content
• High acrylonitrile content with similar properties
OC
to OB but with improved resistance to hydrogen 150°C Excellent Good Excellent Excellent Fair 69-75
(Hydrogenated Nitrile)
sulfide (H2S) and high temperature capability

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PROGRESSING CAVITY PUMP SYSTEMS
Two Run Insertable PC Pump
NOV Monoflo has an innovative, new insertable progressing cavity pump design that
allows the customer to insert a progressing cavity pump inside the production tubing
and pressure test the tubing string with one easy to use tool.

Features and Benefits

• There is no need for a service rig to pull the production tubing to change a
downhole pump
• Pump changes can be done with a flush-by equipped for rod handling
• The unit minimizes the need to remove production tubing, reducing the cost of
downhole gauge installations
• Allows for pressure testing the production tubing as well as the primary seal, while
inserting the stator.
• The system has the ability to use any progressing cavity pump without performing
any modifications.
• The system can pull the rotor out of the well bore without unseating the primary
seal.

Insert Tool

Seating Mandrel
with Primary Seal

Seating Nipple

Stator

Rotor

Tag-Bar

Operating Torque Anchor

Position
Insert
Position
NO-GO Tag™ Progressing Cavity Pumps
The NO-GO Tag system is a new advanced generation tool for rotor placement
in progressing cavity pumps. The NO-GO Tag provides all the functionality of a
traditional bottom tag bar system with the advantages listed below.

Features and Benefits

• Tags within the stator, leaving intake free of obstruction, allowing rotor to
agitate solids
• Coilable through the pump by only pulling up polish rod
• Protects top end of stator elastomer by guiding coil entry through the pump
• Positive tag for proper rotor placement by guiding rotor through timed
helical tag passage into stator elastomer
• Unique integrated design eliminates flow losses and extra connections
• Tags using a conventional rod box
• Ability to land pump lower in well
• Eliminates costly mechanical tools below the pump while maintaining
circulation clean-out capabilities
Application
• Medium to heavy oil
• Wells producing sand
• Wells with history of intake plugging
• Wells with minimal cellar

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PROGRESSING CAVITY PUMP SYSTEMS
Hydraulic Driveheads
NOV Monoflo’s HTD hydraulic drivehead utilizes a bent axis motor that at is
hich
coupled to a hollow shaft bearing box by a belt and pulley system, which
transfers torque to the polished rod. Backspin is controlled through the
ts to
hydraulic system. The motors are available in a variety of displacements
accommodate a wide variety of speeds and torques.
Each model of the NOV Monoflo CG-33 hydraulic drivehead is a beltless tless
sion
top drive using gears to transfer torque to the polished rod. The precision
ground gears reduce noise levels by up to five times in comparison n to
conventional belt drives, making the CG-33 drivehead an ideal soluti ution
otor
for use in populated areas. Each CG-33 drive utilizes a radial piston motor HTD Hydraulic Drivehead
eads
designed to reduce internal friction and run efficiently. These driveheads
are fitted with a hydraulically activated stuffing box that can withstand any
progressing cavity pumping application.

Features and Benefits of the HTD Hydraulic Drivehead

• Motor is available in various displacements
• Standard synchronous belt and sheave system
• Fully enclosed hinged belt guard
Features and Benefits of the CG-33 Hydraulic Drivehead
• Enclosed gear housing eliminates need for belts, thus reducing field
maintenance
• Case hardened and precision ground gears drastically reduce noise levels.
• Gear drive utilizes a radial piston motor connected to the input gear
• Radial piston designed to reduce internal friction, providing better overall
efficiencies
• Motor is available in various displacements
• Motor is easily changed in the field
• Pressurized stuffing box prevents fluid from entering the seal chamber extending CG-33 Hydraulic Drivehead
the life of the seals
• Built in polished rod vise allows stuffing box seal change without removal of
drivehead or flush-by rig
• Gearbox incorporates a field removable main shaft
• Main thrust bearing is housed separately eliminating contaminates on the gears
• Gear drive is compact and easy to handle on vertical and slant wells

Technical Specifications
Model HTD CG-33 Model HTD CG-33

Max. System Pressure 3600 psi (245 kPa) 3500 psi (24,132 kPa) Variable Speed Control Adjustment knob on the pump. Adjustment knob on the pump.

Max. System Temperature¹ 175 °F/ 80 °C 176 °F/80 °C Height Integral 31" (787 mm) 31" (787 mm)

Polish Rod Size 1¼" (32 mm) 1¼" (32 mm) Height Retrofit 47" (1194 mm) N/A

Wellhead Connection 2d” EUE Pin or 38-3000 38”-3000 psi-R31 Flange Width 29" (737 mm) 24" (610 mm)
psi-R31 Flange

Thrust Bearing² Ca90-25,000 lbs / Ca90-33,500 lbs / Weight Integral 400 lbs (181 kg) 240 lbs (109 kg)
ISO-96,300 lbs ISO-129,000 lbs

Backspin Control Check valve on pressure side of Check valve on pressure side of Weight Retrofit 450 lbs (204 kg) N/A
the motor. the motor.

Torque Control Adjustable pressure Adjustable pressure Bearing Box Grease Chevron Delo Grease EP NLGi2 1 tube (Chevron Ulti-Plex
compensator on pump. compensator on pump. Synthetic Grease)

¹ Maximum operating temperature may be limited by hydraulic oil. ² Ca90 load rating is for 90 million revolutions at 500 rpm. Reducing load by 50% increases life 10 times. Reducing speed by 50% doubles hours of life.
Electric Driveheads
NOV Monoflo provides a complete line of Electric Driveheads for all your production
needs.

Features and Benefits

• Robust frame
• Detachable stuffing box
• Operator-friendly guards and motor adjustments C-50 Electric Drivehead
• Easy-to-adjust door for simple belt tightening
• Accessible fill/drain spouts for easy oil changes
• Bearing box is designed with a three-bearing system (Models C-50, C-60, C-80,
and C-33M)
• Hollow shaft bearing box (Model N-25)
• Hydrodynamic brake (Models C-50, C-60, C-80, and C-33M)
• Hydraulically actuated caliper disc braking system (Model N-25)
• Brake reservoir for heat dissipation (Models C-50, C-60, C-80, and C-33M
• Service and technical support C-60 Electric Drivehead

Technical Specifications
Model C-50 C-60 C-80 C-33M N-25

Drive Type Direct Direct Direct Direct Direct

Shaft Type Hollow Hollow Hollow Hollow Hollow

Drive Style Bearing Box Bearing Box Bearing Box Bearing Bearing Box

Input Style Vertical Vertical Vertical Vertical Vertical

C-80 Electric Drivehead
Drive Ratio 1:1 1:1 1:1 1:1 1:1

Backspin Control Hydrodynamic Hydrodynamic Hydrodynamic Hydrodynamic Caliper Disc

Ratings

Max. Output Torque 2000 ft-lbs (2712 Nm) 2500 ft-lbs (3390 Nm) 3500 ft-lbs (4745 Nm) 1575 ft-lbs (2135 Nm) 600 ft-lbs (813 Nm)

Thrust Bearing 195,000 ISO lbf 227,000 ISO lbf 310,000 ISO lbf 45,100 ISO lbf 96,300 ISO lbf

Thrust Bearing¹ 50,500 Ca90 lbf 59,000 Ca90 lbf 80,400 Ca90 lbf 33,000 Ca90 lbf 25,000 Ca90 lbf

Maximum Speed 600 rpm 600 rpm 600 rpm 600 rpm 500 rpm

Horsepower Rating² 20 - 100 80 - 150 120 - 300 10 - 60 10 - 20

Frame Type Single Motor Dual Motor Dual Motor Single Motor Single
1¼” or 1½” 1¼” or 2” C-33M Electric Drivehead
Polish Rod Size 1½” (38 mm) 1¼” (32 mm) 1¼” (32 mm)
(32mm or 38 mm) (38 mm or 51mm)
Max. Operating Temp. 212°F / 100°C 212°F / 100°C 212°F / 100°C 428°F / 220°C 180°F / 80°C

Dimensions

Height with Retro. Stuffing Box 50” (1270mm) 55” (1397mm) 64” (1626mm) 44” (1118mm) 34” (864mm)

Width 35” (889mm) 41” (1041mm) 42” (1067mm) 35” (889mm) 30” (762mm)

Input Shaft Size 3¼” (83 mm) 3¼” (83 mm) 4¼” (108mm) 3¼” (83 mm) 2½” (64 mm)

Weight 1350 lbs (612kg) 1700 lbs (771kg) 2100 lbs (953kg) 1350 lbs (612kg) 600 lbs (272kg)

¹ Ca90 load rating is for 90 million revolutions. Reducing load one half increases life 10 times. Reducing rpm by one half doubles hours of life.
² Maximum HP rating based on frame size only. Care must be taken in selecting motor and sheave combinations to ensure input rod torque is not exceeded.

N-25 Electric Drivehead

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PROGRESSING CAVITY PUMP SYSTEMS
Leak Free Stuffing Box
The NOV Monoflo Leak Free (LF) stuffing box is a pre-built assembly that has been exclusivelyy
designed to simplify monitoring seal wear. It consists of a double mechanical seal supplied in
a single sealed cartridge. It comes pre-filled with NOV Monoflo approved BP Energrease®
LC2 for lubrication of the bearings and with compatible Mobil DTE25 mineral oil for filling
the mechanical seal cavity.

Features and Benefits

• Designed with a two bearing system consisting of seal bearings designed to be in one
cartridge for easy replacement which results in less downtime during maintenance
• Can be mounted directly on drivehead with or without a booth
• Utilizes a double mechanical seal supplied as a sealed cartridge, to deliver extended periods of leak free
operation and contains any leaked fluid inside the unit
• Double sealing mechanism performs an improved sealing function.
• Easy fitting of the cartridge arrangement with no setting requirement normally associated with conventional
mechanical seals; seal abuts bearing to set working length
• Positive drive from the spindle via key through sleeve of the mechanical seal
• All sealing faces are made from solid material for increased pressure and thermal stability
• Equipped with a leakage detection unit which provides a visible indication to any breach of the primary seal
and also ensures barrier fluid lubrication of the seal faces for maximum durability
• The leakage detection unit can be reset after seal replacement

Hydrodynamic Brake
NOV Monoflo has incorporated the well-proven principle of the
Hydrodynamic Brake into the C-Series direct drives to provide safe,
reliable and smooth backspin control.
Brake Stator
The Hydrodynamic Brake consists of a stationary half (stator) and
a rotary half (rotor). The stator is bolted into the housing and the
rotor is coupled to the shaft. During normal operation the rotor spins
Brake Rotor
freely. When the unit goes into backspin, the rotor begins to rotate
in the counter clockwise direction. The working fluid is then forced
to the outside of the rotor and creates a circular flow path inside the
brake cavity. As the energized fluid from the rotor comes into contact
with the stationary fins of the stator, the energy is transferred to the
stator and then back to the working fluid as heat. A small amount of
working fluid is continually removed from the system and replaced
with new fluid. The working fluid contained in the drivehead reservoir
is used as the braking medium, which allows the energy stored in the
fluid column and rod string to safely dissipate without the drivehead
reaching excessive backspin speeds.

Features and Benefits

• Non-friction brake eliminates wear on brake components
• Brake capable of 2000 ft-lbs resisting torque at 250 hp
• Reliable and repeatable braking
• Backspin energy is absorbed by the working fluid
Hydrodynamic Brake Curves
• Heat generated by braking is dissipated by the fluid reservoir
• Consistent braking with minimal maintenance throughout the
drivehead’s life
VFD Controller
The NOV Monoflo Progressing Cavity Pump Controller provides a
number of features specifically designed for operation of progressing
cavity pumps. The drive combines motor and pump control into a
single, compact package that increases production, improves energy
efficiency and enhances the reliability of both new and existing
pumping systems.

Multiple Constraint Optimization

At any instant during the life of a well, there is a single constraint
that limits production. Production can be maximized without
compromising efficiency or reliability by forcing the system to
operate at the constraint limiting production at each instant of time.
Determining the applicable limits and moving smoothly between
them in real time is a key advantage of the National Oilwell Varco
system. Models of all the system elements are run in real time at the
wellhead to detect appropriate limits and enforce associated control
strategies. At different points in time, the system may be limited by
motor voltage, motor current, motor speed, motor torque, motor
thermal capacity, power demand, rod string torque, flow line
pressure, fluid level, or well inflow. Multiple constraint optimization is
particularly beneficial in applications with variable inflow conditions,
such as those found in coal-bed methane, high gas/oil ratio, and
thermally stimulated wells.

Sensorless Operation
The drive uses a number of unique methods for precisely
determining performance parameters from models of the pumping
system elements without requiring external surface or downhole
sensors. Sensorless system variables including rod speed, rod torque, pump speed, pump torque, fluid flow, fluid level,
suction pressure, discharge pressure, and differential pressure can be observed through the drive keypad/display or
recorded as circle charts and time-based plots. Fluid level, pump flow, and total production are displayed in selectable
engineering units.

Sophisticated Modeling
Embedded mathematical models of the drive, motor, drive head, rod string, pump, flow line, tubing, casing, fluid, and
reservoir use component specifications and well completion information along with field setup parameters to monitor
pumping system operation. Identification routines automatically determine installation-dependent system parameters
including those of the motor, rod string, and pump. The models capture the thermal, mechanical, electrical, and
hydraulic behavior of the system to control the pumping process with greater precision than ever before.

Pump Speed Control

The drive provides a number of options for manual, remote, and automatic control of pump speed. Speed commands
can be selected from a number of sources including potentiometer adjustments, keypad presets, serial data
communications, and internal optimization controllers. The motor can be operated up to twice base speed at constant
power. This allows the overall gear ratio to be increased, thereby providing increased low-speed torque without loss
of maximum pump speed. Dual motors can be controlled from a single drive for operation of large pumps. The system
can be configured for optimization of fluid production, gas production, energy efficiency, and/or power flow.

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 Downhole Solutions

Drilling Solutions

Engineering and Project Management Solutions

Corporate Headquarters
7909 Parkwood Circle Drive
Houston, Texas 77036
United States
Phone: 713 375 3700
Fax: 713 346 7687

Sales Lifting and Handling Solutions

8708 West Little York Road
Suite 100
Houston, Texas 77040
United States
Phone: 281 200 1200
Fax: 281 200 1201

Production Solutions

Supply Chain Solutions

Tubular and Corrosion Control Solutions

National Oilwell Varco has produced this brochure for general information only, and it is not
intended for design purposes. Although every effort has been made to maintain the accuracy and
reliability of its contents, National Oilwell Varco in no way assumes responsibility for liability for any Well Service and Completion Solutions
loss, damage or injury resulting from the use of information and data herein. All applications for the
material described are at the user’s risk and are the user’s responsibility.
All brands listed are trademarks of National Oilwell Varco.

One Company . . . Unlimited Solutions

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