Copyright 1999, Society of Petroleum Engineers Inc.

This paper was prepared for presentation at the 1999 SPE Mid-Continent Operations
Symposium held in Oklahoma City, Oklahoma, 2831 March 1999.
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Abstract
The subject Progressive Cavity Pump Optimization System
(PCPOS) continuously analyzes analog system values from
several components at the surface to determine the operating
fluid level of a well. One major component is a load-
measuring device integral to the surface drive system. No
down-hole sensors and/or wires are required. Analyses of the
input values by the PCPOS software provide optimum pump
operation criteria related to the dynamics of the producing
well.
Introduction
The most valuable information about an operating oil well is
the dynamic pumping fluid level. This value shows the
relationship between the pumping rate and the well
productivity. This relationship provides the oilfield personnel
actual well performance data, i.e., well productivity,
completion and reservoir condition. The fluid level value
compared with the pumps theoretical output capacity can
suggest the condition and actual performance of the pumping
system. The pumping elements wear over time, which
decreases volumetric efficiency and requires the speed (rpm)
to be increased to compensate for the decrease. In
conventional operations, adjusting the speed is done manually
by changing gear or pulley ratios that require the system to be
stopped and idle for the time it takes to complete the
adjustment. Without real-time knowledge of well conditions
as they relate to pumping system operation, the analysis of the
well and the pump performance is a time consuming and
intensive effort. Without automated real-time analysis,
catastrophic reduction in well production is usually the only
method of determining a need for a change in the pumping
requirements.
Attempts have been made at automating Progressive Cavity
Pump (PCP) system installations both from the surface and
down-hole, but many have proven to be unreliable and/or too
expensive. Down-hole pressure sensors offer accurate
readings, but are inherently expensive to purchase, install and
maintain. When the sensors fail or malfunction the complete
system must be pulled from the well to investigate and fix the
problem. Pulling the stator from the well, in many PCP
applications, should be the last alternative to solving a
problem and can result in complete damage to the stator.
Therefore, diagnostic tools located at the surface are usually
the most reliable from the standpoint of maintenance and
calibration.
Monitoring current to determine the torque for inference of
the work being performed by the pump and therefore the
differential pressure across the pump has been done and
proven to be unreliable. There are too many variables such as
solids, stator elastomer swell and expansion, and changes in
the medium being pumped that effect the torque of a PCP.
Therefore, the risk is high for incorrect pump operation when
using only current as the main decision making criteria for
operating adjustments.
PCPOS is designed to operate the PCP system with limited
required human interface. Real-time analog input data such as
the weight of the sucker rod string, tubing and casing
pressures, pump rotor speed, operating amperage, and surface
temperature of the fluid are transmitted to a Remote Control
Unit (RCU) which provides communication between the
mechanical surface drive system and the PCPOS program. The
PCPOS integral Artificial Intelligence or Expert System
continuously analyzes the analog input data and, through the
RCU, controls the surface drive by adjusting the rotational
speed of the rotor according to the desired well operating
parameters entered into the PCPOS program. Using real-time
measurements the system can monitor the operating conditions
and make the necessary operating adjustments as frequently as
desired. In addition, remote monitoring and control can be
achieved through the application of compatible remote
transmission systems.
The result is a self-adjusting PCP system optimized to the
well condition changes and the desired dynamic conditions
SPE 52162
Well Optimization Package for Progressive Cavity Pumping Systems
S.T. Klein, SPE, InterRep; W.B. Thrasher, SPE, InterRep; L. Mena, SPE, InterRep; E. Quijada, SPE, PDVSA;
C. Brunings, SPE, PDVSA
2 S.T. KLEIN, W.B. THRASHER, L. MENA, E. QUIJADA, C. BRUNINGS SPE 52162
with local as well as remote control features. Application of
this technology has proven to increase well production and
reduce lifting costs by maximizing the daily production
potential, reducing production equipment failures and
associated down time. PCPOS has been field-tested and is
now being applied in multiple heavy oil producing wells in
Venezuela.
Description of the PCPOS
The PCP System Equipment. The equipment which makes
up a PCP system best suited for the application of PCPOS
consists of: a surface drive that contains an axial load bearing
and an axial load-measuring device; a Variable Fequency
Drive (VFD) to control the speed of the surface drive motor; a
Progressive Cavity Pump (PCP); and in the case of the heavy
oil applications a surface flowline diluent injection system
(Fig. 1).
The Surface Drive System. In all cases to date, the surface
drives have the axial load-measuring device or load cell
integral to the drive. The main shaft of the drive that contains
the axial load bearing is directly coupled to the shaft of a
gearmotor. This configuration is known as the inline or
beltless style. A VFD is used to vary the speed of the motor
and therefore the speed of the rod string and rotor.
The PCP. All of the applications of PCPOS to date
consisted of various sizes (displacement and head) of PCPs of
the 1:2 rotor to stator lobe configuration from a variety of
manufacturers. Both conventional and continuous rod strings
have been utilized.
The Well Head Instrumentation. This is the instrumentation
necessary to supply readings to the expert systems
mathematical model. The axial load measurement device, the
tubing and casing pressure sensors, and surface fluid
temperature sensor are mounted in the appropriate locations at
the well head. If required, a diluent or chemical injection
system can be located in the most appropriate location to the
application. The current (torque) is taken from the VFD. The
system has been developed in compliance with most
automation standards such as 4-20mA, 1-5 Volts, Modbus
RTU protocols, etc. The relationships analyzed by PCPOS
using these analog values establish the dynamic operating
conditions of the system and the dynamic fluid level of the
well.
The Field Hardware. The field computer or RCU (Remote
Control Unit) communicates with the VFD to control the
speed of the drive motor and to monitor power usage by the
system. The RCU is configured to store data and to operate the
PCP system based on basic information downloaded from the
Artificial Intelligence Operation portion of the Expert System.
The RCU handles the Modbus RTU (Remote Terminal Unit)
communications to the Host Computer Expert System, or
SCADA (Supervisory Control And Data Acquisition) System.
The Expert System Software. This is a C++ program
developed using Artificial Intelligence techniques such as
Fuzzy Logic, Neural Networks, Genetic Algorithms and
expert systems. The portion of the Expert System that is at or
near the well location performs the advanced control rules to
optimize the well production and performs advanced analysis
and diagnostics based on the real-time input data. It generates
the control actions over the well and alarm messages on an
operators console (with detailed explanations of the alarm).
The Host Expert System is used as an analytical tool to
develop mathematical models to evaluate the well Inflow
Performance Ratio (IPR) and Outflow Performance Ratio
(OPR), perform individual well historical statistical analysis,
as well as, size the optimum PCP equipment for the known
well conditions. It is also the man-machine interface between
the operator and the PCP pumping system (Fig. 2).
Function of the PCPOS
The basic concept of PCPOS is to use the load supported by
the axial bearing in the surface drive and the other surface
readings to analyze the dynamics of the PCP system in real-
time. It has been proven that the axial load has a physical
relationship with the down-hole pump hydraulic load. The
axial load is the sum of the mechanical loads and hydraulic
loads in the system therefore, in theory, the fluid level in the
casing/tubing annulus can be determined using the following
expression:
LVL
f
= (W
r+
(P
wh
+P
f
+DG)A
e
-P
c
A
r
-L
a
)/ A
r
G(A-1)
As shown, the hydraulic load portion of the expression is
related to the various pressures acting on the down-hole
pumping elements. Knowing the effects of these changing
pressures on the axial load measurement and the relationship
of the axial load to the fluid level under various conditions, the
operating fluid level can be determined with proven
acceptable accuracy. This knowledge base and analysis tool is
built into the PCPOS Expert System.
Features of the Expert System
Artificial Intelligence Operation System. This consists of
the representation of field experience knowledge used to
optimize production and diminish failure possibilities. The
real-time information (field variables: axial load, current,
motor temperature, wellhead pressures and rpm) reaches the
software package by means of a standard communications
platform. An analysis is made on the raw data to determine the
appropriate control action to be taken, for instance: adjust the
pump speed (rpm), adjust the opening percentage of a bypass
valve, or shut down, etc.
A pattern recognition process of dynagraph, current and
pressure charts accomplishes the diagnostic functions carried
out by an artificial self-organizing map neural network. The
target production rate is optimized by the usage of a generic
algorithm that determines the most favorable conditions under
which to operate the well. The control actions are drawn as a
conclusion to a set of Fuzzy Logic rules.
Analytical Tool for PCP System Designs. This software
portion of the expert system allows mathematical designs of a
PCP well to be solved in a Nodal Analysis module to
determine both the IPR and OPR. The optimum PCP system
equipment requirements such as pump size (both pressure
SPE 52162 WELL OPTIMIZATION PACKAGE FOR PROGRESSIVE CAVITY PUMPING SYSTEM 3
capability and displacement), surface drive axial load capacity,
sucker rod diameter, etc. are also determined here. It is
possible to arrive at and set the optimum operating point for a
well then perform a sensitivity analysis of the system design,
re-design or operating parameters. This tool works both on-
line and off-line and has a database that makes actions of
saving and retrieving data possible.
Automated Variables and Control Actions
System Axial load. The axial load value is set within an
operating band and oscillating around a design value. The
design value is determined by the weight of the rods, the pump
size, and the fluid column inside the tubing considering the
desired minimum fluid level. The axial load is the main
control variable, but any changes in this reading must be
analyzed simultaneously with all of the other analog input data
to determine the proper control action to be taken. A gradual
change in the axial load value beyond the operating band
normally would result in a speed adjustment control action
with the intent of reaching the preset design value.
Rotor RPM. The expert system adjusts the pump speed upon
detection of an abnormal operational condition. An abnormal
condition is one that is outside the operating band for any
given variable (Fig. 3). After adjusting the speed it waits for a
preset recovery period for the system to return to the
optimized normal condition. If the optimized normal operation
condition is not achieved, then it repeats the speed adjustment
and the recovery interval again. This goes on until the
optimized normal condition is achieved or one of the variable
values reaches a preset maximum or minimum condition and
signals to shut down.
Automatic Shutdown and Alarms. Under certain conditions
the system needs to be shut down immediately. This occurs
when any one of the variables being monitored reaches its
preset maximum or minimum operating value and the other
variable values substantiate the condition. Conditions that may
lead to this control action include excessively high or low;
well head pressure, operating current, axial load
measurements, or a combination of any two or more of these.
If the expert system determines there to be a condition that
may damage the equipment or the well, then automatic shut
down occurs and alarms issue warnings of potential system
problems.
Chemical and Diluent Injection Control. By monitoring
flowline pressure and fluid temperature at the surface the
amount of chemical or diluent injection volume into the well
or flow line can be controlled. In some heavy oil production
in Venezuela diluent is introduced into the flowline to reduce
viscosity. When both the temperature of the fluid changes and
the flowline pressure increases or decreases the program
accordingly controls the amount of diluent introduced.
Chemicals may be required to prevent corrosion, paraffin
buildup, etc. and the PCPOS program can manage the output
rate of a chemical injection pump or the opening /closing of a
valve actuator.
Laboratory and Field Tests
PCPOS

has been successfully tested and applied both in the
lab and in the field. The first crude oil well and designated
primary test location was MEL-39 in San Tome, Venezuela, a
PDVSA heavy oil well (formerly CORPOVEN S.A.). The
testing was initiated in October 1996 with the involvement of
PDVSA personnel and INTEVEP (the research arm of
PDVSA). The down-hole variables determined by the expert
system were compared to down-hole pressure sensors
(supplied by INTEVEP) located at the pump intake and
discharge and sonic fluid level measurements.
The well characteristics are:
API Gravity: 9.5
Production Rate: 390 bpd
GOR: 200 Scf/Stb
Perforation Depth: 5000 ft
Reservoir Pressure: 1200 psi
Reservoir Temperature: 120F
Gas Saturated Viscosity: 2500 cp
Volumetric Factor: 1.478
Results Achieved:
Statistical error: +5.17% compared to the down-hole
Sensors
-19.6% compared to the sonic fluid
level measurements
10% increase in production
Increase in the PCP system life: 10 months average to
Over 18 months
Protection against two unexpected diluent plant shut
downs
Field Operators assistance cost reduction: $19,700/yr
Reduction in rig requirements: $3,030/yr
Reduction in replacement equipment costs: $6,725/yr
Currently there are multiple wells operating in Venezuelan
heavy and extra heavy oil fields with the axial load monitoring
surface drives installed and some form of PCPOS being
utilized.
Conclusions
-Axial load can be used to diagnose PCP systems with the
correct dynagraphic tool since pattern recognition can be
performed. (Very similar to the systems used for conventional
beam unit sucker rod pumping systems)
- PCPOS yields accurate results and is generally more reliable
and less expensive than down-hole pressure sensor systems.
- A PCP well has a mathematical model that can be effectively
solved and analyzed by using Artificial Intelligence
techniques.
-A truly complete optimization system must contain an Expert
System program to analyze the raw data input and make the
necessary control action decisions without human interface.
This Expert System must be designed in modules to be used at
the well head, in a remote central field location, as well as in
the Production Engineers office.
4 S.T. KLEIN, W.B. THRASHER, L. MENA, E. QUIJADA, C. BRUNINGS SPE 52162
Nomenclature
LVL
f
= fluid level above the pump intake, ft
L
a
= axial load, lb
W
r
= weight of rod string in fluid, lb
P
wh
= wellhead pressure, psi
P
f
= fluid friction pressure, psi
D = pump depth, ft
G = fluid gradient, psi/ft
A
e
= effective rotor area, in
2

P
c
= casing pressure, psi
A
r
= major rotor area, in
2
References
1. Quijada, E., Brunings, C., Mena L., Klein S.T.: Automated
Diagnostic of Progressive Cavity Pumps, manuscript No. 067
presented at the 7
th
UNITAR International Conference, Beijing,
China, October 27-31, 1998.
Fig. 1 Typical PCPOS

Equipment Installation
SPE 52162 WELL OPTIMIZATION PACKAGE FOR PROGRESSIVE CAVITY PUMPING SYSTEM 5
Fig. 2 PCPOS Flow Diagram
Fig. 3 Sample Operating Band for Axial Load Vs Time
Time
Axial
Load
DV
Raise RPM
Lower
Max. Load
Min. Load
}
Normal
Operation
Band