PAPER 2003-006

PETROLEUM SOCIETY

CANADIAN INSTITUTE OF MINING, METALLURGY & PETROLEUM

Application of Intelligent System (DES PCP)

for Monitoring Progressing Cavity Pumps
A.J. Szladow, D. Mills, D. Yong
REDUCT & Lobbe Technologies
This paper is to be presented at the Petroleum Societys Canadian International Petroleum Conference 2003, Calgary, Alberta,
Canada, June 10 12, 2003. Discussion of this paper is invited and may be presented at the meeting if filed in writing with the
technical program chairman prior to the conclusion of the meeting. This paper and any discussion filed will be considered for
publication in Petroleum Society journals. Publication rights are reserved. This is a pre-print and subject to correction.

ABSTRACT
In March 2002 REDUCT & Lobbe completed a
comprehensive field research project for the
Saskatchewan Petroleum Technology Research Center
(SPTRC). This research project addressed the potential
application of intelligent systems for heavy oil
production in Western Canada. The objectives of the
tests were to: 1) assess the opportunities and identify
application areas for intelligent systems; 2) develop and
demonstrate a specialized, site-specific intelligent
system; and 3) assess the performance and potential
benefits of the implemented system.
Six applications were identified as candidates for AI
systems, and Progressing Cavity Pumps (PCPs)
monitoring, diagnosis and control was selected for
demonstration tests. The overall conclusions from the
tests were that intelligent systems have the ability to: 1)
diagnose well instabilities that a SCADA system alone
cannot recognize; 2) notify operators about wells that

require closer scrutiny (review); 3) provide decision

support with respect to recovery from different types of
failures. These benefits are critical in terms of
optimizing PCP operations and retaining and making
available the knowledge of experienced staff.
The value of the potential benefits of a PCP
intelligent system was estimated at up to $ 4,000 per
well per year, or several million dollars per year for a
mid-size PCP operation. Given that the cost of the
software represents only a fraction of SCADA
infrastructure expenditures, the implemented intelligent
system could significantly leverage the SCADA system in
management and operations of PCP wells.
INTRODUCTION
Conventional control and automation helps prevent
costly shutdowns, increases yield and quality, and results
in more effective and efficient operation of the process
equipment. However, automation of some production

aspects is often not easy because oil-producing

operations exhibit complex interactions. To derive better
performance and to supplement conventional control
technologies with more advanced features, the oil
industry has turned, therefore, to advanced IT
technologies that can facilitate the management of
information, knowledge and production decisions.

heavy-oil production and oil treatment

operations;

The project was carried out in four phases:

Phase 1:
Based on consultation with the
industry and technology scoping work, six potential
intelligent systems applications were identified,
namely: PCP Well Monitoring, Trouble Shooting
PCP Wells, Well Optimization, Pump-off Control,
Battery Facilities Optimization, and Field Trucking
Scheduling.

The majority of intelligent systems in the petroleum

sector have been applied for control and monitoring of
crude upgrading processes (1). These applications
improved plant operations through better control and
scheduling of production, and by reducing work
disruptions. The benefits accrued included reduced
energy consumption, improved product recovery,
reduced variation in throughput capacity, increased
throughput, and improved plant optimization. The
following references summarize selected applications of
intelligent systems in oil production and exploration:

Pumparound controls (2)

Smart oil recovery (3)

Scheduling/planning of production (4)

UNIK-CPS (5)

Slurry minder (6)

AcidMan (7)

Gas dehydration (8)

Phase II:
Two intelligent system applications
were studied. These included PCP well monitoring
and optimization, and the use of surface
measurements in support of the optimization and
diagnosis of Progressing Cavity Pumps. The potential
benefits and costs of the PCP optimization and
diagnosis were evaluated and an intelligent system
prototype for monitoring PCP wells (DES PCP) was
developed.
Phase III:
The
software
prototype,
DecisionExpert System for Progressing Cavity Pumps
(DES PCP), was tested based on historical examples
of PCP breakdowns provided by industry. Also,
implementation issues of DES PCP, including
training, were addressed. This formed the basis for
more extensive field tests over a 6 month period.

Project Rational and Implementation

In order to take advantage of Artificial Intelligence
technologies in Saskatchewans heavy oil industry, a
project was undertaken to identify and demonstrate the
potential for artificial intelligence in Saskatchewan oil
fields. This project was conducted under a SPTRC
program developed to assist the Saskatchewan
petroleum industry in identifying opportunities for
implementation of advanced technologies, and was cofunded by the Industry Group of CANMET, Natural
Resources Canada plus Husky Energy and Petrovera.

Phase IV:
The field tests were implemented
from October 2001 to March 2002. The objectives of
the fi0eld tests were to: 1) develop a specialized, sitespecific knowledge base for PCP diagnosis; and 2)
assess the performance and potential benefits of the
system.
Application Selection
Based on discussions with heavy oil producers, six
potential applications were identified: 1) Single Well
Monitoring; 2) Trouble Shooting Process for PCP Wells;
3) Well Optimization; 4) Pump Off Control Process; 5)
Battery Facilities Optimization; 6) Field Trucking

The overall objectives of this project were to assist

Saskatchewan petroleum producers in:

The demonstration of an AI system leading to

improved productivity, equipment maintenance
and safety.

The identification of suitable advanced AIbased methods for improved optimization of

Scheduling. Each of the potential applications was

assessed in terms of the following criteria:

Degree of importance to the participating

companies.

Applicability to the oil industry as a whole.

Technical feasibility of solving the problem

using Artificial Intelligence methods including
expert systems, intelligent agents, neural
networks, data mining, etc.

Technical requirements for demonstrating

developed AI systems including key
features/operations and availability of data,
information, etc.

During the early analysis of PCP historical data it

became apparent that torque is one of the key indicators
of well behavior. Analysis of the relationship between
torque and pump speed revealed two distinct operating
states for PCP wells. The first one, referred here as
Quasi Steady-State, occurs when the pump is operating
within one power setting, the torque and speed vary
inversely so that as torque increases, pump speed
decrease and vice versa (Figure 1, Lines A and B).
However, when the power on the pump is increased,
both pump speed and torque will increase (Figure 1,
changed from form Line A to B, here referred to as a
transition state).
The existence of these two distinct operating states
makes the modeling of PCP behavior complex and
difficult. The control model describing PCP well
behavior needs, therefore, to differentiate between these
two concurrently occurring states. In addition, it has to
account for how the transition and quasi steady-state
dependencies vary as the fluid properties, well design,
and other factors change.

Costs and benefits to be accrued by applying AI

methods.

After assessing all six potential applications, and

consulting with the industry, the work focused on
monitoring and control of PCP operations using surface
measurements. These applications were recommended
because they have
the greatest impact for
Saskatchewans heavy oil industry.

Given that the only continuous (real-time)

measurements available for most PCP wells were
surface measurements (torque, pump speed, tank level,
and tubing or casing pressure), the first objective of the
project was to determine if and what kind of PCP
diagnosis may be feasible using surface measurements
and intelligent systems technologies.

This paper summarizes the tests completed and results

obtained. It discusses the key conclusions and
recommendations based on the field tests.
PCP WELLS DIAGNOSIS

The approach taken was to start by reviewing the

feasibility of monitoring PCP well surface
measurements in order to alert the operator about any
changes in SCADA data that would proactively diagnose
an early development of the sand-off, and thus
recommend actions such as flush-by. At the same time
we had to consider that although well failures do not
occur frequently, they can develop quickly with little
warning and no corresponding evidence in operating
data.

Progressing Cavity Pumps have been established as

the first choice for pump equipment for production of
heavy oil. They offer a number of benefits such as the
capability to: 1) handle co-production of oil, sand, water
and gas; 2) pump high viscosity fluids; 3) deliver high
pumping efficiency with relatively simple installation
and low capital cost. The key operational issues in the
application of PCPs for heavy oil production are
slugging sand, plugged perforation or pump intake,
stator swelling due to dry pump and heat generation. All
of these problems result in expensive and time
consuming repair work. The objective of this project
was, therefore, to address these issues through better
monitoring and control of the pump.

Because of this complexity, REDUCT decided to

implement data mining for analysis of well behavior
patterns and an expert system, DecisionExpert System
(DES, Figure 2) for on-line diagnoses using the mined
patterns/rules. The objective of DES was to advise the

operators when pump behavior became abnormal, or

unsteady, as well as to explain possible causes of the
problem. This was to be based solely on the operating
data available from the SCADA system.

discusses some of PCP wells events, associated data

patterns and DES performance.
DES demonstrated an ability to recognize the relative
importance and sequencing of different events
(hierarchy of warnings) and it provided early warnings
of potential well problems with a confidence factor of 70
to 80 percent (i.e., DES correctly identified well
problems 7 or 8 times out of 10). However, in more
complex situations, where changes of torque and casing
pressure are more erratic (noisy), the accuracy of the
system deteriorated to less than 70 percent. Figure 3
depicts a typical pattern of well breakdown incidents
where spiking casing pressure precedes high torque due
to sand-off, which consequently results in the wells
break down. Both the casing pressure spike and
increased torque were recognized as a unique sand-off
signature by the data mining software used, DataLogic
(9), and later identified in the SCADA real-time data by
the DES system.

As indicated, REDUCT approached this problem by

identifying patterns in the operating data that signified
potential pump problems such as a rapid sand-off
caused by:

Operating practices such as varying pump speed

and torque level.

Changes in casing pressure such as well loading

or casing gas blowdown.

Large changes in pump speed caused by

changing fluid dynamics in the pump well
cavity.

Changes in fluid properties such as increased

sand cuts (sand slaggs).

The patterns derived were then implemented in DES

in order to advise operators about current and potential
future well problems.

In cases where wells were characterized by significant

changes in torque over a period of several hours, DES
was able to recognize these situations and alert the
operators of the impending risks due to well instabilities
(Figure 4). DES PCP also could qualify (explain) well
instabilities in terms of dependencies between torque,
pump speed, casing and tubing pressure. For example,
Figure 5 shows the actions of the operator (reduction of
pump speed) in response to high torque alarms from the
SCADA system. For the same instabilities, DES PCP
qualified that the alarms were significant only if tubing
pressure were also high.

DES PERFORMANCE TESTS

The first step in the DES pilot was to test and modify,
as needed, the DES knowledge base. This required
implementation of: 1) rules/patterns derived using data
mining techniques and based on historical data; and 2)
rules describing PCP operating conditions associated
with plugged tubing, loss of communication, etc. The
key challenge was compensating for the fact that data
describing faulty well operating failures are rare and,
therefore, the DES knowledge base was incomplete.
Therefore, steps implemented during the field tests were
to:

Monitor DES PCP field performance.

Analyze DES PCP logs weekly.

Upgrade/modify the knowledge base.

Further investigation of the first group of alarms

depicted in Figure 5 (oval black circle) showed that there
were some changes in pump speed associated with high
torque, but the tank volume was increasing in a regular
manner. This suggested that the system was still in a
quasi steady-state and the alarm was not serious. What
the analysis pointed to was that adjustment of the pump
speed was not necessary and that using only SCADA
torque alarms may lead to frequent adjustment of pump
operations that are detrimental to long-term well
production.

Five poor performing PCP wells were originally

monitored by DES PCP, but two of them were shut
down shortly after the tests started. The text below

CONCLUSIONS AND RECOMMENDATIONS

The key benefits to be accrued from the

implementation of intelligent systems like DES are to:

The first conclusion from the tests performed was that

because SCADA data contain only a part of the
knowledge related to PCP operations, more active
participation of users in the development of the
knowledge base for PCP diagnosis is essential. The
approach taken by REDUCT was to start DES with the
knowledge base developed from limited historical data,
and later to improve the knowledge of the system by
analysis of test logs. It was also planned to incorporate
pumpers and production engineers knowledge in DES
decision support capabilities. There were, however,
difficulties in soliciting this knowledge.

Monitor PCP wells in order to detect problems

early and reduce breakdowns by early detection
and prevention.

Diagnose the root cause of problems, suggest

solutions and guide operators through recovery
by prioritizing corrective actions.

Improve inexperienced operators performance

by making the knowledge of experienced
operators available to them.

Given the complexities of PCP operations, REDUCT

recommended that DES be used as partner software to
SCADA systems. Such integrated SCADA-DES
systems would perform the following functions.

The second conclusion from the tests was that DES

correctly identifies instabilities in PCP operations. By
instabilities we mean not just an increase of torque, or a
change of pump speed, casing or tubing pressure alone,
but interactions between operating variables that often
precede PCP pump failures such as high sand- off, pump
malfunction or wear, plugged pump intake or tubing,
stator swelling, or a worn or damaged pump. Therefore,
given the above limitations in augmenting the
knowledge base with the pumpers knowledge, the
major benefit of DES during the tests was to alert
operators about serious instabilities of the PCPs.
The tests also indicated that building the knowledge
base is very important if the benefits that DES offers are
to be fully realized. If DES is to provide highly reliable
recommendations in addition to diagnosing instabilities,
it needs to capture the knowledge of the best operators
and embed it in the knowledge base. Doing so would
allow the knowledge to be made accessible to
inexperienced operators and hence would improve their
diagnostic decisions as well as their problem-solving
actions. The management and retention of the
experienced operators knowledge can be of significant
benefit to the industry by preserving the best operators
knowledge.

The SCADA system can inform operators about

breakdowns and high torque problems of the
pump. As a result, operators can be directed to
the well as soon as possible rather than waiting
until the next scheduled inspection.

DES can inform operators about instabilities of

the pumps, often before high torque alarms are
observed by the SCADA system. Considering
that operators monitor hundreds of wells, such
capabilities are very helpful in directing
engineers/operators to inspect the SCADA data
and to make decisions regarding the need for
corrective actions.

DES can inform operators about the best ways of

addressing well problems. This must be based
on the experience and knowledge of the best
operators as proposed to be incorporated in DES
PCP knowledge base.

SUMMARY
DES software performed as designed and expected
without any breakdowns, crashes or other software
problems. The key roadblocks to success experienced
during the field tests and DES installation and tests
related not to the software, but to the need for support
from field staff. The maintenance of the knowledge

As demonstrated, DES could support SCADA

systems by providing additional information on the
performance of wells and providing guidance to less
experienced operators on how to identify and address
PCP problems.

base was also essential for proper operation of DES or

any other intelligent system. Where both management
and field staffs support was in place the tests were
successful and informative.
DES PCP knowledge base, as developed and edited
during the tests, could correctly identify serious PCP
well instabilities and bring them to the attention of the
operators. It could explain the reason for the instability
and provide a probability assessment of the need to
perform a flush-by or change the wells operating
setpoints. It did require, however, the incorporation of
more site/field specific information and knowledge for
the wells monitored.

The knowledge base can be decentralized,

distributed or centralized leaving a flexible
architecture and the freedom to choose different
deployment strategies.

ACKNOWLEDGEMENT

The field test demonstrated that DES PCP software

can monitor PCP wells reliably, and can identify
anomalous events relating to torque; pump speed and
casing pressure or tubing pressure patterns. In general,
DES PCP is a less costly and more effective way to
capture and use operational knowledge. Specific
advantages of DES are:

When changes are implemented to PCP systems

configuration or operations, only the knowledge
base has to be edited. This means that
knowledge can be maintained and changed
rapidly and inexpensively.

There are also differences between how a SCADA

system uses alarms and the DES PCP system alerts the
operator about possible instabilities of a well. DES will
recognize the majority of SCADA alarms; however,
because DES looks for instabilities defined by
interactions of torque, pump speed and casing or tubing
pressure, in some situations DES will recognize critical
situations before the SCADA system could. Also, DES
could identify some problems, which the SCADA
system could not. Therefore, it could add capabilities to
SCADA by providing additional monitoring and ranking
the instabilities of different wells.

The tests conducted provided valuable information

and experience as to the issues that have to be addressed
in implementing intelligent systems at oil company
operations. Although applications of intelligent systems
have some common underlying issues across the oil and
gas industry, production of heavy oil using PCPs has
many unique characteristics and the tests provided
valuable information for all involved as to the
requirements and challenges in implementation of
intelligent systems like DES PCP.

The authors like to acknowledge the support and

contributions made to this project by Mr. Roland
Moberg of the Saskatchewan Petroleum Research
Centre, and Mr. Richard Fry of Energy Mines and
Resources, Canada.
REFERENCES

Separating diagnostic logic from application

codes increases the ease and clarity of the
development and maintenance of the knowledge
base.

1. REDUCT & Lobbe Technologies, Advances in the

application of intelligent systems in heavy industry,
CANMET, 1997.
2. Bullerdiek, E.A. et. al., Advanced controls pay out in 6
weeks at Texas refinery, Oil and Gas Journal, pp 48-52,
June 1995.

DES operational rule components are reusable

and can be easily maintained and edited through
easy-to-understand text files.

3. Armando, F., et. al., Smart oil recovery, IEEE Spectrum,

vol. 33, no. 7, pp. 48-51, 1996.

DES allows an engineer/operator to concentrate

on diagnostic or optimization knowledge and not
on the vagaries of a programming language, i.e.,
rules have English-like syntax instead of
programming language syntax.

4. Numao, M, An integrated scheduling/planning

environment for petrochemical production processes,
Expert Systems with Applications, vol. 8, no.2, pp. 263273, April-June 1995.

5. Lee, J. K. et. al., UNIK-CPS an expert system for

scheduling crude oil delivery to refineries, in Operational
Expert systems in the Far East, Pargamon Press, pp.109121, 1991.

7. ACIDMAN an expert system to assist the acid treatment

of damaged or clogged wells, Atlantic Richfield company,
US.
8. Gas dehydration system for offshore platform wells, SPE
Petroleum Computer Conference, Dallas, 1991, pp.167-179.

6. Kelly, E.B., et.al., SlurryMinder an expert system for

design of cement slurry for the well casing, in Innovative
Applications of Artificial Intelligence 4, The AAAI Press,
pp. 193-215, 1991.

9. Adam Szladow, DataLogic/R: Mining the Knowledge in

Databases, PC AI, p. 25, 1993.

1800
B

TORQUE (PSI)

1600
A

1400
1200
1000
800
600
180

190

200

210

220

230

240

PUMP SPEED (RPM)

Figure 1. DEPENDENCY BETWEEN TORQUE AND PUMP SPEED

(lines represent Quasi Steady-State for different pump settings)

Figure 2. DECISION EXPERT SYSTEM (DES)

Tubing pressure

Casing pressure

90
80
70

20
15

60
50
40
30
20
10
0

10
5

Casing Pressure

Torque (normalized)

Torque

0
Time

Figure 3. DES DIAGNOSIS OF WELL BREAKDOWN (arrow)

cpress

speed

torque

Nomalized Values

3
2
2
1
1
0

Time

Figure 4. DES DIAGNOSIS OF WELL INSTABILITY (dotted lines)

cpress

speed

torque

Normalized Values

2.5
2
1.5
1
0.5
0

Time

Figure 5. DES DIAGNOSIS OF WELL INSTABILITY (no DES alerts)

10