Progressive Cavity Pump
(PCP)
Introduction
A PCP consists of a single rotor which rotates
inside stator, the rotor is made from high
strength steel and stator from elastomer.
When the rotor is inserted in the stator, two
chains of cavities are formed and as the rotor
turns within the stator, the sealed cavity moves
up and carries the well fluid.
introduction
The rotor is attached to the sucker rods and stator
attached to the tubing.
PCP types are designated by two numbers, The first
one is the pumping rate in m3/d at 500 RPM and zero
head. The second one indicates the head capacity in
meters. 600TP900 The pumping rate is 600 m3/d and
head is 900 m.
Definition of oil field PCP
Progressing Cavity pumping (PCP) is a cost-
effective form of artificial lift that simplifies oil
production and withstands erosive attack.
PCPs displace wellbore fluid by transferring
it through a series of small, discrete cavities
RIH PCP at G-3 well,
Gassab-S.Sudan
formed from the turning of a helical rotor
within a stator.
Why is PCP used in petroleum industry?
The PCP is used in oil industry, because of its
pumping ability to produce high viscosity crude oil not
possible to be recovered by the conventional and
traditionally lift methods such as Beam pump, ESP,
and Gas lift.
The use of PC pump in downhole oilfield applications
began in early 1980 with very high overall efficiency
performance.
Advantages of PCP over other pumps
Efficient power usage
Decrease capital cost and operating cost
Excellent for viscous crude.
Resistant to abrasive and solids.
Non-pulsating. Does not gas lock or emulsify fluids.
Oil gravities from 5 to 42 API
High suction capability
Limitations of PCP
Sensitive to overpressure and pump off.
Restricted flow rate (<5000 bpd) and setting depths (<8000 ft)
Limiting operating temperature (normally <250 degrees F)
Not compatible with some chemicals,H2S 6%, CO2 30%,
Aromatics 12%, and high API gravity oils.
Running dry ( if PCP operate without fluid, the pump stator
deteriorates rapidly).
PCP Equipment
PCP Equipment has been divided into two (2),
namely:
Surface Equipment.
Downhole Equipment.
And Accessories
Surface Equipment
The surface equipment of PCP is
generally called Drive Head.
The Drive Head (DH) is further
divided into two parts, namely;
Mechanical parts of DH
Electrical parts of DH
Mechanical components of drive head
Belt Guard
Belts & Pulleys
Stuffing Box with Oryx Seal/parking glance
Hex Shaft with Hex Clamp
Gearbox( Brake system)
PCP BOP
Belt Guard
Accommodates a belt and protects
personnel operating on the PCP’s drive
head.
It prevents hands and clothing from getting
caught in a PCP’s rapidly spinning belt
drive
Therefore, it is generally a safety device.
Belt & pulleys, hex shaft
The function of belts, pulleys & hex shaft
is:
To transmit the rotation to the rod string
Belt
Hex/Rod Clamp
Function:
To carry the load of the rod
string and that of the fluid in the
tubing.
Stuffing Box with Oryx Seal/parking gland
function:
Stuffing box prevents the produced oil Stuffing box
from leaking out. It contains packing gland
that provides the actual sealing.
In general, the stuffing box isolates the packing gland
drive unit from the well fluid.
Gearbox (brake system)
To increase or reduce speed. As a result,
torque output will be the inverse of the speed gearbox
function. It also contains a brake system that
control backward rotation.
In general, it increases the output torque/turning
effect or to change the speed (RPM) of a motor.
PCP BOP
To ensures safe operation and production
of progressive cavity pump (PCP) system.
It is connected between wellhead and
PCP drive head and equipped with ram’s PCP BOP
seal to be able to close on polished rods
to secure wellbore. It also integrates a
flow tee to connect the tubing string to the
production flow line.
Electrical components of Drive Head
AC motor (55kW)
VSD (variable speed drive)
Quill wire
Motor (AC 55kW)
An electric motor (AC) converts
electrical energy into mechanical
energy. It operates through the
interaction between the motor’s
magnetic field and electric current in a AC motor at G-3
wire winding to generate a force in the
form of rotation of a polished rod.
VSD (variable Speed Drive)
VSD allows the production optimization.
VSD acts as a safety device, preventing
PCP from over torque due to sand &
swelling.
Downhole equipment of PCP
Stop bushing/stopping/tag
Polished Rod
bar
Sucker rods Torque anchor
Sucker Rod Centralizers Mule shoe
Rotor
Stator
Pup joint
Polished Rod (PR)
It carries the greatest pumping loads.
Hence transmitting the pumping
movement to sucker rods.
It permits a seal to be formed against
the leaking of well fluids.
Sucker rods
Sucker rod's function is to transmit the
rotation from Top Drive to the rotor.
The max. stress is at the top of the rod
string.
Sucker rod length 25 or 30 ft.
Pony rods 1- 2- 4- 6- 8- 10- 12 ft
Sucker Rods Grades
There are three grades of sucker rods.
API grade C, made from carbon-manganese steel.
For medium duty in noncorrosive fluid.
API grade k, from nickel-molybdenum alloy steel.
For medium duty in corrosive fluid (H2s, Co2).
API grade D, from chrome-molybdenum alloy steel.
For heavy duty in noncorrosive fluid.
Sucker Rods Centralizers
To stabilize rod string
Eliminate tubing and rod coupling
wear.
Reduce torque
Rotor
The rotor seals tightly against the stator and
turns eccentrically inside it. This configuration
creates a set of fixed-size cavities between the
rotor and stator that moves as the rotor rotates
and carry the production fluid through the pump
in pulsation-free linear flow.
Stator
A stator enables the PCP to withstand
the rigorous operating conditions of
enhanced oil recovery methods that
expose the pump to temperature as
high as 350 degrees Celsius.
It is also a stationary housing of a rotor.
Pup Joint
The pup joint is connected on top of the
stator.
Function
To allow eccentric movement of the rotor
head and its coupling, when the inside
diameter of the tubing is too small.
Stop bushing/stopping/tag bar
The stop bushing is connected to the bottom
end of the stator.
Functions:
Stop bushing
it serves as a landing spot during installation
or spacing out of the rotor.
it provides a standoff length of 30cm (1ft) for
the possible elongation of the rod string
when the pump is running.
Torque anchor
The torque anchor is connected to the
bottom end of the stop bushing.
To avoid the risk of tubing disconnection
due to friction and torque between rotor
and stator during operation.
In general, torque anchor prevents the PC
pump from rotating.
Tubing drain
The tubing drain is connected on top pump
assembly, along tubing string.
To provide a simple method for draining
the tubing during string before tripping out.
It has a shear pinned sleeve and it is
activated by inside pressure.
The opening pressure can be adjusted by
using the required number of shear screws.
Mule shoe
The mule shoe is connected to the bottom
end of torque anchor.
It provides a solution to ease tubing entry in
tight hole
In other words, it acts as an intake of the
PC pump.
It is used for removing mud, sand other &
particles from borehole.
Spacing out
The spacing is the length of the rod string that must
be lifted up to ensure proper distance of the rotor
end to stop pin when the pump is running. It is the
safety minimum distance in which the rotor must be
away from the stop pin. This enables proper
operation of the pump without the risk of the rotor to
work in contact with the stop pin. It is done as follow:-
Spacing out
Lay the Polished Rod Assembly beside the
Sucker Rod which was Tagged and place the
Last Tag parallel with the Polished Rod Tag
If the length of the Polished Rod exceeds the
length of the Sucker Rod Break out another
Sucker rod until it exceeds the length of the PR.
Spacing out
Add a Centralizer at the end of the PR and fill
in the remaining length with Pony Rods.
NOTE: Pony Rods should not exceed the
Sucker Rods
Add the Pony Rods to the Rod String.
The rotor end must be far enough from the stop
pin to avoid metal-to-metal running.
Troubleshooting
Troubleshooting is the identification of the failure mode
and application of the recommended practice to deal
with the problems based on technical considerations.
Problem 1: Low continuous flow rate @ Low Pump
Volumetric Efficiency. Speed as previously set.
Amps range is within expected limits.
Troubleshooting
Probable Cause: Poor spacing. Rotor running in
contact with stop pin.
Recommended Actions: Lift rotor. Check stop pin on
bottom device is still working. Re-space. Restart.
Problem 2: Prime mover (electric motor) shuts-
down. Amps are higher than expected limits.
Probable Cause: Motor horsepower undersized for
the application.
Troubleshooting
Recommended Action: Re-check the horsepower
requirements based on hydraulic parameters of the
installation.
Problem 3: Elastomer failure modes
Probable cause: Normal wear and abrasion, high
temperature & chemical attack.
Recommended actions: proper selection, monitor fluid
levels & reduce particle velocity
Thank you for your attention
