SPE-182251-MS

Field Trial Analyzing of Rodless PCP Technology: Problems, Improvements

and Results

Hao Zhongxian, Huang Peng, Zhu Shijia, and Zhang Lixin, RIPED, PetroChina; Liu Dianfeng and L. Cai, Jilin Oil
Field Company

Copyright 2016, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Asia Pacific Oil & Gas Conference and Exhibition held in Perth, Australia, 25-27 October 2016.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Currently, rod-tubing wear and suck rod failure are two serious problems in many oil fields in China.
Because of the problem, in some area, the average mean-time-between-failure is only 200 days. The
workover costs lots of money, not including the loss of oil production. In view of the low daily output
situation of CNPC, problems have not been solved effectively until the development of the innovative
ESPCP system.
A permanent magnet synchronous motor (PMSM) was developed and deployed in the bottom of the
system, allowing adjusting the rotation speed between 50-500 rpm, which could satisfy the requirement of
the PCP. The system included a motor protector, a cardan joint and a PCP from bottom to top.
In the initial field trial, we met many problems, such as the motor protector didn’t work suddenly, the
shaft of the cardan joint broken, the system couldn’t run because of the tubing full of heavy oil. According
to the specific problem, we improved the design of some components.
More than 10 systems have been deployed and the longest working life is over one year. The system
saves 20% energy in average comparing with the pumping unit. It results in fewer operations and reducing
the total cost of ownership. The configuration reduces the surface footprint and environmental impact of
the oil field. It also reduces deployment and workover and results in fewer and safer operations.
This paper presents some problems and improvements of the system, and analyzes the advantages of
the technology.

Background
There are more than 200, 000 oil wells in PetroChina. They mainly adopt rod lifting and more than 92%
of them are pumping unit wells and surface drive PCP wells. The main problems of pump lifting are: (1)
Rod-tubing wear problem. For example, the rod-tubing wear workover of Jilin Oil Field accounts for 48%
of the total workover operations. This problem is more prominent in directional wells and horizontal wells.
The pump inspection period of some blocks is less than 200 days. In this way, workover and oil production
cost lots of money; (2) Safety and environmental hazards. If the wellhead packing is not replaced in time,
there would be oil leak and environmental pollution risks which increase production and treatment costs.
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(3) Large floor area. The floor area of a type 10 pumping unit is above 15 m2, which is more prominent
as to platform wells and artificial islands (such as Jidong Oilfield). Rodless oil production can effectively
resolve the problems mentioned above. Development of the rodless oil production technology is of great
significance for PetroChina.
Currently, the main rodless means of PetroChina are air lift and ESP (electric submersible pump). A total
of more than 2,000 wells that account for 1/100 of the total number of rod pumped wells adopt air lift and
electric submersible pump. This is determined by the well condition of PetroChina. ESP is generally used
for wells with an output of less than 50m³/d and a higher demand on flow rate. Yet, the output of the wells
of PetroChina is generally less than 50m³/d, which affects the extensive use of ESPCP. Air lift encounters
the same problem. In addition, it calls for air source, large one-off investment and well group application,
which fails to satisfy the well condition of PetroChina. Therefore, we have developed the ESPCP lifting
technology.

Introduction
Progressing Cavity Pumps (PCP) have been implemented in oil production for decades. Their advantages
include handling fluids with solid and gas, high volume efficiency, wide range of output and so on. In order
to solve the rod-tubing wear problem of conventional rod driven PCP and get rid of the suck rod, our team
has developed the ESPCP lifting technology which utilizes the low-speed downhole permanent magnet
motor(PMM) to drive the PCP and realizes rodless lifting. Unlike conventional ESP or ES-PCP, there is no
machine gear box. Figure 1 shows an overview of the architecture of the whole system. The PMM is located
on the lower of the assembly, thus ensuring the motor has maximum volume and power. From bottom to
top are respectively motor protector, flexible shaft, PCP, tubing and cable, etc. In the whole system, enough
space is left between the outer diameter of other tools and the casing, which ensures smooth passage of the
cable. The power supply transmits from surface to the motor via the cable. The output torque of the motor
transmits to the PCP rotor via the protector and the flexible shaft. Drilling fluid enters the PCP from its
bottom and is lifted to surface.

Figure 1—Assembly of the downhole direct drive PCP system

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At present, the system is resistant to a temperature of up to 120°C (subject to the rubber of the PCP
stator), and the downhole motor is resistant to a temperature of up to 150°C.
Downhole low-speed and high torque motor. The major requirement to effectively bottom operate PCP
is a motor with low rotational speed and sufficient rotational torque. Unlike conventional ESP motors, the
motor adopts 22-pole permanent magnet rotor structure and 24-slot stator structure, realizing dragging via
the electromagnetic torque generated by the alternating magnetic field, as shown in Figure 2. The designed
voltage rating is 380V and the rated speed is 300rpm (stepless speed regulation between 50-500rpm), which
meets the requirement on typical operating speed of the PCP in the region of 100-500RPM. Since the starting
torque of the PCP is about 2 times of normal operating torque, the motor can overload by 1.5 times in a
short time. For example, the maximum torque of a 15kW motor is up to 700N.m, meeting the operating and
starting requirements of the PCP. The power of the motor is directly related to its volume. In order to satisfy
the application of 5-1/2″ cased well, the designed outer diameter of the motor is 111mm. The length of the
motor is determined according to the power demand. Series motor power has been designed for different
lifting conditions, as shown in Table 1.

Figure 2—Sectional view of the downhole motor

Table 1—Series motor power

Maximum torque Suitable well output Corresponding

Series Power (kW) Length (m)
(N.m) (lift: 1, 500m) pumping unit

1 7.5 4.4 400 ≤10m³/d Type 6

2 9 5.2 480 ≤20m³/d

3 10.5 6 510 ≤30m³/d Type 8-12

4 12 6.7 570 ≤40m³/d

5 15 8.3 700 ≤60m³/d Type 14-16

Figure 3 shows the relationship between the parameter and the load rate of a 12kw motor. We can see that
the output torque of the motor increases steadily with the rise of the load rate and the efficiency basically
remains above 70% which is 20 percent higher than common electric pump motors.
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Figure 3—Performance curve of the motor

Motor protector: The top of the motor is connected with the motor through a flange. With an outer
diameter of 98mm, the flange connects the motor and the wellbore respectively. Its main function is handling
the thrust loads of the PCP and equalizing the internal and external pressure of the downhole motor. Unlike
common ESP protectors, the motor protector is designed with a thrust bearing chamber.
Flexible gearing system Flex sub: It is between the protector and the PCP and adopts a linkage structure
of two ball hinges. Its main function is converting the eccentric movements of the PCP to the concentric
moments of the motor and passing the thrust loads generated by the PCP rotor to the protector.
PCP: Its main function is conveying fluids to surface. Comparing with conventional suck rod drive PCP,
it further lowers the starting torque and increases the rate of revolution to some extent. The designed normal
rate of revolution is between 200-300rpm.
Cable: It is three-core power cable that transmits electric power from surface to the motor.
Surface control system: It displays the voltage, current and other operating parameters of the motor,
regulates the rate of revolution of the downhole motor, and sends the operating parameters of the motor
to the remote terminal.

Field testing and improvments

With the support of Daqing Oil Field and Jilin Oil Field, there were more than 20 systems that had been
deployed. Prior to ESPCP construction, these well candidates had the rod-tubing wear problem, and the
shortest run time was less than 100 days. We conducted field testing in two stages. The testing was firstly
conducted in wells with a pump setting depth of less than 1000m. The ESPCP system showed good
reliability, and the longest run time was more than 1,000 days. Comparing with pumping unit, the downhole
drive PCP saves electricity by over 20% and eliminates the rod-tubing wear problem. In the second stage,
6 wells with a pump setting depth of 1300-1500m were selected for testing. The working fluid level was
maintained at 1100m. The longest run time of these 6 wells was 450 days and there were some problems.
Via analysis and improvements, we have basically resolved these problems by now.

Protector failure
This failure happened most often. Earliest in A1 well, the system stopped running after running for 350
days. The instantaneous starting current was 65A, which was equivalent to that the loaded torque exceeded
570N.m, but the system still cannot be started.
Cause analysis: If a common ESL protector structure was adopted, the axial bearing capacity was
30kN. When the protector was used for the downhole drive PCP, the PCP would generate a larger axial
force because of the change of the downhole condition, the instability of the central shaft of the protector
would invalidate mechanical seal, the sand sedimentation in the protector would accelerate the damage of
mechanical seal, and the entry of drilling fluids into the protector would lead to the damage of thrust bearings
after they lost their lubricating qualities, as shown in Figure 4.
SPE-182251-MS 5

Figure 4—Damaged protector thrust bearings

For this problem, improved design for the structure of the protector was made for the purpose of
improving the axial bearing capacity. First, the diameter of the central shaft of the protector was increased
by 25% to 28mm, the length of the shaft was shortened by 900mm from 1600mm, and double thrust bearing
pack was designed to make the axial bearing capacity reach 70kN; a sand control structure was designed,
and the breath hole was changed to the side of the connecting flange with the outlet downward, which could
effectively avoid sand plug and had been verified by laboratory experiments.
After improvements, field application was conducted with a pump setting depth of 1400m. To date, the
protector has run for one year and the running condition is good.

Figure 5—Improved design of the protector

Flexible shaft failure

After A2 well ran for 452 days, the motor idled (running current: 1A) and did not discharge liquids. After
pulled out, it was found that the central shaft of the flexible shaft was fractured, as shown in Figure 6.

Figure 6—Failure and improvement diagram of the flexible shaft

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Cause analysis: The flexible shaft ran by depending on the rotation of the internal positioned ball and
the friction of the working face. Before running in the hole, the flexible shaft was full of grease. Due to the
density of water, drilling fluids entered the seal chamber after long-term running, which increased the wear
and friction force of the connecting shaft and led to the fracture of the weakest part of the connecting shaft.
Main improvements: The ball and the shaft were designed into an integral structure to enhance the
strength of the shaft. A seal structure was designed to avoid drilling liquids entering ball hinges.
After improvements, no shaft fracture was found in field testing.

Tubing paraffin deposition and plugging

After A3 well ran for 200 days, the oilfield cannot be started 1 day after it was powered off for overhaul.
At workover, it was found that the tubing was plugged by thickened oil. In the operating process, after 20
tubings were pulled upward, the oilfield can be started smoothly.

Figure 7—Starting curve of ESPCP when the tubing is plugged

Cause: Comparing with rod oil production, rodless oil production reduces the agitation of the suck rod
in the tubing and makes wax and thickened oil coagulate more easily, especially when flow velocity is low
or production is stopped.
The main measures presently taken are regular well cleanout and reduction of well suspension time.
In addition, tubing electric heating, increase of flow velocity in tubing with small diameter and chemical
feeding can be performed.

Control system failure

In the wells for field application, the system automatically stopped running in normal operation, which not
only affected the output of the wells but also might give rise to oil pipeline icing in winter and increase
operation and treatment costs.
After many times of tracking and data acquisition, it was found that the three-phase voltages varied
considerably before each automatic stop, respectively being 220V, 194V and 259V. From the perspective
of control data, though no stopping signal was sent manually, the controller received the stopping signal.
According to the analysis, the signal acquiring device was interfered and received the wrong control signal
because of power network fluctuation.
Improvement measures: The power supply of the acquiring device was added with an isolation
transformer and a filter to ensure the power supply of the control loop remained free from harmonic content.
SPE-182251-MS 7

Anti-interference performance was added. Meanwhile, improvements were made on software filtering.
After improvements, no automatic stop phenomenon was found on the field.

Conclusions
In previous research and testing, the main problems of the protector, the flexible shaft and other components
were resolved, and the reliability of the system was improved. At present, the longest pump inspection
period for wells with a pump setting depth of 1500m is 500 days. Currently, this technology is still in
constant improvement. In the future, the continuous measurement technology for downhole parameters will
be studied to realize production control in line with the working fluid level, to further improve the reliability
of the system, to increase the pump setting depth, and to expand the range of application.
Other advantages of ESPCP include realization of complete shut-off wellhead, simple surface equipment
and superior safety and environmental protection performance than the pumping unit system, with more
evident advantages in environment-friendly oil wells of Jilin Oil Field, Huabei Oilfield, etc. With the
constant increase of platform wells and directional wells, the ESPCP technology can play to its advantages in
small floor area and less work amount in subsequent maintenance and boasts a broad prospect of application.