Progressing Cavity PUMPS

Progressing cavity pumping (PCP) systems derive their name from the unique, positive displacement pump
that evolved from the helical gear pump concept first developed by Rene Moineau in the late
1920s. Although these pumps are now most commonly referred to as progressing cavity (PC) pumps, they
also are called screw pumps or Moineau pumps. They are increasingly used for artificial lift, and have been
adapted to a range of challenging lift situations (e.g., heavy oil, high sand production, gassy wells,
directional or horizontal wells). Over the past two decades, with the technical contributions and persistence
of many individuals and companies, PCP systems have experienced a gradual emergence as a common
form of artificial lift.Although precise numbers are difficult to obtain, it is estimated that more than 50,000
wells worldwide currently are being produced with these systems.

The basic surface-driven PCP system configuration is the most common, although electric and hydraulic
downhole drive systems and various other hybrid PCP systems are also available). The downhole PC
pump is a positive displacement pump that consists of two parts:

▪ Helical steel “rotor”

▪ “Stator” comprised of a steel tubular housing with a bonded elastomeric sleeve formed with a multiple
internal helix matched suitably to the rotor configuration.

The stator is typically run into the well on the bottom of the production tubing, while the rotor is connected
to the bottom of the sucker rod string. Rotation of the rod string by means of a surface drive system causes
the rotor to spin within the fixed stator, creating the pumping action necessary to produce fluids to surface.
PCP systems have several unique design features and operating characteristics that favor their selection
for many applications.

▪ High overall system energy efficiency, typically in the 55 to 75% range.

▪ Ability to produce high concentrations of sand or other produced solids.
▪ Ability to tolerate high percentages of free gas.
▪ No valves or reciprocating parts to clog, gas lock, or wear.
▪ Good resistance to abrasion.
▪ Low internal shear rates (limits fluid emulsification through agitation).
▪ Relatively low power costs and continuous power demand (prime mover capacity fully utilized).
▪ Relatively simple installation and operation.
▪ Generally low maintenance.
▪ Low profile surface equipment.
▪ Low surface noise levels.

PCP systems, however, also have some limitations and special considerations:

▪ Limited production rates (maximum of 800 m3/d [5,040 B/D] in large-diameter pumps, much lower in
small-diameter pumps).
▪ Limited lift capacity (maximum of 3000 m [9,840 ft]).
▪ Limited temperature capability (routine use to 100°C [212°F], potential use to 180°C [350°F] with
special elastomers).
▪ Sensitivity to fluid environment (stator elastomer may swell or deteriorate on exposure to certain fluids,
including well treatment fluids).
▪ Subject to low volumetric efficiency in wells producing substantial quantities of gas.
▪ Sucker rod strings may be susceptible to fatigue failures.
▪ Pump stator may sustain permanent damage if pumped dry for even short periods.
▪ Rod-string and tubing wear can be problematic in directional and horizontal wells.
▪ Most systems require the tubing to be pulled to replace the pump.
▪ Vibration problems may occur in high-speed applications (mitigation may require the use of tubing
anchors and stabilization of the rod string).
▪ Paraffin control can be an issue in waxy crude applications (rotation as opposed to reciprocation of the
rod string precludes use of scrapers for effective wax removal).
▪ Lack of experience with system design, installation, and operation, especially in some areas.

PCP systems currently provide a highly efficient and economical means of artificial lift.

Applications
Use of a PCP system should be evaluated for situations that are:

▪ High-viscosity oil wells

▪ High-sand-cut wells
▪ Low-productivity wells
▪ Gassy wells
▪ Directional- and horizontal-well applications
▪ Hostile fluid conditions
▪ High-speed operations (see discussion of impact in Rod and tubing design for PCP systems
▪ Coalbed-methane and water-source wells
▪ Elevated-temperature applications.

A steel shaft rotor of diameter d has been formed into a helix. The rotor is rotated inside an
elastomeric pump body or stator, which has been molded in the form of a double helix with a pitch of
the same diameter and exactly twice the length of the pitch given to the rotor, when assembled, the
centre line of the rotor and the stator are slightly offset, creating a series if fluid filled cavities along
the length of the pump.
The figure below helps to explain how the interference fit between the rotor and stator creates two
chains of spiral (fluid filled) cavities.
Working of PCP

The rotor within the stator operates as a pump. This causes the fluid, trapped in the sealed cavities, to
progress along the length of the pump from the suction to the pump Discharge. These cavities change
neither size nor shape during this progression. Shows how, as one cavity diminishes, the next one
increases at exactly the same rate; giving a constant, non-pulsating flow. It acts as a positive
displacement pump. The pressure increase that can be achieved by the pump depends on the number
of “seal-lines” formed along the pump body by the rotor and stator. Typically, this is found to be 300-
200 kpa pressure increase per stage. It is found that fluid will “slip” backwards if a greater pressure
increase is demanded from the pump. This can be avoided by increasing the number of pump stages.
Wear of either the stator of rotor will decrease this value since the maximum pressure increase
depends on this interference fit. However, the construction of the stator body from an elastomer
makes this pump design relatively tolerant to produced solids - particularly since they are often used
to pump viscous oils which provides a lubrication film to protect the rotor and stator from wear.