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Customer Info

2010

The Direct DriveHead and


The Smart Pumper

Direct DriveHead, Inc.


18000 Groeschke Road B-3
Houston, Texas 77084
www.directdrivehead.com
Tel: 281-829-5559
Fax: 281-578-0109

The Direct DriveHead with Smart Pumper Automation

I.

Executive Summary

II.

Development History
a. Problematic Issues of old style (belt & pulley) drive heads,
b. Design Changes that fixed the problems,
c. Field Testing, and
d. AUTOMATION which covers a production engineers wish list.

III. Deployment
a.

Operating the Direct DriveHead

b.

Maintenance of the Direct DriveHead

IV. Manufacturing Consortium behind the Direct DriveHead


a.

On-Time Completion and Delivery

b.

Quality / Made in the USA

c.

Factory Warranties

d.

Assembly & Testing

V. Technical Summary
VI. Operational Advantages
a.

Case Study 1

b.

Case Study 2

VII. Automation Testing Functionality and Reports


Exhibits:
Well Data Form to use to obtain a quote
DriveHead HP Sizing Graph Potential Volume over Depth
American Oil & Gas Reporter: New Technology Lifts Artificial Lift

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Executive Summary
The patented Direct DriveHead TM with automation known as the Smart Pumper TM
provides progressive cavity pump (PCP) users with the very best artificial lift system
possible for wells down to 6000 feet deep. See list of capabilities herein.
The Direct DriveHead design eliminated problematic issues related to old style belt
and pulley designs to provide users with a system that is more energy efficient, requires
less maintenance, and is easier and safer to use. The Direct DriveHead and
Progressive Cavity Pump represent a powerful and economic artificial lifts system for
most wells. Examples: pump oil 8 - 38 gravity; dewater gas wells, coal bed methane
applications (CBM), to pump heavy and light oil and more.
Pump from 1 to 1200 barrels per day with the Direct DriveHead depending on horse
power, depth and PCP geometry. Refer to the enclosed Direct DriveHead HP Model
Sizing Graph enclosed.
The Smart Pumper TM with its built-in web based two way communication has
eliminated the need to spend $10s of $1,000s of dollars on sophisticated scada systems
and the cost of engineers to set it up, third party communication specialists, plus other
surprises typical of scada installations because the Smart Pumper is preprogrammed,
self determining with communications built-in to provide users full access and control of
their wells as standard equipment.
The Smart Pumper TM automatically and continuously manages your pump speed to
achieve the fluid level you select, over a period of days you define, for a smooth draw
down to avoid common pumping problems and optimize production. Conduct a 24-48
hour build up test via the web by selecting your stop well button and then data log
down hole pressure over time. By using all 8 analog and 8 digital inputs, the user
can create a very SMART operation. Set warning and actionable responses to the
data log from 16 variables you can define over time like flow line pressure to detect
leaks and/or line blockage to plan maintenance and/or save the pump from excessive
pressure, fluid level (hole in tubing and/or pump wear), down-hole pressure, downhole temperature, casing pressure, metered gas and fluid flow, calculates pump
rate at given speeds (pump wear), line voltage, amps (parted rods), HP, KW, Torque
(sanding up), tank levels, and much more. Put 10 Direct DriveHeads into a single
field with The Smart Pumper TM and the collective power will enable you to data log
(monitor and control) 160 data points and control up to 20 digital switches in that field
from your desktop.
The Smart Pumper uses a Secure Web Interface Platform to Your File Server to
allow users to view entire field(s) in a list of wells form with status codes to help the
operator quickly prioritize daily field maintenance activity. Dig deeper into a selected
well of interest to review data logged on that particular well for analytical work. The
Smart Pumper provides you with instant messaging as faults and/or warnings occur.
See details of user defined capabilities below in the exhibit section.
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Development History
The Direct-Drive Drive-Head TM was developed out of the need to fix problems and
maintenance issues related to common belt and pulley style drive-heads.
Problematic Issues: If you have used belt and pulley drives in the past, most likely
youve encountered some of the following situations which commonly occur: The belts
slip and stretch and require constant readjustment and tightening to delay the
inevitable belt failure which often results in the pump becoming stuck. The load
bearing section of belt and pulley drive systems is located within the housing and
when the load bearing needs replacement, it requires a roustabout company to remove
the drive head from the well and send the entire unit to a machine shop. Anchoring
the drive head to prevent it from spinning up (if loose) on the well head causing
damage to electrical connections.
Design Changes: The direct-drive design eliminated the belts and pulleys,
positioned the load bearing section so it can be serviced in the field by the pumper,
incorporated the stuffing box and pumping tee into the housing which saves cost
and provides a means to simply anchor the Direct DriveHead into the casing head for
stabilization and greater safety. Solving these problems (2004) resulted in the creation
of the Direct DriveHead which requires less maintenance, proved to be energy efficient
and powerful. U.S. Patent No. 7 044 215B2 May 2006
Field testing: Field testing (20052008) was conducted in a very
difficult to produce sand laden
heavy oil field where the belt and
pulley drives often failed (Field:
Parrylands, Country: Trinidad).

2004
Prototype
in Trinidad

Automation: DDH automation is


referred herein as The Smart
Pumper TM. It was developed and
also field tested in the Parrylands
Heavy Oil Field to overcome the
2008 5HP
very difficult to produce / pumping
Factory Model
environment.
The associated
sand laden heavy crude was also very hard on the PCP which is a powerful pump that
can be used on any kind of well, including sand laden fluids, but will also fail due to
improper use. Accepted and used worldwide, the PCP like other rod pumps need
Continuous Fluid Level Monitoring to optimize production and protect it from dry
pumping. To accomplish this, the DDH team developed the Smart Pumper TM from a
production engineers wish list perspective and from hands-on experience. As a result,
user will find The Smart Pumper is very simple to use. It requires no programming,
has two way communications built-in and uses the web to provide users with
valuable data, alarms, warning, well and facility data and more.
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Today, it is recognized that The


Smart Pumper can also be
used to control and manage
any type of drive head made
regardless of maker, pump
jacks, salt water disposal
systems,
tank
transfer
facilities and more.
The
TM
Smart Pumper
field tested
and proven since 2007
(computer and software) is also
made in the USA. See more on
Smart Pumper below and use
your imagination on how else one
can utilize this solid and powerful
platform!

Deployment:

Over the past four years, eighty five (85) Direct DriveHeads have
been put into service in various areas. The areas include California, Indiana, Kansas,
New Mexico, Texas and Trinidad. The types of wells include those with light oil,
heavy oil, and dewater gas wells. Well depth has ranged from 1200 feet to 5500
feet. Thirty percent of the wells are vertical, seventy percent are highly deviated (3560 degrees) and 4 of the wells are horizontal. The horizontal wells have the PCP set in
the lateral section (at 90 degrees) and have run for 2 years without rod, tubing or pump
failure using a simple inexpensive rod guide that was found to work very effectively at
preventing rod/tubing wear. Also during this test period, none of the load bearings in
the field failed. See Bearing Housing a top of the Direct DriveHead Pictured Below.

Operation and Management of the DDH unit:

Once installed the Direct


DriveHead speed can be adjusted to match well bore inflow by two methods:
I. Manually Check Fluid Level and manually adjust the DDH speed to match inflow by
a. Using the VFD that is standard equipment to vary pump speed from 25-200%
b. Extend Pump Speed range by Gear Reduction from 14:1 to 9:1 to and/or,
II. Automation that manages pump speed to achieve targeted fluid levels; Simple to
use with Open Communication on a solid state platform that is preprogrammed.
(See Detail).

Maintenance and Special Features:

Using and Maintaining the Direct

DriveHead is simple..
The DDH electric motor, bearing section, and gear drive are off the shelf items provided
by leading US manufacturing companies. Greasing the electric motor periodically and
servicing and tightening the stuffing box are all that is required. The rest of the parts
require no servicing including the bearing section which is lubricated within and sealed.
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In addition, all parts including the load bearing section can be replaced by a single
person in the field without removing the drive head from the well. The DDH 5HP and
30HP units provide more than the necessary torque and speed to operate all of the PCP
pumps made in the world to deliver volumes handled by most PCPs.

Manufacturing Consortium:

The follow U.S. manufacturing companies are


behind the development and are supporting the growth of the Direct DriveHead:

Baldor Electric Company, Fort Smith, Arkansas (Primary Center)


Boston Gear, Quincy, Massachusetts
NTN Bearing Corporation, Mount Prospect, Illinois
MD TOTCO / National Oil Well Varco Austin, Texas
Skinner Brothers Co., Inc., Tulsa, Oklahoma.

(See DDH Company Backed List and Profiles within Exhibit Section Below

The strength of these companies have and will continue to provide major advantage to
Direct DriveHead in many ways. Here are three: 1. From advancing initial concept to
Delivering Factory Quality Units with Warranty, 2. The ability to quickly engineer
and enhance the Units per customer request and/or other and 3. The ability to meet
any demand (Scalable Supply & Assembly) for an on-time delivery of one to one
thousand units, with off the shelf spare parts available.

Assembly: The Direct DriveHeads are assembled, tested, and shipped from its
facility in Houston. DDH 12,000 square foot assembly facility is situated in Houston,
Texas in an ideal location for inexpensive global distribution of The Direct DriveHead
and PCPs. Trans-Ocean shipping cost of 40 Fully Assembled Automated Direct
DriveHeads with 40 PCPs to virtually any Country in the World is less than $8,000
per container ($200 per Drive + Pump). This price also includes the cost of buying the 40
seaworthy shipping container that can be used by the oil company making the purchase
as a field warehouse to protect supplies in remote oilfields. (DDH Weight +/-400# PCP
= +/- 200#).

Technical Summary: The original DDH configuration consisted of a frame with a


special configuration (built by NOV) powered by a 5HP A.C. motor connected to a doublereduction helical gear drive and/or right angle worm gear drive which transfers a
significant amount of torque to the polish rod to rotate the rod string. Torque capability
from the 5HP design may surprise some delivering up to 260+ ft-lbs of torque on a
continues basis. A person only needs 60 ft-lbs of toque to lift 60 barrels of fluid per day
from 6000 feet. A 30 HP configuration is also available.
(See HP Required to pump certain volumes from various depths within the Exhibit
Section Below).
A digital phase inverter / controller (VFD) is built into each DriveHead as standard
equipment to allows users to manually change the electric motor speed to control
pump speed as fluid levels rise and/or fall within the well bore. If coupled with The
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Smart Pumper, you have the most powerful Automation Solution possible that
you can see and control from the web.
In low volume wells, back spin tend to be less of a problem; however even a 5HP unit
can create and/or experience situations where it will occur. In these situations, the back
spin speed is reduced by the gear reducer (like pick-up in first gear transmission slows truck
when you cut the gas) and by activating an optional dynamic electronic breaking system
through one of DDHs VFD models. The gear drive is also interchangeable from 14:1 to
9:1 to provide additional speed range. On the 30HP motor a disc brake is used to
control back spin.
Built directly into the Direct DriveHead housing is a combination stuffing box and
pumping tee, which eliminated the need to buy a pumping tee and more importantly,
provides a means to anchor the unit to the surface head to prevent unit rotation on its
base (which has been a common problem to the old style drive heads).
The key innovative elements of the DDH design, for which a U.S. patent has been
received, are:
The vertical in-line and right angle gear drive configuration, which eliminated all
belts and pulleys associated with old style drive head between the electric
motor and rod string,
The adjustable pivoting back-plate, on which the motor and gear drive are
mounted, allowing for simple access to service and/or replace motors, gear
drives, and load bearings,
Load bearing section mounted on top of the housing versus within the
housing for simple and easy access for replacement without removing the drive
head from the wellhead.
Other key innovations by DDH for which it has patent pending status and claims
include:
A low profile right angle gear drive unit with hollow output shaft with the load
bearing built into the housing of the gear drive and,
A pump down the well PCP designs for dewatering CBM wells by injecting
fluids down into a lower horizon versus pumping to the surface for disposal later.

Operating Advantages:
Case Study 1: Comparison of the Direct DriveHead Operation against Traditional
Belt-and-Pulley PCP Drive Heads in Parrylands. See Table I Below for Results.
The impetus for this innovative design was operational problems with belt-and-pulley
PCP drive heads in a challenging oil field environment in Trinidad. The Parrylands Field
produces heavy oil from a loosely consolidated sandstone reservoir at variable
production rates. Although PCP are more than adequate to pump sediment-laden heavy
crudes (up to 50% sand), sudden variations in sediment content produce significant
changes in torque loading. The resulting wear on the belt-and-pulley drive was
exacerbated by slippage caused by torque spikes, heavy rains, in addition to normal
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wear caused by belt stretch and pulley misalignment. When the belt-and-pulley system
fails, a stationary PCP may become stuck, potentially requiring a workover rig and high
pressure pump to pull the tubing and strip out the rods.
E-182 Prod. Graph: Prototype Direct DriveHead Testing Started 3/2004. Unit moved to
E-237 on Jan. 08 to show case Factory Inline Version shown above. The prototype
was still pumping as of 12/09.

Belt Failure Stuck Pump


Direct DriveHead

E-182 in 08
Factory Model

Design and operational trials of the DDH in Parrylands are described in detail Society
of Petroleum Engineers Paper No. 93913 PP Boyles and Stinson April, (2005). Table
I illustrates operating efficiencies and cost savings gained by their introduction. Fieldwide replacement of traditional PCP drives with DDH is in progress.
Table I
Belt & Pulley versus Direct Drivehead
Well:

E182
Belt & Pully Drive
Additional Lease Cost Over Reg. Exp
LOE Cost
Ave. Daily Production by Bbls
3.5
Lost Days Due to Belt Failure
188
Lost Days Due Other
Lost Production
658 $ 23,030.00
BBL/Value
Cum test Production Bbls
476
Oil Price
$35
Belt Replacement & Labor
4 $ 1,000.00
Work Over Rig Days Required
2 $ 4,800.00
Stuck Pump
1
$
350.00
Cost & Labor for fluid level
6 $ 2,100.00
Shoot Fluid Levels & Adj Speed No. of Times
Days in Operation
136 324
41.98%
Total Additional Lease Operational Cost
$ 30,930.42

E182
Direct DriveHead
LOE Cost
5
0
5
25 $
875.00
1800

360 365

0
1 $ 2,400.00
1
0
6 $ 2,100.00
99%
$ 5,375.99

E181
Direct DriveHead
Plus Smart Pumper
8
0
0
0 $
2920
0
0
0
2190 $
365 365
$

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100%
-

Case Study 2:
Comparing DDH against Traditional Pumping Unit for Artificial Lift
The Walnut Oil Field, Los Angeles Basin, California, is a mature heavy oil field that has
been producing for two decades.
Lufkin 114 and 160 pump jacks powered by 25 hp electric motors (on timers) were
providing the artificial lift in this field.
The operator switched to the Direct DriveHead and PCP when the tubing pump wore
out and a rig was required. They realized a 50% reduction in electric consumption
immediately and the savings actually paid out the cost of the Direct DriveHead and PCP
over a 20 month period.
In addition, the operator sold their pump jacks as surplus equipment after they were
convinced they had a reliable alternative. The price they received for their D114 greatly
exceeded the cost of the Direct DriveHead. Two additional units have been installed
since the test. The Operator Team Resources states it will replace all of its pump
jacks in this field as the tubing pumps fail over time.
Photo shows two 5HP Direct DriveHeads in the Walnut Oil Field pumping the same
volume of oil as the two D160 Pump Jacks using 25HP motors with sinker bars.

Don Holcombe, Production Manager


Cell: 714-321-4306.

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The Automated Robotic Direct DriveHead TM


With its large processing & communications capability,

Can do the following for you too


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The Smart Pumper is fully automated system that eliminates the guess work associated
with well and lease operations that can lead to costly mistakes. Most production
engineers who manage low volume wells wish they could cost justify the automation
of their artificial lift system to maintain the fluid level at a given set point and record
valuable diagnostic information over time. Now they can.
The Smart Pumper TM Shown right item (5) is more than just a
monitoring and shut-off system to protect your pump. It is a
powerful computer that can in effect, digitize your entire oil field,
monitor and control multiple functions from each well site, data log
and deliver all key information needed to manage your entire oil
field from a central control room for decision making processes.

5.

2.

The Smart Pumper TM software automatically pumps your well to a


fluid level you select. Set and/or change the target from your
laptop at anytime. It will automatically maintain the level you set
over time without any interaction speeding up and/or slowing down
as reservoir and or pump condition changes.
Application: Use to control and monitor any Drive Head, PumpJacks, Salt Water Disposal Systems, Electric Submersible (ESP),
Tank Level Controls and more. It connects directly to any VFD for
total motor control or digital switch activation. Plugs into existing well(s) and facilities
and can quickly interface with existing SCADA systems (SQL format). VFD shown in
photo item (2).

Built-in two way communications allows changes to operating parameters from


anywhere in the world from a desk top or laptop computer authorized to do so.
The Smart Pumper TM data logs every aspect of your operation which over time creates
a powerful diagnostic tool to understand your well and other field operation aspects.
Users will see pump wear before the pumper, know the rods parted within minutes of
occurrence, and much more!
Web Interface enables one to make operational changes from your laptop without
going to the control room or well site and receive alarms and well information notices.
Open Communications with Web interface and user definable parameters.
Can emulate a control room scada system without the price tag or connect to one.
Two-Way Communication through Radio, Cell, or Satellite.
Definable 8 analog and 8 digital inputs. Definable alarms, faults, and warnings.
Define who receives notices.
Data Logging over Time:
Down Hole Pressure - Down Hole Temperature
Casing Pressure - Flow Line Pressure(s) - Separator PSI
Metered Gas and Fluid Rates
Electric Motor Parameters (Hertz, Voltage, Amps, Torque, HP, Temperature)
Tank Level(s) and more.
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Automation In Action and Reports:

Reports
Pump Speed / Time
Pump Output / Time
Metered Fluid / Time
Casing Flow / Time
Total Gas and Total Fluid
Fluid Above Pump / Time
Target Fluid Level / Time
Well Bore Fluid Level / Time
Down Hole Pressure / Time
Casing Pressure / Time
Flowline Pressure / Time
HP, Torque, KW, Hz / Time
Voltage / Time
Temp / Time and other
assignable values

Motor Speed
Over Same Time (Hz)

Production Rate
Over Same Time

Testing The Smart Pumper

TM

in 2007. As shown, it automatically manages operations and


motor speed while it determines fluid level to lower the level to the target you set. In the process, it
optimizes production while protecting your PCP. In this example, Operator selected a fluid level of 400
feet above the pump as their target. A year later, they lowered the target from their desktop.
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Introducing the Low Profile Direct DriveHead

Stands 40 above well-head


Fully Automated Smart Pumper
Two Way Communications
Metering fluid and gas flow
Monitor & Data Log
Down-Hole Pressure
Flow-line Monitoring
Casing Pressure
Tank Level
Tank Switching and more
Alarms with email notification

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The Direct DriveHead with Smart Pumper Automation

Please Use Well Data Form for Ordering:


Fax: 281-578-0109 and/or Email: info@directdrivehead.com

(page 1)

Client/Location Information
Contact
Name:
Company:
Address:
Address
(Line 2):
City:

State:

Zip:

Country:
Phone:

Fax:

Email
Address:
Confirm
Email
Address:

Well Completion Data


Field:
Casing
Size
(inch.):
Liner
Size
(inch.):
Perforation Depth (in ft.)

Well:

Weight:

Shoe @:

Weight:

Shoe @:

Top Perf:

Bottom
Perf:

Tubing
Size
(inch.):
Well Depth

Weight:

MD:

TVD, ft.;

Well Location
Onshore:

Offshore:

Production Data
Pump Setting Depth
Ft.:

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The Direct DriveHead with Smart Pumper Automation

Please Use Well Data Form for Ordering:


Fax: 281-578-0109 and/or Email: info@directdrivehead.com

(page 2)

Current Flow Rate


BFPD:

H20 Cut %:

Producing GOR
CuFt/bbl:
Static Fluid Level
Ft.:
Well Head Pressure
PSI:

Fluid Property Data


Oil
Gravity:

API

Viscosity
cPo @

F @ Formation

Water
Specific Gravity:

g/cc

Design Requirements
Design Flow Rate:

BFPD

Desired Pump Setting Depth:

Ft.

Power Supply Available:

Voltage

Single or 3 Phase:

Other Data
Sand Content:

Paraffin:

H2S Content:

Other:

Comments/Questions

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