®

MG Style
Drive 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 PC Pump Products & Services 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 Weatherford Canada Partnership cannot accept any responsibility whatsoever and disclaims
all liability thereof.

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.
PC Pump Manual

Table of Contents

Introduction Pg. 1-2

Drivehead Selection Pg. 3

Input Data Sheet Pg. 4

Complete Specifications Chart Pg. 5-6

Direct Drive Equipment Options Pg. 6

Diagrams of Driveheads Pg. 7-9

Drive Installation Procedures Pg. 10-11

Drivehead Removal Procedures Pg. 12

Polished Rod Clamp Installation Procedures Pg. 13-14

Drivehead Start-Up Procedures Pg. 15

Drivehead Shut-Down Procedures Pg. 15

Motor and Sheave Ratio Limitations Pg. 16-18

Maintenance Schedule Pg. 19

Maintenance Procedures Pg. 19

Stuffing Box Information, Set-Up and Maintenance Pg.20-23

Direct Drive System Troubleshooting Pg. 24

Appendix Pg. 25-33

Weatherford Canada Partnership Warranty Pg. 34

Notes Pg. 35
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Introduction

MG Style Direct Drives

The diverse configuration of the MG style driveheads make them remarkably durable, reliable and easy to maintain. These units are
driven through belts and sheaves; typically by an electric motor, but can be driven via a hydraulic motor. The motor is installed on an
adjustable door that is a component of the drive frame. A hinged belt guard completely encloses the belts and sheaves but provide easy
access and maximum safety. The drive unit's hollow shaft is coupled to the polished rod with a polished rod clamp. Precision bushings
inside the shaft ensure proper alignment of the polished rod. A sturdy wellhead frame supports the assembly with a variety of stuffing
box options available. The Mini G and MG are available with an integral rotating stuffing box, which is denoted by "-I". A complete
list of all options available are outlined on page 6. Minimal maintenance is all that is required. When other servicing is required the
individual component construction of the drive allows for easy repair.

Weatherford’s MG style direct drives utilize a patented* totally enclosed backspin control system that uses the centrifugal force created
during backspin to engage large shoes against a stationary housing. This system is immersed in synthetic oil that controls fluctuating
temperatures while lubricating all moving parts to ensure a long service life. A unique design feature of this style of backspin control
is that speed reduction does not begin until the polished rod speed reaches a predetermined speed as outlined in the table below. Once
the polished rod speed is reduced to below this speed the shoes are allowed to retract and allow for a quick and controlled fluid dump.

Mini G MG Dual MG MG250

Backspin Speed
(rpm) 150 250 250 180

*US Patent# 6,079,489, Canadian Patent# 2,322,656

1
 4 1

Driven Sheave Driver Sheave 2 3

5
6
Equipment List
7
1. Polished Rod Guard
8
2. Drivehead
3. Electric or Hydraulic Motor
4. Belts and Sheaves
5. Remote Tachometer
9
6. Booth Guard 10
7. Stuffing Box Wellhead Connection
11
8. Polished Rod Support Clamp
12 13
9. Polished Rod
10. Polished/Sucker Rod Change-Over Coupling 14
15
11. Rod Guides
16
12. Sucker Rod Couplings
13. Stator Thread to Tubing Thread Change-Over 17
14. Sucker Rods 18
15. Tubing Pup-Joint
16. Rotor/Sucker Rod Change Over Coupling
17. Stator (includes Tagbar Sub)
19
18. Rotor
19. Tagbar Sub (part of Stator) 20
20. Torque Anchor/No-Turn Tool

2
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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 motor or internal combustion engine)

Weatherford PC Pump currently manufactures a variety of wellhead drives to match every application encountered by
progressing cavity pumping systems. These are summarized below.

HTD and - precise torque control and adjustable wellhead speed is possible without the use of a VFD (Variable Frequency Drive)
Inline - hydraulic fixed orifice restriction backspin control system
- hydraulic skid powered by an internal combustion engine or an electric prime mover is required to power these units

M2 - right angle gearbox drive (2:1) designed for applications requiring up to 60 HP

- automatic external caliper and disc backspin control system featuring “test on the fly”
- internal combustion engine, electric prime mover or hydraulic motor can power these units

M4 - direct drive (1:1) designed for applications requiring up to 60 HP

- automatic external caliper and disc backspin control system featuring “test on the fly”
- electric prime mover or hydraulic motor can power these units

MC4 - direct drive (1:1) designed for applications requiring up to 60 HP

- automatic external caliper and disc backspin control system
- electric prime mover or hydraulic motor can power these units

AF30 - direct drive (1:1) designed for applications requiring up to 30 HP

- automatic internal hydraulic pad backspin control system
- electric prime mover or hydraulic motor can power these units

Mini G - direct drive (1:1) designed for applications requiring up to 60 HP

- automatic internal centrifugal friction backspin control system
- electric prime mover or hydraulic motor can power these units

MG - direct drive (1:1) designed for applications requiring up to 125 HP

- automatic internal centrifugal friction backspin control system
- electric prime mover or hydraulic motor can power these units

Dual MG - direct drive (1:1) designed for applications requiring up to 150 HP with two 75 HP motors
- automatic internal centrifugal friction backspin control system
- electric prime mover or hydraulic motor can power these units

MG250 - direct drive (1:1) designed for applications requiring up to 250 HP with two 125 HP motors
- automatic internal centrifugal friction backspin control system
- electric prime mover or hydraulic motor can power these units
These are only guidelines. For more information please refer to the "Drive Specifications Table" on Pages 5 and 6 which itemizes the limits of
all drives. To determine the optimum drive for your particular application please contact your nearest Weatherford Technical or Sales Representative.

3
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PC Pump Design Form

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: Contact:

Well Name: Phone:
Location: e-mail: Fax:
Country: Date:
WELL DATA Units Circle One PRODUCTION AND FLUID DATA
Vertical: Horizontal: Slant: Current Production: m3pd-bfpd
Total Depth: mkb-ftkb Projected Production: m3pd-bfpd
Perforations (Top): mkb-ftkb Water Cut: %
(Bottom): mkb-ftkb Abrasive Cut: %
Pump Landing Depth: mkb-ftkb Gas/Oil Ratio: m3/m3-bbls/scf
Producing Fluid Level From Surface Total Fluid Viscosity: cp C-F
Current: mkb-ftkb API Oil Gravity: Degrees
Projected: mkb-ftkb H2S: ppm Water S.G.:
Flowline Pressure: kpa-psi C02: ppm Water Salinity: ppm
Casing Pressure: kpa-psi Aromatic (Benzene, Toluene, Xylene): vol%
Casing size: mm-in Bottom Hole Temperature: C-F
Tubing Size: mm-in Temperature Gradient: C/m-F/ft
Rod Size & Grade: mm-in Treating Chemicals:
IPR DATA
Static Reservoir Pressure: kpa-psi SURFACE EQUIPMENT
Bubble Point Pressure: kpa-psi Primer Mover Type: Gas Electric
Test Point #1 Test Point #2 Surface Drive: Direct Hydraulic
Producing Pressure(s): kpa-psi Operating Frequency: Line Voltage:
Fluid Rate(s): m3pd-bfpd Flow-Tee to Drivehead Connection:
Productivity Index: (m3/kpa-bbls/psi) Flow Tee Style & Size:
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

PC Pump Design and Technical Support

4
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Table 1: MG Style Drive Specifications

DRIVE NAME / MODEL Mini G Mini G-I MG MG-I Dual MG MG250 AF30
Drive Type Direct Drive Direct Drive Direct Drive Direct Drive Direct Drive
Drive Ratio 1:1 1:1 1:1 1:1 1:1
Drive Style Bearing Box Bearing Box Bearing Box Bearing Box Bearing Box
Input Shaft Vertical Vertical Vertical Vertical Vertical
Shaft Type Hollow Shaft Hollow Shaft Hollow Shaft Hollow Shaft Hollow Shaft
Ratings
Maximum Input Polished Rod Torque (ft-lbs) 2000 2000 2000 3500 1000
Thrust Bearing - Standard (ISO/Ca90 Rating (lbs)1 129,000 / 33,500 194,000 / 50,300 194,000 / 50,300 310,000 / 80,400 100,000 / 25,900
- Optional (ISO/Ca90 Rating (lbs)1 N/A 310,000 / 80,400 310,000 / 80,400 N/A N/A
Maximum Polished Rod Speed (rpm) 600 600 600 600 600
Maximum Motor Size (hp) 60 125 75 x 2 125 x 2 30
Polished Rod Size (in) 1 1/4 1 1/4 or 1 1/2 7 1 1/2 1 1/2 1 1/4
Maximum Suggested Temperature (Component-Temperature) Seal - 110°C Seal - 110°C Seal - 110°C Seal - 110°C Seal - 110°C
Dimensions & Weights (Excluding Motor)
Height 56 40 64 48 68 5/8 68 5/8 44
Input Shaft Size (in) 2 3/4 2 3/4 2 3/4 2 3/4 2 3/4
Drive/Frame Weight (lbs) 1180 1000 1780 1600 2300 2350 440
Backspin Control Internal Centrifugal Friction Internal Centrifugal Friction Internal Centrifugal Friction Internal Centrifugal Friction Internal Centrifugal Friction
API Wellhead Connection2 2 7/8” Pin or 31/8” 3000 psi Flange 2 7/8” Pin or 31/8” 3000 psi Flange 5 1/8” 3000 psi Flange 5 1/8” 3000 psi Flange 2 7/8” Pin or 31/8” 3000 psi Flange
Prime Mover Electric or Hydraulic Electric or Hydraulic Electric or Hydraulic Electric or Hydraulic Electric or Hydraulic
Power Transmission3
Driven Sheave Maximum Diameter (in) 30 30 31 1/2 31 1/2 25
Drive Sheave Maximum Diameter (in)4 11.5 14 13 13 11
Drive Sheave Minimum Diameter (in)5 4.9 4.9 4.9 4.9 4.9
Maximum Number of Belts 4 ea Type C 4 ea Type C
8 ea Type C
6 ea Type 5V 6 ea Type 5V
10 ea Type 5V
1 ea Synchronous 1 ea Synchronous
Minimum Center Distance (in)6 12 1/2 + D 17 + D 15 1/2 + D

Note: Maximum ratings are individual specs. Maximum torque, hp, and speed cannot occur simultaneously. Drive models in shaded area of the chart have separate manuals available from Weatherford.

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.
2 Various connection types are available on request.

3 For a detailed index of power transmission configurations refer to the Weatherford Progressing Cavity Pumping Systems CD.

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

5 Ensure that the top bearing in your motor can handle the additional overhung load that results from using smaller sheaves.

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

7 Integral rotating stuffing box is not available with1 1/2" polished rod.

8 Continuous Allowable Rated Gear Torque is 1350 ft-lbs. Intermittent Rated Gear Torque is 1650 ft-lbs.

9 When an Extra Capacity (E/C) bearing is used the water/glycol cooled disc backspin control system is used.

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

11 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.

5
MG Style Drive Specifications Cont.
MC4 MC4-I M4 M4-I M2 M2-I HTD HTD-I Inline Inline-I
Direct Drive Direct Drive Gear Drive Hydraulic Hydraulic
1:1 1:1 2:1 1:1 1:1
Bearing Box Bearing Box Gear Box Bearing Box Bearing Box
Vertical Vertical Right Angle Vertical Vertical
Hollow Shaft Hollow Shaft Hollow Shaft Hollow Shaft Hollow Shaft

1500 2000 13508 200010 150010

129,000 / 33,500 129,000 / 33,500 129,000 / 33,500 100,000 / 25,900 100,000 / 25,900
N/A N/A 194,000 / 50,3009 N/A N/A
600 600 600 600 700
60 60 60 N/A N/A
1 1/4 1 1/4 or 1 1/27 1 1/4 or 1 1/27 1 1/4 1 1/4
Disc - 215°C Disc - 215°C Disc - 215°C Seal - 110°C11 Seal - 110°C

53 39 53 39 49 35 56 25 50 33
2 3/4 2 3/4 2 3/4 2 1/2, 2 3/4 N/A
850 800 1120 1090 1290 1250 668 600 672 492
Automatic External Caliper & Disc Automatic External Caliper & Disc Automatic External Caliper & Disc Hydraulic Fixed Orifice Hydraulic Fixed Orifice
2 7/8” Pin or 31/8” 3000 psi Flange 2 7/8” Pin or 31/8” 3000 psi Flange 2 7/8” Pin or 31/8” 3000 psi Flange 2 7/8” Pin or 31/8” 3000 psi Flange 2 7/8” Pin or 31/8” 3000 psi Flange
Electric or Hydraulic Electric or Hydraulic Internal Combustion Engine, Electric or Hydraulic Hydraulic Hydraulic

30 30 30 24 N/A
11.5 11.5 14 9 N/A
4.9 4.9 4.9 4.9 N/A
4 ea Type C
6 ea Type 5V 1 ea Synchronous N/A
1 ea Synchronous
12 1/2 + D 15 1/2 + D 21 3/8 - 32 15/16 (depends on motor size) N/A N/A

Table 2: Direct Drive Equipment Options

OPTIONS DESCRIPTION
Support Arms Support Arms Mounted on Drive Frame
Stuffing Box Retrofit Rotating
Integral Rotating (not available with 1 1/2” polished rod)
Conventional or Injectable Packing Threaded
Conventional or Injectable Packing Flanged
Storage Stand Stand for Transporting and Storing the Drive
CSA Approved Digital Tachometer (Class I, DIV II) Magnetic Pickup Mounted on Drive
Polished Rod Guard 24” Long Rolled Perforated Plate, Fastened w/ Over Center Latch
Booth Guard Complete Enclosure of Weatherford Booth, Fastened w/ Spring Clips
Polished Rod Support Clamp Clap Mounted Between Drivehead and Flow Tee
Ejection Clamp Transfers Upward Axial Load into Bearing Box

6
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Figure 1: Mini G Wellhead Drive Assembly

Polished Rod Clamp

Hinged Belt Guard

Bearing Housing

Drive Frame

Integral Stuffing Box

Electric Motor (Optional)

Mini G-I

Polished Rod Clamp

Hinged Belt Guard

Bearing Housing

Drive Frame

Electric Motor (Optional)

Retrofit Stuffing Box

Mini G with Retrofit Rotating Stuffing Box

7
Figure 2: MG Wellhead Drive Assembly
Polished Rod Clamp

Hinged Belt Guard

Bearing Housing

Drive Frame

Electric Motor (Optional)

Integral Stuffing Box

MG-I

Polished Rod Clamp

Hinged Belt Guard

Bearing Housing

Drive Frame

Electric Motor (Optional)

Retrofit Stuffing Box

MG with Retrofit Rotating Stuffing Box

8
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Figure 3: MG250 Wellhead Drive Assembly

Polished Rod Clamps

Hinged Belt Guard

Bearing Housing

Drive Frame

Electric Motor Electric Motor (Optional)

(Optional)

Retrofit Stuffing Box

MG250 with Retrofit Rotating Stuffing Box

9
Drivehead Installation Procedures
1. Once the rotor is correctly landed in the stator, refer to PC Pump installations procedures in PC Pump Operators Manual, the length of the
sucker rods in the hole must be adjusted to allow for the polished rod. From the top of the flow tee add on the height of the surface drive as
determined in Table 1: MG Series Drivehead Specifications on page 5. Add an additional 30 cm (12 in.) for the polished rod clamp and stick-
up. For a drive equipped with a Stacking Polished Rod Drive clamp, add an additional 45 cm (18 in.). Place a target mark on the sucker rod
at this point to represent the desired length for the rod string, including the polished rod.

2. Remove enough of the sucker rods to make room for the polished rod. The difference between the sucker rod removed versus the length of
polished rod added must be made up with pony rods. To prevent surface vibration problems, any pony rods should be buried at least two full
sucker rod lengths down the rod string. The polished rod should be long enough to allow the rotor to be pulled totally out of the stator without
removing the surface equipment. Not only is this important to allow a proper flush-by procedure but it is also a safety consideration in well
servicing operations. Rotor lengths for all Weatherford Pumps are available in the Specifications and Capacities Manual.
Note: All rod string connections should be made up to manufacturers specifications.

3. Using a short pony rod on top of the polished rod as a handling sub, pick up and attach the polished rod to the sucker rod string using a
polished rod coupling. To ensure proper sealing of the stuffing box, it is critical that the polished rod is straight and does not have significant
wear or corrosion.

4. Reconfirm the pump space-out with the modified rod string configuration. The target mark should be within 15 cm (6 in.) of the top of the
polished rod. If it is not, make the necessary adjustments to the pony rod lengths.
Warning: Polished rod stick-up of more than 60 cm (24 in) above the top of the drive clamp can cause severe damage during recoil. Stick-
up should be minimized to 30 cm (12 in) or less.

5. When the rod string is properly positioned, install a clamp on the polished rod adjacent to the top of the flow tee or engage the polished rod
support clamp.

6. File off any burrs and rough spots on the polished rod, to prevent damage to the stuffing box and/or bushings in the driveshaft.
NEVER LEAVE PIPE WRENCH MARKS ON POLISHED RODS.

7. 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 drivehead shaft and stuffing box.

8. Remove the polished rod handling pony rod.

9. Install a polished rod alignment tool (bullet) on top of the polished rod, to keep from damaging the polished rod threads and/or the stuffing
box packing.

10. If drivehead with an attached stuffing box is being installed, skip to step 18.

11. Lift the stuffing box assembly up and slide it over top of the polished rod.

12. If a Polished Rod Support Clamp is being used, skip to Step 14 below.

13. Reattach the handling pony rod to the polished rod and lift the rod string only enough so the rod weight is removed from the clamp on the
polished rod, at which point the clamp can be temporarily removed.

14. Lower the stuffing box assembly onto the flow tee and bolt or thread it into place. Tighten all wellhead fittings to the maximum torque
specifications.

10
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Drivehead Installation Procedures Cont.

15. If a Polished Rod Support Clamp is being used, skip to Step 18.

16. Reinstall the polished rod clamp, adjacent to the top of the stuffing box, and lower the rod string to hold the polished rod in place.

17. Remove the polished rod handling pony.

18. Use a 3 point sling and lift the drivehead up and orient over top of the polished rod with a picker/crane truck or a winch line.
Warning: Use the lifting hooks on the guard or frame, Do not lift the wellhead drive by the sheaves.

19. Lower the drivehead over top of the polished rod.

20. If a Polished Rod Support Clamp is being used, skip to Step 23 below.

21. If installing a drivehead equipped with an integral stuffing box without a polished rod support clamp, remove the polished rod alignment tool
(bullet). Reattach the handling pony rod to the polished rod and lift the rod string only enough so the rod weight is removed from the clamp
on the polished rod and remove the clamp.

22. Lower the drivehead over top of the polished rod and align the mounting bolt holes with the wellhead. To facilitate proper alignment, ensure
that the mating regions of the drivehead and wellhead/stuffing box flange are free of mud and other debris.
Note: For slant well applications, the drivehead should be oriented so that the motor is up.

23. Connect the drivehead to the wellhead/stuffing box flange.

24. Remove the 3 point sling and picker/crane truck or the winch line.

25. Clean the polished rod of any grease or oil along the area where the polished rod drive clamp will be located.

26. Install the polished rod drive clamp, following procedures on page 13.

27. Support the rod string weight from the pony rod using elevators, and remove the polished rod clamp on top of the stuffing box or disengage
the polished rod support clamp following the procedures on page 14. With driveheads equipped with an integral stuffing box ensure that the
hex drive clamp at the top of the mainshaft is engaged properly.

28. Lower the elevators then engage the polished rod drive clamp into the mainshaft.

29. Remove the elevators and handling pony rod.

Note: Place a coupling on the top of the polished rod. Do not leave a pony rod on top of the polished rod during pumping operations.

30. On threaded wellhead connections tightly wrap the safety chain on the drivehead frame around the flow tee to prevent the drivehead from backing
off. A safety chain is not required when there are no threaded connections below the drivehead.

31. Check and tighten all nuts and bolts on the wellhead drive.

32. If applicable, install the polished rod and booth guard.

33. If applicable, install the support arms.

Refer to page 15 in this manual for specific start-up procedures.

11
Drivehead Removal Procedures
1. Follow the drivehead shut-down procedures on page 15.

2. Disconnect the hoses or wiring to the electric motor.

3. Attach a 2’ pony rod and rod coupling to the polished rod.

4. With the use of a flushby or rig attach the working line to the 2’ pony rod.

5. Pull up on the polished rod to pick up the rod weight.

6. Begin to loosen off the polished rod drive clamp bolts.

7. Once the clamp has been loosened off, begin to pull up on the polished rod (approx. 2 –3 feet).

8. Screw in the rod BOPs to isolate the production tubing and close the flowline valve to the production line.

9. Attach the winch line or picker to the lifting lugs on the drivehead. Ensure that the drivehead will be balanced.

10. Begin to remove the bolts from the wellhead flange or unscrew the drivehead from the flow tee.

11. Once the drive has been loosened off, begin to lift the drive with the winch line or picker. (approx. 2 –3 feet).

12. Engage the polished rod support clamp following the procedures on page 14 and go to step 14.

13. If a polished rod support clamp is not being used, install a two bolt rod clamp and a 1” steel plate on the flow tee of the wellhead
to support the rods.

14. Remove the 2’ pony rod and rod coupling from the end of the polished rod.

15. Lift the drivehead off over the polished rod.

12
 ®

Polished Rod Drive Clamp Installation Procedures

Once the drivehead has been installed on the wellhead the polished rod clamp must be secured Polished Rod
to the mainshaft and polished rod. Clamp
4 1

1. Place the polished rod clamp on the mainshaft ensuring that the slot on the bottom of the clamp 3/4”x 4”
is aligned with the mainshaft. 2 5 Structural
Bolts
2. 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. 6 3

3. The bolts for the clamp should be tightened in the sequence numbered above.

4. Evenly tighten bolts 1, 2 and 3. (i.e do not tighten bolt 1 all the way then move on to bolt 2).
Drive Mainshaft
5. Evenly tighten bolts 4, 5 and 6. (i.e. do not tighten bolt 4 all the way then move on to bolt 5).

6. Once all the bolts have been installed ensure that they have been tightened to 250 ft-lbs.

Stacking Polished Rod Drive Clamp

Dual MG E/C and MG250 require stacking polished rod clamps
Once the drivehead has been installed on the wellhead the polished rod clamp must be secured
to the mainshaft and polished rod.

1. Place the first polished rod clamp on the mainshaft ensuring that the slot on the bottom of the Clamp #2
clamp is aligned with the mainshaft.
10 7
2. 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. 8 11
3. The bolts for the clamp should be tightened in the sequence numbered above.
12 9
4. Evenly tighten bolts 1, 2 and 3. (i.e do not tighten bolt 1 all the way then move on to bolt 2).

5. Evenly tighten bolts 4, 5 and 6. (i.e. do not tighten bolt 4 all the way then move on to bolt 5).
Clamp #1
6. Place the second polished rod clamp on the mainshaft ensuring that the slot on the bottom of the 4 1
clamp is aligned with the top of the first clamp.

7. Install the nuts and bolts into the clamp and tighten loosely. Bolts 7, 8 and 9 should have the nuts 2 5
showing and bolts 10, 11 and 12 should have the bolt head showing.

8. The bolts for the clamp should be tightened in the sequence numbered above. 6 3

9. Evenly tighten bolts 7, 8 and 9. (i.e do not tighten bolt 7all the way then move on to bolt 8).

10. Evenly tighten bolts 10, 11 and 12. (i.e. do not tighten bolt 10 all the way then move on to bolt 11).
Drive Mainshaft
11. Once all the bolts have been installed ensure that they have been tightened to 250 ft-lbs.

13
Polished Rod Support Clamp Procedures
Installation
1. Visually inspect the jaws to ensure that they are retracted and are in good working condition.

2. Position clamp between drivehead flange and wellhead flange.

3. The studs that secure the drivehead to the wellhead may need to be lengthened to ensure that there is sufficient thread exposed to screw on the nut.

4. Tighten the stud bolts in a star pattern.

Note: For applications with increased axial loads the polished rod support clamp can be stacked.
Contact your local Weatherford representative to determine if stacked polished rod support clamps are required.

Engagement
1. Follow the drivehead shut-down procedures on page 15.

2. Slowly tighten the four bolts equally, using the notches on the bolts as a reference point, on the clamp in a star pattern to 250 ft-lbs. torque.

Notches

3. Recheck each bolt for 250 ft-lbs. torque a circular pattern.

Note: Bolts must be engaged and disengaged slowly to prevent damage to the o-ring seals.

Disengagement
1. Ensure the weight of the rods is supported.

2. Release the torque on the bolts being aware of any potential energy in the system.

3. Back out bolts 2 – 4 turns.

4. Clamp is now disengaged and drivehead can be started up following the drivehead start-up procedures on page 15.

Maintenance
The o-rings and back-up rings that are on the bolts that engage the jaws of the clamp can be replaced in the field.
If the jaws become damaged the polished rod support clamp must be returned to Weatherford for repair. 8-112 Back-Up
To replace the o-rings and back-up rings: Follow the drivehead shut-down procedures on page 15. Ring
1. Ensure that all pressure is removed from the polished rod support clamp.
2-112 Viton
2. Remove the four bolts on the clamp. O-Ring

3. Remove and replace the o-rings and back-up rings.

4. Reinstall the bolts in the clamp, tightening the bolts against the polished rod to engage the bolts into the jaws.

5. Retract the bolts following the disengagement procedure above.

14
 ®

Drivehead Start-Up Procedures

Ensure proper drivehead installation procedures were followed as outlined on page 10. Prior to any adjustments or
maintenance of a drivehead ensure lock out and/or safety clamps are properly in place according to manufacturer’s and
production company procedures.
1. Inform all personnel related to start-up of the procedures to be followed (i.e. tailgate meeting).

2. Set all casing, tubing, downstream flow line components and safety devices correctly for operation.

3. Check that bearing box oil level, belt condition/tension and stuffing box are ready for operation.

4. Remove or disengage all lock out and/or safety clamps.

5. Ensure that drivehead configuration and/or VFD parameters are compatible with manufacturer’s drive string specifications
(Refer to Appendix H).
6. Confirm proper drive string rotation (i.e. bump electric motor).

7. Start drivehead at specified start up RPM.

8. Monitor for any unusual noises, vibrations, leaks and excessive drivehead temperatures.

9. Once fluid is established at surface, confirm safety devices are operating correctly (i.e. High Pressure Flow Line Shutdown).

10. Monitor drivehead operation on an increased level until normal production is established.

Drivehead Shut-Down Procedures

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 ratings of the belts and sheaves causing them 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.

Important: The friction fit of the rotor inside the stator, the drag of the rod string against the tubing and any friction
inside the surface drive components will not allow the fluid in the tubing to completely equalize with the fluid in the casing.
Therefore, after a drivehead has been shut-down and backspin stops, there is still potential for additional recoil. Caution
must be taken when approaching any well that has been shut-down.

1. Inform all personnel related to shut-down of the procedures to be followed (i.e. tailgate meeting).

2. Be familiar with well operating conditions prior to shut-down including fluid level, speed and torque.

3. Approach the well with caution; include a visual inspection and check for any abnormal operating conditions.

4. Turn drive off at the master control panel and observe backspin control performance. If the well is equipped with a VFD, refer to the
VFD manufacturers shutdown procedures. As a minimum, gradually ramp down the speed of the drive prior to shutting it down.

5. Do not approach the drivehead until the polished rod has come to a complete stop.

6. Shut off and lock out the master control panel.

7. Prior to well servicing and/or drivehead maintenance follow the recommended polished rod support clamp engagement procedures
on page14.

15
Motor and Sheave Ratio Limitations
History shows that 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 string’s 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 backspin control 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 pages 17 & 18 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.
• 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.
16
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 backspin 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 flux vector drive controller 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 torque limiting device 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 backspin control device performance.
 ®

Motor and Sheave Ratio Limitations Cont.

Mini G Driveheads
6

4
Sheave Ratios

0
0 10 20 30 40 50 60
Motor Horsepower

MG Driveheads
6

LIGHT GREY ZONE

Safe Operating 4
Range
Sheave Ratios

3
WHITE ZONE

Limited
Operating
Range 2

DARK GREY ZONE 1

This area of the
operating range is safe
only if an approved
torque limiting device 0
is used. 0 10 20 30 40 50 60 70 80 90 100 110 120 125
Motor Horsepower

17
Motor and Sheave Ratio Limitations Cont.
Dual MG Driveheads
6

4
Sheave Ratios

0
0 10 20 30 40 50 60 70 75
Motor Horsepower

MG 250 Driveheads
6

LIGHT GREY ZONE

Safe Operating 4
Range
Sheave Ratios

3
WHITE ZONE

Limited
Operating
Range 2

DARK GREY ZONE 1

This area of the
operating range is safe
only if an approved
torque limiting device 0
is used. 0 10 20 30 40 50 60 70 80 90 100 110 120 125
Motor Horsepower

18
 ®

Table 4 : Drive Maintenance Schedule

MG Style Drives
MAINTENANCE FREQUENCY
MG/Dual MG & MG250 BEARING HOUSINGS
Change Oil1 Annually
Oil Type2 Mobil SHC 630
Oil Quantity 26 litres. Keep filled to oil level line
Mini G BEARING HOUSING
Change Oil1 Annually
Oil Type2 Mobil SHC 630
Oil Quantity 13 litres. Keep filled to oil level line

1Oil change schedule based on 300 RPM, 24 hour operation of drive units. Faster operation may require more frequent oil changes. First
month oil change is recommended because tests have shown that the highest concentrations of wear particles are generated within the first
500 hours of use. With each oil change, check and tighten nuts and bolts on the motor support frames and belt guards, check and tighten
belt tension, ensure the belts and sheaves are not cracked or damaged and check oil level.

2 Do Not Mix Oil Types. When changing oil types, a complete oil change must be performed. Use Mobil SHC 630 or equivalent.

Wellhead Drive Belt Replacement Procedures

1. Shut down wellhead drive by following the Drivehead Shut Down Procedures on page15.

2. Follow Polished Rod Support Clamp Engagement Procedures on page 14.

3. Close flow line valve to production tank.

4. Open the hinged belt guard.

5. Close the motor mount door to the fully closed position.

6. Remove the old belt.

7. Install new drive belt/belts and tighten to the appropriate tension.

8. Close and secure the hinged belt guard.

9. Follow Polished Rod Support Clamp Disengagement Procedures on page 14.

10. Open flowline valve to production tank.

11. Start drive by following the Drivehead Start-up Procedures on page 15.

19
Weatherford Stuffing Boxes
All Progressing Cavity Drives require a stuffing box to create a
seal between the polished rod and tubing. Weatherford PC Pump
manufactures a variety of stuffing boxes:
• Conventional
• Conventional with injectable packing
• Retrofit Rotating
• Integral Rotating
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.

Conventional Retrofit Rotating

• Rope style Packing • Flanged lipseal
• Flanged or pinned wellhead attachment • Flanged wellhead attachment

Cap
Snap Rings
Teflon Spacer Tapered Bushings
Cap
Seal Poly Seals
Top Brass
Packing Rings Snap Ring Rotating Sleeve
Ball Bearings
Sampling Valve
Spring
Plugs Flanged Lipseal Grease Zerks
Sampling Valve
Bottom Brass Flanged Lipseal Bushings
Polypak Seal

Snap Ring Retaining Ring

Conventional with Injectable Packing Integral Rotating

• Injectable packing that conforms to a new or worn polished rod • Flanged lipseal
• Flanged or pinned wellhead attachment • Flanged wellhead attachment

Cap
Integral Shaft
Top Brass
Spring Brass Spacer Snap Ring
Ball Bearing
Injectable Packing Adapter Sampling Valve
Packing Ring Valve Ball Bearing Grease Zerks
Brass Washers
Brass Spacer Pipe Nipple Sampling Valve
Plug
Wiper Seals Bottom Brass Flanged Lipseal
Polypak Seal

20
 ®

Stuffing Box Setup Procedures

Conventional Stuffing Boxes
1. Once the drivehead with the stuffing box has been installed on the wellhead following the procedures on page 10, loosen cap at the top
of the stuffing box.
2. Grease the stuffing box with a high quality lithium based grease.

Injectable Packing Stuffing Boxes

1. Once the drivehead with the stuffing box has been installed on the
wellhead following the procedures on page 10, ensure that the cap is
hand tight only. There should be four (4)threads left showing as
illustrated to the right. This will maintain constant pressure on the Four (4)
stuffing box spring, which will ensure complete compression of the Threads
injectable packing.
2. Do not over tighten the stuffing box cap, this will cause over
heating and accelerate packing wear, inevitably leading to premature
wear.

Retrofit Stuffing Boxes

1. Once the drivehead with the stuffing box has been installed on the
wellhead following the procedures on page 10, position the rotating
sleeve so that it will be between 1/4” and 3/4” above the stationary parts
as illustrated to the right. The sleeve will lift as the cap is tightened.
2. Firmly tighten the cap, while backing up the rotating sleeve. This cap
1/4” to 3/4”
secures the rotating sleeve to the polished rod. Damage to the assembly
will result if the cap is not tight. Space
3. When operating properly, the cap should turn with the polished rod.
4. Open the lowest sampling valve and apply high quality lithium based
grease from the other side.
5. Purge out all the old grease and repeat on the upper chamber.
6. Close the sampling valves.

Integral Stuffing Boxes

1. Once the drivehead with the stuffing box attached has been installed on the wellhead following the procedures on page 10, ensure that
the hex drive is properly engaged with the polished rod clamp.
2. Open the lowest sampling valve and apply high quality lithium based grease from the other side.
3. Purge out all the old grease and repeat on the upper chamber.
4. Close the sampling valves.

21
Stuffing Box Maintenance
Stuffing box maintenance procedures vary by well location. Depending on application severity, daily greasing may be required but a
minimum of weekly greasing is recommended.

Conventional Stuffing Boxes

After initial start-up, grease daily for the first two days.

To apply grease:
1. Always wipe away any excess grease and dirt from around the fitting before greasing.
2. Apply 8 – 10 shots of grease.
3. Ensure the stuffing box cap is hand tight.

To change packing rings:

1. Follow the drivehead shut-down procedures on page 15.
2. Close the rod BOPs and flowline valves.
3. Bleed off any pressure from the flow tee.
4. 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
hand tight, and open the rod BOPs and flowline valves.

The stuffing box has a brass bushing in the body and another in the cap that centralizes 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 when required.

Do not over tighten the stuffing box cap – this will cause overheating of the stuffing box packing and accelerate wear
on the polished rod.

Conventional with Injectable Packing Stuffing Boxes

1. Inspect the stuffing box and ensure that the cap is still snug.
2. If the cap is loose or production fluid starts to leak, hand tighten down the stuffing box cap to reform the injectable packing to the
polished rod.
3. When the cap has bottomed out on the stuffing box body, new injectable packing must be reinjected into the stuffing box.

Packing Injection Procedure:

1. Follow drive shutdown procedures on page 15.

2. Back off the stuffing box cap until you have four (4) threads left showing as illustrated below.

Four (4)
Threads

3/8”
Fitting

3. Connect the injecting gun to the 3/8” fitting on the stuffing box.
4. Open air bleeder on the back of the gun.
5. Inject the packing until there is resistance on the gun (This will indicate the packing cavity is full). Caution: Do not
over fill stuffing box. Keep the bleed screw end of the gun elevated during use.
6. Ensure that the stuffing box cap is hand tight.
7. Start the drive following the drive start-up procedures on page 15.

22
 ®

Stuffing Box Maintenance Cont.

Procedure for refilling Injectable Packing Gun:

1. Open the main bypass valve and air bleed screws.

Air Bleed Screw

Bypass Valve

2. Remove the cap from the packing cylinder

Packing Cylinder

Removable Cap

3. Push the plate inside the packing cylinder to the bottomed out position (some packing will still be in cylinder)
4. Fill the cylinder with injectable packing (careful not to get packing on the cylinder threads)
5. Replace cap on cylinder, hand tighten only
6. Close bypass valve and air bleed screw.
Note: Air bleed screw must be open during use of injection gun.

Retrofit Rotating and Integral Rotating Stuffing Boxes

1. Check for seal wear on a weekly basis. Open the lowest sampling valve on the body of the seal assembly. Some grease may
eak 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.
2. 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.

23
Direct Drive Troubleshooting
MG, Dual MG, MG250 & Mini G:
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.

Stuffing box leaks:

Conventional Stuffing Boxes

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.

Conventional with Injectable Packing Stuffing Boxes

1. Stuffing box cap is too tight.
2. Worn bushings or components from misalignment.
a) 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 the motor. Temperature will indicate how much
friction is in the stuffing box.

Retrofit Rotating Stuffing Boxes Cap

1. If the cap does not turn with the polished rod, it must be tightened
down. Review installation instructions and tighten the cap. Tapered
2. If the inside sleeve pushes up too high as the cap istightened: Bushing
a) Make sure there is no pressure in the flow line.
Rotating
b) If threads are showing under the cap ensure the tapered bushing Sleeve
is seated properly. Push the sleeve downward and tighten the cap.
3. Make sure polished rod is clean. 1/4” x 3/4”
Space
Stationary
Housing

If assistance with installation or maintenance is required, please contact your local Weatherford representative.

24
 ®
Appendix A: Definitions
Applied Torque
Applied torque is that applied to the top of the rod string by the surface
drive.
Auxiliary Equipment
Auxiliary equipment is any component which can be changed by the end
user. Examples are sheaves, belts, motors guards, motor controllers, torque
limiting devices, and speed limiting devices.
Backspin
Backspin is the process by which the surface drive turns in the direction
opposite to normal operation. Backspin is driven by the strain energy of the
rod string and the differential fluid pressure across the pump.
Dissipation Rate
Dissipation rate refers to the power transferred to the surroundings by the
braking system in the form of heat.
Dynamic Fluid Level
Dynamic fluid level is the distance from the wellhead to the top of the liquid
column in the annular space between the tubing and casing during normal
operation.
Electric Motor Brake
Electric motor brakes control the power to and/or from the electric prime
mover during backspin to create a braking effect on the system.
Energy Capacity
The energy capacity of a surface drive is a measure of the total work the
brake can do over the expected duration of a shutdown event. For example,
a braking system which manages stored energy by absorption and not
dissipation has a finite energy capacity defined by thermodynamic
characteristics and maximum allowable operating temperature. A brake
which can dissipate energy as fast as it is generated by the shutdown process
has an infinite energy capacity.
Flow Losses
Flow losses refer to internal friction of moving fluids resulting in pressure
loss.
Fluid Dump Case
The fluid dump case describes most normal shutdowns where power to the
surface drive is removed thereby allowing backspin. The differential fluid
pressure across the pump causes the rotor and rod string to rotate in the
direction opposite to normal pumping, allowing fluid to flow from the
production tubing back through the pump. Backspin continues until torque
resulting from differential pressure across the pump equals friction torque
in the system.
Fluid Energy
Work potentially done by gravity acting on the fluid in the production system.
Fluid Head
Fluid head is pressure resulting from gravity acting on a column of fluid.
Fluid head is used to describe the pressure differential between two fluid
columns contributing to the total differential pressure across the pump
which in turn produces torque.
Friction Brake
A friction braking system reacts torque by applying a normal force to a
sliding surface creating drag.
Hydraulic Brake
A hydraulic braking system reacts torque by pumping liquid through an
orifice resulting in a pressure drop.
Mass Moment of Inertia
Mass moment of inertia is a measure of rotating equipment response to
applied torque.
PC-Pump
A progressing cavity pump is comprised of a stator and rotor. The geometry
of the assembly is such that it constitutes two or more series of spiral,
separate cavities. When the rotor rotates inside the stator, the cavities move
spirally from one end of the stator the other, creating a positive displacement
pumping action.
PC-Pump Surface Drive
The surface drive is a machine which transfers rotational power from the
prime mover to the rod string, transfers axial load from the rod string to a
surface foundation, and manages stored energy during shutdown events.
Residual Fluid Head
Residual fluid head is the condition caused by friction in the PC-Pump,
equaling torque generated by fluid pressure over the effective area of the
pump, resulting in non-obvious presence of energy in the system which
may be released unexpectedly.
Rod String
The rod string is a rod or series of rods capable of transferring torsion from
the surface drive to the pump. The rod string typically reacts axial load from
the pump to the surface drive.
Safe Operating Torque
Safe Operating torque is that applied torque which will never result in an
unsafe operating condition. This value will be very low; specific applications
will permit assignment of a less conservative operating torque.
Strain Energy
Strain energy is the work potentially done by the elastic torsional deformation
of the rod string. Strain energy is typically of smaller magnitude than the
fluid energy, but may be released much more quickly thereby placing
different requirements on the braking system.
Stuck Pump Case
The stuck pump case describes one extreme of the possible conditions at
shutdown. PC-Pump rotors sometimes become "stuck" in the stator and
become effectively locked together. The top of the rod string continues to
turn while the bottom stops, causing the rod string to further wind up as a
torsional spring causing increased torque. When drive torque is removed,
backspin occurs.
Thrust Bearing
Device typically contained in the surface drive which reacts axial load from
the rod string while allowing it to rotate.
Torque Limiting Device
A torque limiting device prevents the system from applying torsion greater
than a prescribed value to the rod string. Slow reaction time and dependence
on ambient temperature makes "heaters" in the electric power supply system
unacceptable as torque limiting devices. Acceptable devices will apply
torque no greater than 110% of the torque limiter setpoint during a stuck
pump event.
Tubing Head Pressure/Casing Head Pressure
Tubing head pressure/casing head pressures are measured at the wellhead
and contribute to the total differential pressure across the PC-Pump.
25
Appendix B: 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.
*reprinted from Canadian Association of Petroleum Producers(CAPP) Safety Alert Guide
26
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.
 ®

Appendix C: 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: HP = (T x RPM) / 5252

To find Torque: Use the formula: T = (HP x 5252) / RPM
To find Speed: Use the formula: 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 100 500 750 1000 1200 1500 1800 2400 3000 3600
RPM RPM RPM RPM RPM RPM RPM RPM RPM RPM
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

Appendix D:
Unit Conversions and Equivalents
S.I. S.I. to Imperial Imperial to S.I. Imperial
multiply by multiply by
celsius degrees (°C) 1.800 + 32 0.5556 - 17.8 fahrenheit degrees (°F)
cubic metre (m3) 6.29 0.159 barrel (bbls)
cubic metre (m3) 0.03531 28.32 thousand cubic feet (mcf)
standard cubic metre gas per 5.618 0.178 standard cubic foot gas per
standard cubic metre oil 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) 1.341 0.7457 horsepower (hp)
litre (I) 0.220 4.54 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) 0.0394 25.4 inch (in)
Newton (N) 0.2248 4.448 pound-force (lbf)
Newton-metre (N•m) 0.7376 1.356 foot-pound (ft•lb)

27
Appendix E: 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
Ethane Gas 1,730 BTU/ft3 140 ft3 per hp day
Methane Gas 962 BTU/ft3 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

28
 ®

Appendix F: Useful Formulas

1. Fluid Rate 6. Belt Length

VNη volumetric π(D + d) (D - d)2
Q= L = 2C + +
100 2 4C
where: Q = Fluid Rate (m3/D)
V = Pump Displacemnent (m3/D/100RPM) where: L = Belt Length (in)
N = Pump Rotational Speed (RPM) C = Center Distance (in)
η volumetric = Pump Volumetric Efficiency (%) D = Driven (Large) Sheave Pitch Diameter (in)
d = Driver (Small) Sheave Pitch Diameter (in)
2. Pump Torque
VP net
T= + T friction 7. Sheave Rim Velocity
124.6
πDN
V=
where: T = Pump Torque (ft.lbs) 12
V = Pump Displacement (m3/D/100RPM)
Pnet = Net Lift (m of head) where: V = Sheave Rim Velocity (ft/min)
T friction = Pump Friction (ft.lbs)
D = Sheave Diameter (in)
3. Net Lift N = Sheave Rotational Speed (RPM)
Pnet = (P thp + P tbgliquid + P tbglosses ) - (P chp + P csggas + P csgliquid )
9.81

where: P net = Net Lift (m Head) 8. Polish Rod Speed

P thp = Tubing Head Pressure (kPa)
P bgliquid = TubingLiquid Column Pressure (kPa)
P tbglosses = Tubing Flow Losses (kPa)
P c p = Casing Head Pressure (kPa)
P csggas = Casing Gas Column Pressure (kPa) Motor Sheave RPM x Motor Sheave Diameter
P csgliquid = Casing Liquid Column Pressure (kPa)
Drive Sheave Diameter
Polish Rod RPM =
Drive Ratio
4. Power (Electrical)
I line Vηp
P= Production Rate (m3/d)
431.2 Polish Rod RPM =
Pump displacement (m3/d/RPM)
where: P = Power (hp)
I line = Line Current (amps) 9. Viscosity
V = Line-to-Line Voltage (V) γρ
µ=
η = Motor Efficiency (%)
p = Motor Power Factor 1000

where: µ = Dynamic Viscosity (centipoise)

γ = Kinematic Viscosity (centistokes)
5. Fluid Density (based on API Gravity) ρ = Fluid Density (kilograms per cubic meter)
141.5
ρ= x 1000
API +131.5
where: ρ = Fluid Density (kg/m3)
API = API Gravity

29
Appendix G: Prime Mover Specifications
Electric Motors (60 Hz TEFC)
Size Speed Frame Weight Shaft Diameter
(hp) (RPM) Size (lbs) (in.)
50 Hz 60 Hz
3 1000 1200 213T 99 1 3/8
5 1000 1200 215T 123 1 3/8
7.5 1000 1200 254T 203 1 5/8
10 1000 1200 256T 243 1 5/8
15 1000 1200 284T 287 1 7/8
20 1000 1200 286T 397 1 7/8
25 1000 1200 324T 494 2 1/8
30 1000 1200 326T 511 2 1/8
40 1000 1200 364T 750 2 3/8
50 1000 1200 365T 811 2 3/8
60 1000 1200 404T 1160 2 7/8
75 1000 1200 405T 1300 2 7/8
100 1000 1200 444T 1700 3 3/8
125 1000 1200 445T 1900 3 3/8
7.5 1540 1800 213T 95 1 3/8
10 1540 1800 215T 110 1 3/8
15 1540 1800 254T 155 1 5/8
20 1540 1800 256T 188 1 5/8
25 1540 1800 284T 267 1 7/8
30 1540 1800 286T 316 1 7/8
40 1540 1800 324T 386 2 1/8
50 1540 1800 326T 437 2 1/8
60 1540 1800 364T 810 2 3/8
75 1540 1800 365T 910 2 3/8
100 1540 1800 444T 1700 2 7/8
125 1540 1800 445T 1900 2 7/8

Gas Engines (All horsepower ratings are continuous, based on 2000 ft elevation with propane fuel)
Speed Weight Shaft Diameter
Model Horsepower Clutch
(RPM) (lbs) (in)
Arrow C46 5 - 10 400 - 800 1360 C107-SP5 1 7/16
Arrow C66 7 - 14 350 - 700 1640 C110-HP4 2 1/4
Arrow C96 11 - 20 300 - 600 2580 C110-HP3 2 1/4
Arrow C106 17 - 32 300 - 800 2690 SP111-HP3 2 1/4
Arrow C255 32 - 55 350 -750 3980 SP114-P1 3
Arrow Y12 6 - 10 475 - 950 1151 C107-SP5 1 7/16
Arrow Y18 8 - 14 350 - 700 1455 C110-HP4 2 1/4
Arrow Y24 13 - 22 400 - 800 2145 C110-HP3 2 1/4
Arrow Y33 17 - 30 400 - 800 2980 SP111-HP3 2 1/4
Arrow L795 35 - 65 300 - 600 4510 SOE114-PO 3
Contental TM 27 33 - 41 1500 - 1800 950 C110-HP4 2 1/4

Cummins 5.9 33 - 49
1200 - 1800 964 SP111-HP3 2 1/4
56 - 84
66 - 99
Cummins 8.3 1200 - 1800 1480 SP111-HP3 2 1/4
79 - 118
Gemini G26P 8 - 22 600 - 1600 1350 C111-HP4 2 1/4
GM 4.3 l (262 ci) 35 - 52 1200 -1800 980 SP111-HP3 2 1/4
GM 5.7 I (350 ci) 48 - 71 1200 -1800 1080 SP111-HP3 2 1/4
GM 7.4 I (454 ci) 65 - 98 1200 - 1800 1225 SP111-HP3 2 1/4
GM 8.1 l (496 ci) 76 - 120 1200 - 1800 1390 SP111-HP3 2 1/4
Hercules G2300 33 - 57 1200 - 2400 950 SP111-HP31 2 1/4
Hercules G3400 52 - 98 1200 - 2400 1065 SP111-HP31 2 1/4
Kubota 16 6 - 16 300 - 1100 992 C108-HP4 1 3/4
Kubota 32 9 - 32 300 - 1100 1764 C110-HP4 2 1/4
Lister HR2 11 - 23 1000 - 1800 840 C108-HP4 1 3/4
Lister HR3 17 - 34 1000 - 1800 970 C108-HP4 1 3/4
1will also accept SP111-HP4, C111-HP3 or C111-HP4

30
 ®

Appendix H: Sucker Rod Specifications

Weatherford Rod
Rod Grade Physical Properties Maximum Recommended Torque
Tensile Yield
Sucker Rod COROD 13/16" 7/8" 1"* 1 1/8"
Strength Strength
1000 PSI 1000 PSI
MD56 - 115-140 85 Min - 700 1000 -
D - 115-140 85 Min - 750 1100 1600
KD63 - 115-140 85 Min - 700 1000 1500
T66/XD - 140-150 115 Min - 800 1200 1700
EL - N/A N/A - 1000 1500 2000
Weight, lbs / ft - - - - 2.22 2.90 3.68
- D Carbon Steel 115 Min 85 Min 500 640 955 -
- D Chrome Moly 115 Min 90 Min - 640 955 -
- D Chrome Moly Alloy 140 Min 110 Min - 900 1300 -
- Weight, lbs / ft - - 1.76 2.04 2.67 -

Norris Rod
Rod Grade Physical Properties Maximum Recommended Torque
Tensile Yield
Sucker Rod 7/8" 1"* 1 1/8" 1 1/4"** 1 1/2"
Strength Strength
1000 PSI 1000 PSI
54 115-140 90 Min 700 1000 - - -
75 120-140 90 Min 750 1100 1600 2100 3150
78 120-140 90 Min 700 1000 1500 2000 -
96 135-150 115 Min 800 1200 1700 - -
97 140-150 115 Min 800 1200 1700 2500 3750
Weight, lbs / ft - - 2.22 2.9 3.68 4.17 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 Piston (C1045), Norloy (8620)
Size 431 SS, 4140 Alloy
1 1/4" 1,800
1 1/2" 2,800

Specifications are subject to change without prior notice

31
Appendix I: Viscosity Charts

Dynamic Viscosity as a function of Temperature and Oil Grade

1000
ISO GRADE
32
46
68
100
Dynamic Viscosity (Cp)

150
220
320

100

10
-80 -60 -40 -20 0 20 40 60 80 100 120
Temperature (C)

Kinematic Viscosity as a function of Temperature and Oil Grade

1000
ISO GRADE
32
46
68
100
Kinematic Viscosity (cSt)

150
220
320

100

10
-80 -60 -40 -20 0 20 40 60 80 100 120
Temperature (C)

32
 ®

Appendix I: Viscosity Charts Cont.

Kinematic Viscosity as a function of Temperature and Crude Oil

1
KINEMATIC VISCOSITY, CENTISTOKES

Crude Oil
API Gravity

TEMPERATURE, DEGREES CELSIUS

33
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 Internal
Combustion Gas Engines for a period of 1500 hours (2 months) run time. Partnership warrants rotating stuffing boxes to be free
from defects in workmanship and material under normal use (not to exceed 500 rpm or 500 psi) 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.

34
Notes

35
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 2004 Weatherford • All rights reserved • ALS3049 • 0604/1000 • Printed in Canada