SPE-181142-MS

Successful Application of Root Cause Analysis on Progressive Cavity

Pumps Failures in Orinoco Oil Belt

Sara V. Rangel, Algimar S. Delgado, Micksu J. Han, Isaac B. Gamez, Sandra K. Rosales, and Robert A. Morety,
Petropiar; Jhonatan A. Pereira, INTEVEP

Copyright 2016, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Latin America and Caribbean Heavy and Extra Heavy Oil Conference held in Lima, Peru, 19-20 October 2016.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
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consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
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Abstract
Huyapari Field, located in the Orinoco Oil Belt is operated by PETROPIAR, a joint venture between PDVSA
and Chevron, where over 600 horizontal wells have been perforated and completed with progressive cavity
pumps (PCP) as the preferred artificial lift method to produce extra heavy oil. With the objective to identify
and address the main causes of failure affecting PCPs run life and performance, high repair costs as well as
lost production, Root Cause Analysis (RCA) is currently being implemented, giving outstanding benefits
by involving both suppliers and customers in a continuous improvement and learning experience.
Between 2003 and 2011, PCP run life was 884 days on average. In 2012, this number decreased
dramatically to 306 days with no changes in the reservoir characteristics besides normal depletion. Between
2012 and 2013, 74% of installed PCPs failed before reaching one year in operation, with an average run
life of 162 days. Deferred production increased significantly and annual operational expenses duplicated,
mostly because of PCP replacements.
In response, Petropiar began in 2013 a joint effort with six manufacturers to review the process involving
PCPs selection, design, simulation, transportation, storage, installation, operation, monitoring, diagnostic
and pulling. To date, more than 100 pumps have been analyzed applying RCA and including: borescope
inspection, destructive analysis, hardness measurement, simulation and review of operating conditions,
production history, pump installation & pull out reports, wellbore geometry among others.
The procedure for carrying out this RCA experience and implementing lessons learned is presented in this
paper, including identification of various manufacturing quality issues for which, specific tests were put in
place to evaluate key characteristics like bonding for example. Quality controls requirements were revisited
and elastomers compatibility tests were included as part of the procurement process. On the other hand, new
non-conventional technologies have been applied to meet challenging conditions to produce extra heavy oil
with high gas production. PCP run life increased by 56% while failures on PCPs with less than 365 days
run life decreased by 31% when compared with previous years.
2 SPE-181142-MS

Introduction
The Orinoco Oil Belt has approximately 50,000 km2 of the East Venezuela Basin Province that is under laid
by more than 1 trillion barrels of heavy oil-in-place. The area has been divided in 4 zones for exploration
and production purposes named Boyacá, Junín, Ayacucho and Carabobo (Fig. 1). Huyapari Field (Ayacucho
area) produces extra heavy crude oil, located Orinoco Belt southeastern Venezuela. The field is operated by
Petropiar. SA, an association between Petroleos de Venezuela S.A. (PDVSA) and Chevron.

Figure 1—Location of Huyupari Field, Venezuela

Petropiar is one of the four major projects of production of heavy crude oil currently operating in the
Orinoco Oil Belt. The reservoir presents sands with a stacked channel sequence, deposited in an upper delta
plain. In addition, it presents a mechanism of production mainly through gas expansion in solution with
heavy crude deposits in unconsolidated sands.
Produced fluids have a gravity in a range between 7.5 and 9.5 °API, Gas Oil Ratio (GOR) between 80 and
2500 scf/STB, vertical depth around 850 m and viscosities from 2000 to 4000 cP at reservoir conditions.
Extra-heavy crude has a foamy performance, with great amount of gas in solution at atmospheric conditions.
After more than 10 years of intensive production programs, Huyapari Field has more than 600 horizontals
wells distributed in 50 pads. Current production is around 150,000 bopd. Since the start of production of
the Huyapari Field, by PDVSA in 2001, the only artificial lift method which is being used for oil extraction
is progressing cavity pumping (PCP). All wells are completed with bottom-hole pressure and temperature
sensors and are monitored real time.
The collection production system of the field is closed and uses twin screw multiphase pumps to transfer
fluid from well pads to Bare Operational Center (COB) for treatment, measurement and pumping to an
upgrader facility. To facilitate the transport of heavy oil, a dilution process is performed at the production
header on each well pad, to reduce its viscosity. This process is done by mixing with naphtha with a density
between 40° and 60° API from the upgrader plant, which is distributed to the field through an independent
diluent network.

Description of problem
Since Petropiar began to operate in 2001 until 2011, the average run life of pumps was 866 days, reaching a
maximum of 1105 days in 2006 and decreasing to a minimum of 306 days, six years later (Fig. 2). During the
first ten years of production, the maximum quantity of failures recorded per year was 183 pumps in 2011;
SPE-181142-MS 3

from which, 42% occurred with less than 365 days on operation, which is pump warranty time. However,
in previous years, only 20% of pumps failed with less than one year in well.

Figure 2—Historic of PCP failures in Huyapari Field

In 2012, a total of 374 pumps failed, more than double that of previous year. From these, 74% occurred
during period of warranty, with an average run life of 139 days. It meant a well repair frequency of 2.6
interventions per year. As a result, repair costs duplicated and deferred production was 3.6 million barrels
per year.
In response to these alarming numbers, in 2013, Petropiar began a joint effort with six vendors to
determine root cause of pump failures with less than 365 days run life (warranty period). Ever since, a total
of 103 pumps has been submitted to analysis. This paper shows results of 77 root cause analysis (RCA)
completed at moment.

Workflow Root Cause Analysis (RCA) of Pump Failures

Root cause analysis (RCA) investigates and determines the factors that affect pump performance and causes
its failure. It corresponds to inspection grade 3 (failure investigation), according to ISO 15136. The objective
is to take actions to avoid the same failure to occur again in the future and to increase run time of next
equipment installed, saving in repair costs and reducing oil production lost.
On the basis of lessons learned, the RCA process was improving with time to increase quantity of pumps
submitted to teardown analysis. Fig. 3 shows all process, as is done nowadays. This is a multidisciplinary
activity that requires participation of: optimization engineers, workover team, manufacturers and storage
department. In 2013, with increase of pump failures, Petropiar organized a RCA team as part of optimization
engineering department, to follow the process with all manufacturers involved and to guaranty analysis of
most quantity possible of pumps.
4 SPE-181142-MS

Figure 3—Flow Chart of Root Cause Analysis Process

SPE-181142-MS 5

RCA process divides in three (03) stages:

Progressive Cavity Pump Preparation. Once optimization engineer confirms no production of a well
because of pump failure and it is in warranty (run life less than 365 days), begin the process to collect all
evidence to determine factors that possibly caused failure.
Initially, the engineer asks pump preparation for next analysis, to workover team. It means to contact
vendor prior to pull it, to clean the remaining oil inside stator, to tie rotor with stator and to identify it with
well name, date of extraction and pump manufacturer and model.
As soon as the pump is at surface, the vendor's technician visually inspects the rotor, stator, tag bar and
torque anchor. This inspection includes introducing borescope (Fig. 4) along the entire length of the stator
to visually inspect the interior surface of the elastomer.

Figure 4—Boroscope Record

Vendor technician describes in the pull out report all observations about the condition of the elastomer
along stator, results of borescope inspection, using failure descriptors indicated in table 1 and 2 and
specifying severity and location of damages. To facilitate visual identification at storage area, Petropiar
designated a color for each vendor to paint on a little area of the stator while it is still on the pad.

Table 1—Rotor condition inspection results (From: ISO 15316-12009)

6 SPE-181142-MS

Table 2—Stator condition inspection results (From: ISO 15316-12009)

Preliminary failure report (non – destructive analysis). As part of RCA, optimization engineer completes
a preliminary failure report (Fig. 5), specifically designed by / for Petropiar, according to its operation and
production conditions. This report includes 33 simple questions with yes/no answers to help make decisions.

Figure 5—Preliminary Failure Report

SPE-181142-MS 7

This report includes:

• Photographs of pump: Before moving the pump from the well pad to storage at COB, optimization
engineer takes pictures of equipment (Fig. 6) including stator, rotor, torque anchor, perforated joint,
rods, tubing and connections.

Figure 6—Visual inspection of equipment

Optimization engineer register rotor, stator and tag bar inspection results as shown in Tables 1 and 2,
respectively. He also registers condition of tubing, rods (body and couplings) and torque anchor and if
applicable, takes samples of sand from blind plug for future granulometric analysis.

• Revision of operational variables: it consists of reviewing the following parameters during

operation period: pump velocity, torque, bottom-hole temperature, pump intake, discharge and
tubing pressure. At this stage, engineer evaluates: changes of velocity, variations of torque to
constant velocity, pump submergence, variations of tubing pressure (wellhead pressurization),
increase or reduction of bottom hole pressure, frequency and causes of stops. Failure report includes
a graph of these variables during period of pump operation (Fig. 7).
• History of production: it comprises review of volume of gas produced, Gas Oil Relationship
(GOR), water cut, apparent volumetric efficiency and optimal operating velocity (at which major
oil rate is obtained with less gas rate). Failure report includes a graph of well production history
(Fig. 8).
• Survey and geometry: generally, engineer selects the pump installation depth between top and
base of tangent zone, where dog leg severity is near 1 °/100 ft. Sometimes in order to gain
submergence, the pump is located below the base of the tangent. Because of that, inclination, DLS
and pump depth are reviewed.
• Simulation of well condition: it is well known that free gas directly affects pump performance. To
determine gas volumetric fraction inside the pump, it is necessary to evaluate whether the pump was
operating in an unfavorable condition that accelerated failure. This analysis includes simulation
with specialized software to also review tubing/rod contact, annular gas separation and volumetric
efficiency.
• Installation report: The revision of installation procedures and elements of completion string is
necessary to support root cause analysis.
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• Pull out report: As part of non-destructive analysis, engineer reviews the report of detailed stator
inspection done with borescope. This report helps identify failure modes that couldn't be visualized
by external inspection of stator.

Figure 7—Example of operation variables behavior

Figure 8—Example of history of well production

The result is a preliminary report in which optimization engineer identifies cause of failure. This contains
well information and pump data showed in Fig 5. In this report, conditions considered unfavorable for pump
performance are automatically highlighted in yellow color. Engineer writes any additional comment in the
comments section.
In some cases, it is impossible for the engineer to determine root cause or contributing factors of failure,
with only available well information; then failure cause is considered "unknown" until a complete teardown
analysis is performed.
Teardown analysis. After the pump has been inspected at the wellsite by the vendor, it is transported to
warranty pumps storage of Petropiar (Fig. 09.b). Here, each rack is identified with a color that previously
SPE-181142-MS 9

was assigned to each manufacturer. This is the same color that each vendor uses to identify pumps inspected
immediately after being pulled.
Before adding these visual controls, storekeeper located all pumps (including pumps that weren't in
warranty) at the same place (Fig. 09.a). With the increase of pumps premature failures from 2012, initial
condition of warranty pumps storage made it difficult to identify and select candidates for teardown analysis.
Reorganization of storage in 2014 increased the number of pumps submitted to RCA, minimizing time
locating pumps and ensuring a systematic follow up of pumps analysis.

Figure 9—Warranty pumps storage

After identifying pumps in warranty pump storage, RCA team coordinates with vendor to move them. The
rotor is visually inspected (Fig. 10) and photographed, using descriptors from table 1 to record observations
in body, coating, weld and coupling.

Figure 10—Inspection visual of rotor

In accordance to ISO 15136, manufacturer cut the stator in three or more transversal and longitudinal
sections in top, middle and bottom (Fig. 11), to expose the elastomer. RCA team and vendor register
failure modes observed using descriptors from table 2, and take photographs of any feature with a detailed
description of the location of the feature in the stator; manufacturer include these pictures in the failure
report.
10 SPE-181142-MS

Figure 11—PCP Teardown Analysis

The pump supplier along with the RCA team does at least three measurements of elastomer hardness
(Shore A) on the cut surface, seal lines and major diameters on each slabbed section (Fig. 12). These
measurements are compared with the nominal material parameters for the specific elastomer type, to
determine whether elastomer hardened (hysteresis), swelled or maintained its properties.

Figure 12—Measurement of elastomer hardness – electronic hardness meter

As part of investigation, the RCA team sends to vendor all data and necessary information to prepare a
complete failure report, which should include at a minimum:
– Basic Information: well name, pump model, serial number, installation and failure date.
– Graph of operational variables behavior (period of pump running).
– History of well production: oil, water, gas and sand cut (period of pump running).
– Survey.
– Completion diagram corresponding to analyzed pump.
– Well simulation with a specific PCP software to calculate free gas at pump intake.
– Pump installation report.
– Pump pull out report (boroscope).
– Photography of rotor and stator cross-section with its respective mode failure descriptors (top, middle
and bottom).
– Root cause of failure and possible contributor factors.
SPE-181142-MS 11

– Recommendations to increase equipment run life in the future.

– Applicability or not of guaranty.
Whether the root cause is associated to manufacturing problem, provider must replace pump and initiate
an investigation to determine and correct specific mistake during fabrication process, to warranty this failure
won't happen again in future. Depending of primary failure, this may require specific tests like hot push out
test, ultrasonic analysis and/or electronic microscopies.
If pump warranty doesn't apply, optimization engineers meet to review and discuss results of failure
analysis. At this point, Petropiar could ask supplier a review of quality control documentation. If the
problems during manufacturing process caused pump failure, before one year of operation, then as it
explained above, equipment must be replaced.
For each case, optimization engineer, RCA team and vendor generates recommendations and propose
improvement to increase pumps run life and to minimize frequency of pump premature failures. To control
the process and to monitor improvements application, engineers save all information obtained from RCA
in a failure pumps database and generate the following monthly metrics:

• Mean time to failure (MTTF):

• Recurrent index:

• Failure index:

• Average run life:

Results and Improvements

Results obtained after applying RCA, divided in two parts, depending of element primarily affected:
Rotor Failures. Visual inspection of equipment at Petropiar storage, before being installed allowed
the identification of 18 rotors from two vendors with fabrication problems. Replacement of these rotors
represented to suppliers a total cost of $329,450.
Fig. 13 show defects found in seven rotors from pump manufacturer I. Fig. 13a showed different damages
at coating, such as: partial chrome loss, cracking and pitting. In addition, 11 rotors of pump manufacturer
II (Fig. 13b) also showed pitting, corrosion and irregular surface at hydraulic regulators.
12 SPE-181142-MS

Figure 13—Types of damage observed in visual inspection of new rotors

Vendor I sent damaged rotors to factory plant lab to identify and determine root cause of problem means of
physical – chemical analysis, including inspection by penetrating fluids, visual and stereoscopic inspection,
microstructural analysis, corrosive test and hardness test.
In general, rotors showed high degree of microstructural discontinuities in chrome: micro voids
and macro cracks (Fig. 14). Base material did not present macro fissures or discontinuities. Chemical
composition in cracked areas resulted similar to surfaces not cracked. In the same way hardness of all rotors
was in expected range.

Figure 14—Macro cracks and micro voids in chrome surface

Microstructural discontinuities on chrome coating, originated during electrodeposition process

(chromed) and polished (post-chromed) were the factor that primary affected integrity of rotors, because of
SPE-181142-MS 13

these reduced corrosion resistance of coating. Rotors were stored outdoor, exposed to rain, wet and direct
sun; unfavorable conditions that also contributed to damage.
From these results, manufacturer I began to apply the highest level of quality control (Q1) for rotors,
in accordance with ISO 15136, which requires inspection of 100% of equipment, including rotor coating
testing (thickness, surface finish and coupon hardness) and radiographic or ultrasonic examination. The
vendors also began to cover rotors surface with corrosion inhibitor.
On the other hand, manufacturer II duplicated visual quality controls, trained workers about the
importance of these inspections as well as automatic polishing and appropriate greasing to prevent premature
corrosion of rotor.
After replacement of damaged rotors, Petropiar requests realization of pump bench tests with new rotors
to warrant an adequate fit.
Stator Failures - Teardown analysis. Fig. 15 shows distribution of root causes obtained after completing
RCA of 77 warranty pumps (run life less than 365 days). 56% of failures occurred because of free gas (high
GOR), representing first cause of pump letdown, followed by manufacturing problems with 36%. The 8%
remaining are distributed between mistakes during installation process, normal / expected wear and tear
and sand.

Figure 15—Distribution of root cause of PCP Failures

Considering, free gas and manufacturing issues are two main failure causes, with an impact of 92%. They
are detailed below:
1. Free gas: pump failure modes because of high free gas were: gas permissivity / explosive
decompression, hysteresis, run dry and bond failure. As it is observed in Fig. 16, for study cases,
elastomer resulted burned, blistered, torn, hardened and debonded.
According to simulation, in these wells, free gas is between 51-81%, with an average of 65%.
Because of permeability of elastomer, gas infiltrates into its matrix and expands when a pressure
drop occurs (e.g. shut down or overpressure in wellhead), resulting in explosive decompression. This
14 SPE-181142-MS

generates tear (Fig. 16.d) and blisters / bubbles (Fig. 16.a) within the elastomer. In some cases, gas
migrates through metal – elastomer interface causing severe debonding (Fig. 16.e).
In wells with highest gas content, hysteresis occurs because of pump internal heating as result of
lack of lubrication rotor – elastomer. This increase of temperature leads to elastomer hardening (Fig.
16.b), changes in its mechanicals properties and in some cases burned elastomer (Fig. 16.c).
From these results, Petropiar took the following actions:
a. To try progressive cavity pumps especially designed to produce oil wells with high free gas
content (more than 50%). This includes acquisition of charge pumps to separate gas to annular
and installation of hydraulically regulated pumps (HRPCP) to handle free gas throughout the
pump. These two types of equipment were installed in repeat failure wells caused by gas. Today,
a total of 21 charge pumps and 15 HRPCPs have been successfully installed.
b. To manufacture and to install bottom hole gas separators. Nowadays, 11 wells with gas
separators below the pump are operating in Huyapari Field.
c. To reduce one size of rotors in order to reduce interference and increase back flow so as to
minimize hysteresis. This requirement will be made to vendors in next procurement processes.
2. Manufacturing problems: This originated from three different specific causes (Fig. 17), that will
be detailed below:
a. Quality control: 36% of pump failures attributed to manufacturing problems, specifically
because of a poor quality control. Vendor that presented this problem (Vendor A), installed in
Petropiar a total of 107 pumps between 2013 and 2014, 40% failed under warranty with 191
days average run life. The 60% remaining have an average run life of 740 days, being currently
one of pump suppliers with longer average run life in Huyapari Field.
From this vendor, 13 pumps that failed prematurely were analyzed. They showed tear, cracks
and debonding (Fig. 18). As product of RCA, vendor assumed manufacturing problems as cause
of failure of 10 pumps, replacing them in response to warranty claim. This represents $501,029.
However, this means only 30% of all associated costs; another 70% corresponding to deferred
production and cost for workover service is assumed by client (table 1).
Based on these results, Petropiar decision was to ask all vendors, as requirement to participate
in procurement process, documentation corresponding to highest level of quality control (Q1),
according to ISO 15316. Additionally, each pump model offered must have at least three
successful applications in Huyapari field before its use could be expanded.
b. Fabrication problem (debonding): Between 2014 and 2015, 96% of pump failures from
Vendor B, occurred with less than 1 year running. In consequence, Petropiar lost a total of $4.5
million due to repair, deferred production and equipment costs (Table 4).
Cuts done to eight pumps from this manufacturer showed elastomer debonding along the
stator. Fig. 19 shows an example of elastomer debonding from intake to discharge in a pump
with only 39 days operating. Average run life of these failed pumps was 99 days and GOR of
wells where they were installed was 310 SCF/STB on average. Base on this analysis, provider
recognized the manufacturing issues and went on to replace all PCPs submitted to RCA, with
a total cost of $286,840.
As result of RCA, in May 2015, Petropiar stopped usage of 191 new pumps from this vendor.
This represented 48% of its inventory. These pumps were examined in two ways to determine
percentage of equipment with debonding problems. First part of analysis was nondestructive and
it consisted of evaluating seven pumps with ultrasound to determine adhesion absence between
elastomer and housing.
SPE-181142-MS 15

Ultrasound technique consists in the aplication of high frequency sound waves. Those
frequencies ranged from 200,000 until 25,000,000 cycles per second (200 kHz to 25 MHz).
It was used test system by pulse, which is emission of short duration ultrasonic pulses with a
defined frequency.
Results of ultrasound examination showed that 46% of selected population presented areas
distributed in different PCP sectors (bottom, middle and top) without adhesion of less than 6
mm of diameter. Fig 20 shows multiples echoes generated in section with adhesion (Fig.20a)
and without adhesion (Fig. 20b).
Second part of analysis consisted to evaluate 12 pumps by means of hot push out tests, to
determine lots of fabrication affected. Results weren't conclusive and vendor decided to replace
100% of new pumps to ensure equipment reliability. Manufacturer determined that the problem
was probably caused by an inadequate preparation of housing surface before bonding. This
problem costed the vendor $ 6.9 million in only pump replacement, without accounting for
transportation and nationalization expenses.
On the other hand, the decision to not use new pumps from this vendor help saved at least $
4 million in pump premature failures between June and December 2015.
Initially, this supplier tested bond to only 20% of fabricated pumps. After this experience,
Petropiar began to claim bond retention tests to 100% of acquired pumps, according to Q1 from
ISO 151316.
c. Material selection: in 2015, 74% of pumps from Vendor C failed during warranty period, with
137 days run life average. From these, a total of 10 different pump models were submitted
to RCA. Pumps analyzed showed: delamination, tear and blisters (Fig. 21). Additionally,
measurement of hardness shore A, showed elastomer hardened.
In view of high failure index of these pumps, elastomeric compatibility tests were done as
part of RCA. Eight wells with repetitive pump failures were sampled from lower, middle and
upper reservoirs with different conditions of GOR and water cut. Tests were done at bottom
hole temperature and pressure. It means 180° F (25° F higher than bottom hole temperature)
during 168 hours, under an atmosphere of gas mixture CO2 / N2 at a total pressure of 1700 psi,
which is average discharge pressure pump and partial pressure of CO2 gas of 300 psi. Autoclaves
depressurization was carried out rapidly, at a rate of 15 psi / min.
As a result, specimens of elastomer presented blisters (Fig. 22) and damage type 2 (minimum
damage, one or two blisters 3 mm long) and 3 (external and internal damage, many blisters and
cracks, more than 3 mm long) according to NACE TM 0297 (Classification of visual damage).
Elastomeric material showed negative changes in mass for all conditions, except high water
cut. PDVSA - INTEVEP norm indicate for standard rotors, both volume swelling and mass
should be less than 3% (Table 5), but it doesn't specify about negative values. In case of under –
dimensioned rotor, PDVSA – INTEVEP require a range of 3-8%; it means all conditions tested
are out of specification. In practice, it could result in hysteresis and explosive decompression,
also associated to low hardness elastomer (63 shore A at initial condition), enabling permeation
gas.
Values of tensile properties for most conditions evaluated were out of acceptance criteria.
Permanent deformation showed significant variation from original value of virgin elastomer.
Because these premature failures cost Petropiar $10 million in 2015; next procurement
process will include elastomeric compatibility tests as indispensable requirement to participate.
16 SPE-181142-MS

Figure 16—Damaged stators because of high free gas

Figure 17—Specific failure causes associated to manufacturing as general failure cause

Figure 18—Damaged stators because of manufacturing problems (Quality Control)

Table 3—Costs associated to warranty pumps by manufacturing problems (Quality Control)

Pumps replaced Total PCP Total Deferred Total Workover Total Cost assumed
Vendor for Warranty Price ($) Production Cost ($) Service Cost ($) Cost ($) by PDVSA ($)

A 10 501,029 1,150,974 396,520 2,048,533 1,547,504

Table 4—Costs associated to Pump Failures caused by Fabrication Problem (Debonding)

Total Total Cost (repair

PCP Cost Deferred service + + PCP
(35.855$/ Production Repair Cost + Deferred
Year Count of Failures PCP) Deferred Production (bbll Cost (40 $/bbl) ($39,652) Production ($)

2014 3 107,565 6,800 272,000 118,956 498,521

2015 24 860,520 54,800 2,192,000 951,648 4,004,168

TOTAL 27 968,085 61,600 2,464,000 1,070,604 4,502,689

SPE-181142-MS 17

Figure 19—Damaged stator with 39 days running because of Fabrication problems (Debonding)

Figure 20—Multiples echoes generated in interphase elastomer – housing

Figure 21—Damaged stators because of manufacturing problems (Material Selection)

18 SPE-181142-MS

Figure 22—Tube tests after immersion tests

Table 5—Acceptance criteria used in polymers lab to elastomeric material selection for PCP

Property Norm Acceptance Criteria

Hardness Shore A (%) ASTM-D2240 ±10

Tensil Resistance (%) ASTM-D412 ±20

Elongation to Rupture (%) ASTM-D412 ±20

Compression Set ASTM-D395 ≥35% rejection

<3% (standard rotor);

Swelling (%) ASTM-D471 3-8% (under dimensioned
rotor); >8% rejection

Control of Process – Key Performance Indicators (KPI)

With the objective to measure effectiveness of improvements implemented, some KPI's are used:
1. Average Run life: Fig. 1 shows that from begin of RCA in 2013; average run life is increasing each
year. Today, this is 477 days, a 56% greater than in 2012, when it decreased to an historical minimum
of 306 days.
Manufacturing problem affected the number of premature failures in 2015, with an increase of 36%
in pump failures with less than one year operating compared to previous year.
2. Mean Time to Failure (MTTF): At the end of April 2016, total MTTF was 675 days (Fig. 23), this
measure has been stable during the last two years. Annual MTTF reached a minimum of 324 days at
the end of 2012, increasing to a maximum of 686 days in the last trimester of 2014 and stabilizing
around 560 days during last 7 months.
3. Failure Index: Failure index reached it maximum value in 2012, when 80% of actives wells were
intervened because of pump failure. From the start of RCA in 2013, these value decreased to reach a
minimum of 49% (Fig. 24). In 2015, failure index increased to 56% without reaching critical value
observed three years before.
4. Recurrent Index: historically, recurrent index was near 1. In 2012, this value reached a maximum of
1.73 pump failures per well. Since 2013 until 2015, this value was 1.24 average. At the moment this
paper is written, recurrent index in 2016 is 1.01 (Fig. 25).
SPE-181142-MS 19

Figure 23—Mean Time to Failure

Figure 24—PCP Failure Index

20 SPE-181142-MS

Figure 25—Recurrent Index

Conclusions
1. Root cause analysis (RCA) is a useful tool to improve run life of progressive cavity pumps.
2. Teardown analysis is necessary to determine root cause of pump failures.
3. An exhaustive revision of operational variables and production history of well is key to finding factors
that affect pump performance.
4. Visual inspection before installing equipment is necessary to prevent use of defecting equipment.
5. Preparing and organizing appropriately pumps after failure makes it easier to perform analysis.
6. Usage of different KPI's is a good control measure.
7. Elastomeric compatibility tests with production fluid are necessary to guaranty appropriate materials
selection.
8. High gas content is main cause of failure for the pumps analyzed.
9. Non-conventional technologies PCPs are necessary to produce oil wells with high GOR.
10. A strict quality control is highly necessary to guaranty durability and reliability of pumps.
11. Surface preparation of stator before elastomeric bonding is highly related with bond quality.
12. An adequate rotor coating is required to guaranty its preservation at environmental conditions.
13. Avoiding the use of defective equipment represents a significant way to eliminate repair costs and
deferred production.

Recommendations:
1. To include stator diameter and rotor measure in RCA process.
2. To analyze operating and production conditions of pump with more than one year run life.
3. To ask vendors documentation that demonstrates the highest quality control.
4. To visit plants to observe manufacturing procedures and quality controls.
5. To begin RCA as soon as first pump premature failure occurs to make the right decisions.
SPE-181142-MS 21

References
ISO 15136-1. 2010. Petroleum and natural gas industries—Progressing cavity pumps systems for artificial lift—Part 1:
Pumps, first edition.
Han, O., Rangel, S., Delgado A. et al 2015. Increased life cycle time in progressive cavity pumps through high nitrile
elastomers characterization in the Orinoco Oil Belt "Hugo Rafael Chavez Frias". Presented at 3er South American Oil
and Gas Congress, Maracaibo, Zulia State, Venezuela, 27–30 October. SPE WVPS-525.
Moreno, O., Gamez, I., Sanchez, C. et al 2015. Successful Massive Application for Gas Separation in Deviated Wells
Extra-Heavy oil production PCP. Presented at 3er South American Oil and Gas Congress, Maracaibo, Zulia State,
Venezuela, 27–30 October. SPE-WVS-523.
Moreno, O., Gil, J., Gamez, I. et al 2015. Charge Pump applications in horizontal wells for gas separation in extra-heavy
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