2.

4b Progressing Cavity Pumping

This section presents the operating principals, operating limits, and system
requirements for progressing cavity pump systems. Recommended
practices, operating considerations, and costs are discussed.
This
discussion will be limited to conventional and insertable PC pumps used for
gas well deliquification. The emphasis will be on CBM/CSG wells and
shallow gas applications since production from PC pump systems becomes
limited for deeper applications.
2.4b.1 System Description
The surface and subsurface equipment for a typical electric drive system are
shown below:

Selection of Artificial Lift Systems for Deliquifying Gas Wells

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(Illustrations courtesy of Weatherford International)

Surface drives are typically electrically driven. Gas engine driven generators
can be used to supply electricity where line power is not available. Hydraulic
transmissions consisting of an engine driven pump driving a hydraulic motor
on the surface drive are also common.
Most surface drives have belt and sheave reductions to provide additional
speed adjustment. Geared systems and inline electric or hydraulic systems
are also available. All surface drive systems must have adequate backspin
control and the ability to absorb the stored energy of the rod string torsion
plus the full column of fluid.

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The stuffing box includes a seal to keep pressurized well fluids from
escaping. Stuffing boxes for PC pump systems are specifically designed to
seal against rotating polished rods.
Stuffing boxes designed for
reciprocating rod applications should not be used for PC pump systems
unless they are qualified by the manufacturer for use with rotating rods or PC
pump systems.
Below the stuffing box the pumping tee provides a flow connection to the
production tubing. Special composite pumping tees for PC pump systems
clamp on the polished rod to support the rod string and seal against the
polished rod to isolate well fluids. This allows the stuffing box and surface
drive to be serviced or removed safely without pulling the rod string.
The stators for conventional PC pumps are run as part of the production
tubing string. The rotor is run into the well on the end of the rod string which
consists of either jointed sucker rod or continuous rod.
The downhole assembly includes a tagbar to allow the rotor to be positively
located relative to the stator. Installation procedures include running the
rotor to the tagbar and then spacing back to align the rotor into the stator.
The rotor space-out is unique to the pump geometry, well operating
conditions, and rod string configuration.
Tubing insertable systems are available in which the stator and rotor are run
as one assembly with the rod string inside of the tubing. This simplifies
running and retrieval, so insertable pumps are usually preferred over
conventional pumps. The use of insertable pumps is limited by the tubing
size.
Large systems may require a no-turn device to prevent the torque in the
pump from loosening the tubing connections. Smaller systems with properly
torqued tubing typically do not require no-turn devices although no-turn
devices are often included as a precaution.

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Tubing

Pump Seating Nipple

Seating Mandrel

Extension Tube

Pull Rod

PC Pump

Tag Bar

No-Turn Tool

Insertable PC Pump Downhole Assembly

(Illustration courtesy of Weatherford International)
2.4b.2 Operating Principals
PC pumps consist of a rotor turning inside of a stator whereby the rotor is the
only moving component. The rotor is helical and typically has a round cross
section (single lobe). The stator cavity is also helical, but the stator pitch is
twice the pitch of the rotor. The stator cavity cross-sectional shape has one
more lobe than the rotor. For a single lobe rotor, the stator cavity crosssection is like a rectangle with rounded ends (2 lobes) similar to a race track.
The resulting assembly creates sealed cavities between the rotor and stator
which progress from the pump inlet to the outlet as the rotor turns (a
progressing cavity pump). The cavities are sealed so the pump is a positive
displacement device. Therefore a PC pump will hold a column of fluid when
the pump rotation stops.
Seal line

Selection of Artificial Lift Systems for Deliquifying Gas Wells

Single Lobe

Page 5

Multi-lobe

(Figures courtesy of Weatherford International)

The lift capacity (depth rating) of the pump is dependent on the number of
stages and the fit of the rotor to the stator. The volume capacity (production
rate) of the pump is dependent upon the cavity size and the pump rate of
rotation. The cavity size is determined by the rotor eccentricity and pitch.
Long pitches and high eccentricity result in high displacement (high
production volume) per rotor revolution. Short pitch pumps reduce the fluid
velocity through the pump which reduces abrasive wear on the pump from
fluids that contain particulate matter. Relatively long pitches relative to
eccentricity are used for less viscous liquids such as water, while relatively
short pitches relative to eccentricity are used for more viscous liquids such
as heavy oil.

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Figures courtesy of Weatherford International

2.4b.3 Operating Limits
The PC pump rotary motion and positive displacement combined with direct
mechanical drive from the surface result in the highest system efficiency of
any lift system. The volumetric efficiency of the pump is directly related to
the stator-to-rotor interference fit. Tighter fits allow less slippage and result
in higher volumetric efficiency. Looser fits provide increased cooling and
lubrication resulting in longer life for the pump. Therefore, efficiency is often
a trade-off for operating life.
PC pump systems are relatively tolerant of sand and particulate matter
compared to most common lift technologies. The elastomer in the stator
deforms to accommodate particulate matter pressed against the stator ID by
the rotor lobes. The particles are then released back into the flow stream
after the rotor lobe passes by.
Because of high efficiency and tolerance to particulate matter, PC pump
systems are ideal for use in many CBM/CSG wells. In deep CBM/CSG wells
(typically > 6000 TVD) and where local PC pump service expertise is limited
rod pump systems tend to be more competitive. In shallow CBM/CSG wells
(less than 1500 TVD) lower cost small ESP systems can be competitive.

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PC pumps have no valves or centrifugal stages so they will not gas lock
although they will have reduced efficiency in the presence of gas. Excessive
GLR through the pump for extended periods of time can damage the
elastomer due to elastomer hysteresis heating in the absence of liquid
cooling.
Typical Range

Maximum

Operating depth TVD

1,000 to 4,500 ft

8,600 ft

Operating volume

5 to 2,500 BPD

5,000 BPD

75 to 185F

Over 300F

Wellbore deviation

<15/100 ft build angle

15/100 ft build angle

Corrosion handling

Good to 185 F

Fair > 185 F

Gas tolerance

Limited for CO2 and aromatic BETEX gasses

Gas handling

Will not gas lock, high GLR reduces efficiency

Operating temperature

Solids handling
Fluid Gravity

Excellent
8 to 45 API (limited for aromatic BETEX gasses)

Prime mover type

Offshore application

Gas engine or electric motor

Good for pump landed above deep-set SSSV

System efficiency

55% to 70%

Figure courtesy of Weatherford International

Typical operating speeds are between 150 and 400 rpm. Speeds slower
than 150 rpm can result in stick-slip behavior due to system fluid properties
and friction elements (rod friction within the tubing, rotor/stator interference
fit). Speeds over 500 rpm can result in excessive rod whirl which can
damage the rotor and tubing.
Rotors are sized for a specific interference fit with the stator elastomer in
order to allow a designed amount of slippage (fluid leakage) between stages
to provide pump lubrication and cooling. Most systems are designed for
volumetric efficiencies of 60% to 85%. Depending on the application
conditions higher efficiencies may compromise pump run life, and lower
efficiencies will increase operating costs.
2.4b.4 Operating Requirements
PC pump systems can run off of the electric grid, or they can use natural gas
powered engines or local power generation.
PC pump technology may be the most efficient lift technology, especially for
abrasive fluids, but it is also the most easily misapplied technology. PC
pump systems should be designed on a well-by-well basis according to the

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Page 8

depth, fluid properties, production rates, etc. of individual wells. Systems

should be designed by experienced PC pump applications personnel.
Trained PC pump service personnel are required to install, commission, and
maintain PC pump systems.
System monitoring is required in order to optimize pump operation relative to
changing well conditions and to prevent pump-off conditions. Variable speed
controllers with automatic PC pump pump-off controls are important.
Telemetry and remote monitoring is recommended.
2.4b.5 Life Expectancy
Life expectancy in CBM/CSG wells has averaged around 18 months globally
and typically ranges from 12 to 36 months. Although solids and coal fines
can be detrimental to any pump, PC pump system failures in CBM/CSG
have more often been related to rod-tubing wear and continuous gas
production through the pump. The rod-tubing wear is related to the well
geometry and the resulting water-wet side loads between the sucker rod
couplings and the tubing ID. Water is not a good lubricant and can be
especially abrasive when solids are present.
In some areas high
concentration of CO2 in the produced water can cause Explosive
Decompression (ED) of the stator elastomer. Special elastomers have been
developed to mitigate the damage caused by ED.
Pump failures can be minimized by close attention to avoiding pump-off
conditions and by minimizing the amount of gas through the pump. Landing
the pump below the gas entry interval, the use of subsurface gauges and
VFDs (variable frequency drives) with pump-off logic all help extend pump
operating life.
Tubing and rod damage can be minimized by using continuous rod systems
to eliminate the couplings and the corresponding concentrated side contact
forces. Continuous rod will have 75% less side load pressure than
conventional sucker rod couplings in PC pump applications because the side
load is spread along the length of the rod. If conventional sucker rod is used,
tubing rotators and repositioning of the rod string can extend the life of
tubing.
In Canada and similar areas with significant PC pump manufacturing
infrastructure it is common to re-use rotors as the stators wear and are
replaced. Rotors for these applications have extra-chrome or similar hard
coatings to provide extended life. Typically, three stators will be replaced for
each rotor replaced.
In locations where PC pump manufacturing
infrastructure is less developed the rotor hard coating thickness may be
reduced in order to minimize costs since the rotors will not be reused. In
these applications the rotors are designed to last as long as the stators.

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2.4b.6 Costs
While costs will be dependent upon system features, complexity and local
operational costs some general rules-of-thumb apply: In low to medium
volume CBM/CSG applications procurement costs (CAPEX) tend to be split
for the subsurface pump assembly and components, for the rod string,
for the surface drive, and for the surface VFD controls.
Operating costs (OPEX) vary greatly depending on the local cost of power or
fuel and must include maintenance and service costs since PC pump
systems require periodic attention. In general, OPEX will be less than
comparable other lift technologies due to high operating efficiency and low
failure rates. Only lift technologies such as plunger lift and gas lift that
leverage formation energy will have lower operating costs per barrel lifted.
Although PC pumps are the most energy efficient form of lift, skilled PC
pump service personnel will be required to keep the systems in optimum
operating condition. In the absence of skilled service personnel reliability
and associated costs will be compromised.
2.4b.7 Recommended Practices
Specific installation, operation, and maintenance guidelines are provided by
suppliers for systems and components. The following suggested guidelines
represent best practices for PC pump systems.
Design for Free Gas
Free gas occupies space in the pump cavity. This reduces liquid
displacement and reduces pump lubrication and cooling. In gas wells
attempts should be made to reduce the amount of free gas that enters the
PCP. The following practices should be considered when free gas is present:

Land the PCP below the perforations.

If the pump is landed above the perforations a tail-joint assembly

should extend below the pump to effectively place the intake below
the perforations.

Use a downhole gas separator.

Use a charge tandem PC pump configuration in which a higher

volume capacity lower lift pump compresses well fluids prior to the
intake of the primary lift pump. Tandem pumps must be sized to allow
the rotor of the lower pump to pass through the stator of the upper
pump during run-in and retrieval (See illustration, below)

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(Illustration courtesy of Weatherford International)

Design for Highly Deviated Wells
Continuous sucker rod is recommended for any PC pump system installed in
deviated wells. The continuous rod will greatly reduce side loads and tubing
wear without the reliability issues associated with sucker rod guides.
Biased intake separators are available to reduce gas ingestion in deviated
wells. The separators draw in liquids from the low side of the tubing while
allowing gas to pass along the high side of the tubing.
Design for Particulate Matter
High concentrations of particulate matter can be produced with PC pump
systems if attention is given to not allow the particulate matter to settle in the
tubing or rat-hole.

Production tubing should be sized so that produced fluid velocities are

adequate to lift particulate matter to the surface. Smaller tubing will
increase fluid velocities. The following chart illustrates the critical

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velocities required to lift a coal particle to surface inside 2.875 tubing

with 0.875 sucker rods. Based on the chart a production rate of 109
bbls/day would be required to lift a US Standard Sieve Number 20
particle to surface.

(Chart courtesy of Weatherford International)

For high concentrations of particulate matter a recirculation pump

arrangement can be used to keep particulate matter in suspension
prior to pumping. This is similar to the charge pump arrangement
described above except a perforated nipple is located between the
tandem pumps to allow fluid to recirculate from the discharge of the
lower pump back to its intake.

Design for Water and Thermal Elastomer Swell

The amount of fluid and thermal elastomer swell is unique to the elastomer
compound and fluid conditions. At elevated temperatures >60C the amount
of fluid swell is significant with some elastomers. Therefore it is common for
the manufacturer to perform a fluid compatibility test using the produced fluid
under simulated operating conditions.
The fluid compatibility testing
accomplishes two purposes.
1. Identifies the best elastomer for the application.
2. Provides the ability to model and select rotor dimensions that will
provide an optimized and balanced rotor/stator interference fit across

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the stator cavity profile. Incorrect rotor/stator fit can result in poor
performance and run life.
2.4b.8 Trouble-shooting
Suggested solutions

X
X X

X
X

X X X

Pump locks up

Packing gland leakage

X X X
X
X
X
X X X X
X X X X X X X
X
X
X
X

Packing gland too tight

Packing gland not tight enough

X X X X X
X X X X

X
X

X
X

Excessive free gas at pump intake

(Table courtesy of PCM)

Wear on pump components

X X

Discharge pressure above design point

Pump speed above design point

Pump speed too slow
Drive belts slipping
Incorrect rotor setting
Drive mounting insecure
Drive head bearing wear / failure
Worn pump (rotor / stator)
Low voltage
Abrasives in the packing gland area
Failure of drive arrangement
Incompatible treating chemicals
Pump discharge blocked/valve closed
Stator worn / damaged
Packing glands destroy packing
Motor is too small
Incorrect rotor spacing
Stator elastomer swollen
Pump sanded in

Excessive packing gland wear

Possible causes
Percentage
abrasion
above
maximum
recommended
Sucker rods parted
Tubing parted
Inadequate fluid (reservoir or completion
related)
Hole in tubing or collar
Motor supply or wiring
Pump intake blocked
Fluid viscosity above design point
Fluid temperature above / below design point
Fluid viscosity below design point

Excessive noise and vibration

Motor overheats

Excessive power

Motor stalls at pump-up

Pump will not start

Production drops off

Intermittent production

No production

Observed problems

X X

X
X X
X X X
X

X X X X X

X
X X X X
X
X X X X X

X X X
X
X
X

X X
X X X
X X X X
X
X
X
X
X
X

X X
X

X
X X X X
X X X X X
X
X
X
X X
X X
X
X X
X
X
X
X
X
X
X

Select correct rotor fit, decrease

pump speed
Fish parted rod and replace
Tighten new tubing adequately
Reduce pump speed/put well on
timer
Replace tubing or collar
Check electrical supply and wiring
Pull up rotor, circulate well
Decrease pump speed
Select correct rotor fit
Increase pump speed
Check flow line for blockage/closed
valve
Adjust packing gland
Adjust packing gland
Install gas anchor, reduce speed or
lower pump
Decrease pump speed
Increase pump speed
Check belt tension
Check and adjust rotor spacing
Check/tighten all mounting hardware
Replace or overhaul surface drive
Replace worn components
Check voltage / wiring sizes
Check packing type and condition
Check failed drive components
Re-check chemical compatibility
Relieve pressure. Clear blockages
Replace worn parts
Check polished rod for wear
Check and re-calculate motor size
Re-space rotor
Re-evaluate elastomer selection
Perform flush by or pull pump

Selection of Artificial Lift Systems for Deliquifying Gas Wells

Examples of damaged rotors
Figures 1 to 3 show examples of different types of rotor damage.
(Photographs provided courtesy of CFER Technologies.)

Figure 0 Worn rotor

Figure 0 Rotor cracked from excessive heat

Page 13

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Figure 0 Pitted rotor

Examples of damaged stators

Figures 4 to 11 show examples of different types of stator damage.
(Photographs provided courtesy of CFER Technologies.)

Figure 0 Blistered stator, possibly from decomprerssion of absorbed gasses

Selection of Artificial Lift Systems for Deliquifying Gas Wells

Figure 0 Burned/overheated stator

Figure 0 Eroded/pressure washed stator

Figure 0 De-bonded stator

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Selection of Artificial Lift Systems for Deliquifying Gas Wells

Figure 0 Scratched/grooved stator

Figure 0 Torn/chunked stator

Figure 0 Stators contaminated with foreign material (two examples)

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Selection of Artificial Lift Systems for Deliquifying Gas Wells

Figure 0 Worn stator

Page 17