Progressive Cavity Pumps: Training Guide

Progressive Cavity
Pumps
Training Guide
Lufkin Automation
11375 W. Sam Houston Parkway South, Suite 800
Houston, Texas 77031
Tel: 281.495.1100 Fax: 281.495.6333
E-mail: lufkauto@lufkin.com
IMPORTANT
READ THIS NOTICE BEFORE USING THIS PRODUCT
Information in this document is subject to change without notice
and does not represent a commitment on the part of LUFKIN
AUTOMATION.
No part of this manual may be reproduced or transmitted in any
form or by any means, electronic or mechanical, including
photocopying and recording, for any purpose other than the
purchaser's personal use without the written permission of LUFKIN
AUTOMATION.
All trademarks are the property of their respective owners and are used for
explanation purposes only with no intent to infringe.
Copyright Lufkin Automation, Inc., 2003
Part No. 099.5510
Table of Contents
1
About This Training Module............................................................................1
Overview about Progressive Cavity Pumps....................................................2

2.1
Rotor Component...................................................................................5
2.2
Stator Component..................................................................................7
2.3
Elastomers..............................................................................................8
2.4
Interference..........................................................................................10
Critical Factors for Specifying and Operating a PCP System.......................11
PCP Advantages and Disadvantages...........................................................14
Copyright 2003, Lufkin Automation
iii
Progressive Cavity Pumps Training Guide
1 About This Training Module

Introduction
Knowledge of the correct progressive cavity pump (PCP) is

important criteria that you need to know for achieving costeffective fluid lift and avoid costly premature repair and
replacement.
What You
Will Learn
In this module you will learn about:
The components making up a PCP system
Critical factors for designing and operating a PCP system
Advantages and disadvantage of using a PCP
2 Overview about Progressive Cavity Pumps

Introduction
A progressive cavity pump (PCP) is a simple two-part pump

consisting of a rotor and a stator. The rotor is a metal singlehelix that rotates within an elastomer double-helix stator. Figure
1 is an example.
Figure 1. Progressive Cavity Pump
This system is sometimes known as a Moineaux pump, which is

named after its inventor.
Performance
The PCP creates a moving cavity that acts as a positive

displacement pump. Actual performance is positive
displacement within specified pressure limits.
Figure 2 illustrates some pump performance data.
Overview about Progressive Cavity Pumps (continued)

Performance
(continued
Figure 2. PCP Performance Data
Displacement Pump displacement is the volume generated at open flow by a

complete turn of the rotor. It is equal to the volume of two
cavities.
Displacement is positive because the cavities are sealed from
each other. No backpressure is exerted on the pump.
Cavity length (stator pitch) is the minimum length required for a
pump to create effective pumping action. In a shorter pump,
each cavity opens simultaneously at both ends some time
during the cycle of the rotor.
A minimum length pump is equal to two rotor pitches, which
constitutes a stage. This is similar to an elementary pump, which
generates a certain pressure differential between suction and
discharge.
Overview about Progressive Cavity Pumps (continued)

Technical
Advances
PCP technology is old, but it has undergone major technological

advances in the last 20 years, especially to satisfy oil field
needs. Some of the advances include:
Higher pressure ratings
Greater depth ability due to longer lengths/additional stages
Better ability to handle higher temperatures, sand, and light

oil
Improved elastomers
Multiple Uses New uses for PCP technology have come one the scene over
the last few years. This pump is now used for:
Current
Applications
Heavy oil production (primary use)
Dewatering in coal degasification projects
Shallow light oil extraction
High water cut applications
Current applications are tubing PCP with rotor-on-rod and statoron-tubing.

Lower volume applications (such as for heavy oil production)
can be insert-rod.
Drive
Systems
Two drive systems are available.
Low-speed, high-torque hydraulic or electric drive, which are

used for heavy oil
High-speed, lower-torque gear reducers, which are used for

light oil. The prime mover can be either electric motor or gas
engine.
The pump can be driven by guided conventional sucker rod or

by round-continuous sucker rod.
2.1 Rotor Component

Overview
The rotor (see Figure 1 on page 2) is a continuous helix made

from a single piece of steel that is chrome plated. One of the
extremities is fitted with an API male thread for connection to the
rod string.
The external diameter of the PCP is limited, and therefore it
must conform to the drift diameter of the well casing.
The high heads that oil well pumps must overcome to lift well
fluid to the surface require large numbers of stages (i.e., pumps
of great length). This length is limited only by the manufacturing
facilities.
Available
Sizes
Several rotor diameters are available for each pump model,

usually up to 14 of slightly different diameters. These diameter
ranges, combined with various chrome thicknesses, make it
possible to provide fine adjustments for interferences.
Length is usually limited by the length of the commercial steel
bars available. Currently, they are machined to a maximum
length (including the head and thread) of 30.3 ft (9.25 m).
In all pump models the total rotor length exceeds the length of
the stator by 1.5 ft (45 to 50 cm). When the rotor is correctly
spaced out, this is the length of the rotor head, which must jut
out from the stator.
Drive System
The rotor is driven from the surface, usually through a sucker

rod string. The drive system does not need any universal joint
because the drive string provides the flexibility required between
the rotor and drive shaft at the surface.
Pump performance is limited, among other factors, by the torque
capacity of the drive string.
Note Most PCP systems for oil wells have their drive system at
the surface. However, another design exists that has a
drive system consisting of a downhole electrosubmersible motor. It is called an electro-submersible
PCP (ESPCP).
Rotor Component (continued)

Manufacturing The rotor is machined with a special lathe from a cylindrical
high-strength steel bar.
After it is machined, it is plated with a hard metal (usually
chrome) through an electro-chemical process.
2.2 Stator Component

Overview
The stator (see Figure 1 on page 2) is the housing for the rotor.
Available
Sizes
Only one stator size is manufactured for each pump model.

Stators are symmetrical, and manufactured in three-meter
elements maximum. They have the same male thread at each
end, and are connected with couplings.
They are connected with great care and precision in the factory.
Pump models longer than three meters have stators made of 2,
3, 4, or 5 elements.
Note Torque must not be applied to any of the couplings under
any circumstances.
Manufacturing A stator is manufactured by injecting an elastomer (see page 8)

under high temperature and pressure between a steel pipe and
a core. The core is similar to a two-lobe rotor with a profile that
is negative to the stator inner profile.
Before the elastomer is injected, the inner surface of the steel
pipe is coated with a special adhesive.
After the elastomer is vulcanized, it is allowed to cool and
shrink, and then the core can be removed. The amount of
shrinkage depends on the type of elastomer.
2.3 Elastomers
Overview
Elastomers are the material used for constructing the stator.

They are the heart of the PCP because they are the internal
profile of the stator.
Resilience
Properties
This material is used because of its resilience properties. It

combines elasticity and resistance to deformation. This property
is also called memory.
Its characteristics make it possible to design pumps with an
interference fit between the rotor and stator. This interference
provides the watertight seal needed between the cavities, and
therefore, the head rating of the pump.
Factors
Adversely
Affecting
Elastomers
Elastomers are made of materials that undergo adverse

changes when exposed to certain wellbore fluid characteristics,
and physical and chemical agents.
Wellbore fluid characteristics include:
Oil gravity
Water cut
Gas/liquid ratio at pump level
Temperature at pump level
Physical or chemical agents include:
Abrasive particles, such as sand
Aggressive agents, such as aromatics (benzene, xylene,

toluene, CO2, and H2S
Note Determining the characteristics and agents at the well is a

critical step required before designing a PCP system.
Elastomers (continued)
Changes
Elastomers
Undergo
When
Exposed to
Adverse
Factors
The most common adverse changes elastomers can undergo

include:
Swelling, resulting in excessive interference that overheats

the elastomer and causes excessive torque in the rod string
Hardening, resulting in resilience loss, which shortens pump

life
Softening, resulting in deterioration of the seal between the

cavities, which drops head rating
Note High temperatures make all these changes more

adverse.
2.4 Interference
Overview
The interference between the rotor and stator is an important

paramount regarding the efficiency and life of the PCP.
Insufficient
and
Excessive
Interference
Insufficient interference can cause excessive slippage, which

leads to poor pump performance.
Affects of
Temperature
and Aromatic
Components
Interference is always higher downhole than it is at the surface,

because of higher temperatures and the presence of aromatic
components in the crude.
Optimizing
Performance
Excessive interference can result in overheating and

deterioration of the elastomer, overtorquing of the rod string, and
reduced useful pump life.
Increased temperature causes thermal expansion of the

elastomer
Aromatics cause swelling of the elastomer
In order to optimize pump performance and pump life, it is

essential to evaluate how much interference is increased
between the surface and downhole conditions. Accurate
evaluation requires precise knowledge about downhole
temperature and well fluid composition.
Adjusting interference at the surface is possible in order to have
the PCP adequately sized under downhole conditions. Making
use of the range of rotor diameters and/or chrome thicknesses
will adjust interference.
10
3 Critical Factors for Specifying and Operating a PCP

System
Most
Important
Factors
Two of the most important factors that must be considered when

designing a PCP system are:
Determining the pressure differential that develops across

the pump, which determines the number of stages in the
pump
Calculating the required flow rate of the fluid, which affects

the model number (size) of the pump
Pressure
The pump pressure requirement consists of two components.
Requirements
Hydrostatic head, which is determined by tubing length, flow
line pressure, fluid level, API fluid gravity.
Flow Rate
Friction losses, which are influenced by tubing ID, coupling

OD, fluid viscosity, rod OD, and production rate.
Flow rate is the volume of liquid displaced per day at zero head
(open flow). It is expressed in m3/d or bpd.
Liquid volume depends on two parameters.
Pump displacement, usually given in cc
Pump speed, given in rpm
11
Critical Factors for Specifying and Operating a PCP

System (continued)
Method for
Determining
Flow Rate
Flow rate is equal to the displacement multiplied by the number

of turns of the rotor per day (d).
Displacement can be calculated using three parameters.
D = Diameter of rotor
E = Eccentricity of pump
P = Pitch of stator
From the cross sections of the pump shown in Figure 3, notice

that the fluid area is equal to 4DE. For each turn of the rotor, the
fluid progresses a distance equal to P. Therefore, the
displacement is equal to 4 DEP.
Figure 3. Elements and Parameters of a PCP
12
Critical Factors for Specifying and Operating a PCP

System (continued)
Flow Rate
Calculation
Example
Given Data
D = 3.5 cm
E = 0.8 cm
P = 30.0 cm
Pump speed = 350 rpm
Solution
Displacement = 4DEP = 336 cm3
Number of rotor turns per day = 350 1,440 (number of

minutes per day) = 504,000
Flow rate = 336 504,000 cm3/d = 169.3 m3/d = 1,065 bpd
13
4 PCP Advantages and Disadvantages

Advantages
Below are some of the advantages of using PCPs.
Low capital cost. It is an inexpensive method for bringing on

primary production. In heavy oil, it is typically installed even
when a conventional beam pump will be required in a future
thermal phase. PCPs require minimal surface preparation,
because the drive unit is mounted on the wellhead, and can
include a variable speed electric motor as a prime mover.
Typically hydraulic power packs are skid-mounted and can
drive multiple wells.
Operating efficiency is as good or better than standard API

pumps.
No cyclical rod stretch.
Production limitations due to rod fall in heavy oil

applications are eliminated.
Wide turndown range is available so that the pumping rate

can be matched to the production rate through speed
control.
High tolerance to sand. PCPs have performed with sand

cuts exceeding 50 percent.
Easy maintenance because the pump can be pulled and

replaced while the original is sent out for testing and repair.
Insert PCPs with continuous rod can be pulled and rerun in
hours. Surface unit repairs are simple and do not require a
crane or large crew.
Pump operation is independent of horizontal/vertical

orientation.
Disadvantages Below are some of the disadvantages of using PCPs.
Maximum operating temperature is 350 F (180 C).
Some light oils cause some elastomers to swell.
14
PCP Advantages and Disadvantages (continued)

Disadvantages
(continued)
Higher pump repair costs than for conventional API pumps.

Not tolerant to pump off conditions. Lubrication is required,
and if a well is pumped off or significant gas is in the pump,
the elastomer can be damaged.
15

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Progressive Cavity

Copyright Lufkin Automation, Inc., 2003

Part No. 099.5510

About This Training Module............................................................................1

Overview about Progressive Cavity Pumps....................................................2

Critical Factors for Specifying and Operating a PCP System.......................11

PCP Advantages and Disadvantages...........................................................14

Copyright 2003, Lufkin Automation