The APPEA Journal 2020, 000, 000–000

Extended abstract
https://doi.org/10.1071/AJ19023

Progressive cavity pump tubing drain valves: operator-

savings illustration

Peter Mark Smith

Baker Hughes, 2 Benoi Road, 629876 Singapore. Email: PeterMark.Smith@bakerhughes.com

Abstract. Three case studies show how three progressive cavity pump (PCP) operators used Zenith® (Baker
Hughes) tubing drain valves to protect problematic PCPs from blockage and damage, reducing downtime and
avoiding cost of backflush operations. The efficient solids management system incorporated in the Zenith PCP tubing
drain valve (PCP-TDV) reliably safeguards pumping equipment from damage or blockage caused by descending
solids when the pump is shut down, eliminating unplanned downtime and costly equipment replacement. Addressing
the failings of alternative valves, the Zenith PCP-TDV effectively reduces the requirement for well workover,
preventing pump-off, increasing uptime and lift system run-life, even in heavy oil and high viscosity fluid operations.
The Zenith PCP-TDV provides an innovative solution to costly pump damage, while preventing recirculation and
simplifying backflush operations. The addition of backflush capability is designed to allow the pump rotor to be
retracted and reset without running out of hole. A further addition specific to the coal seam gas market is the inclusion
of a tubing pressure-activated, single-use locking piston, so as to allow external pressure to be subjected to the
PCP-TDV without pumping being open, thus allowing the string to be set with no well fluid ingress into the
production string and pump before operation.

Keywords: backflush, CBM, coal seam gas, downtime, PCP optimisation, PCP-TDV, pump damage, sand, solids, well
fluid ingress.

Accepted 24 February 2020, published online dd mmm yyyy

Introduction Figure 1 shows a cut-away drawing of a PCP-TDV. Figure 2

The progressive cavity pump tubing drain valve (PCP-TDV)
is a tubing-mounted downhole tool installed as part of a
PCP completion. The PCP-TDV protects the pump from sand
and debris settlement and prevents rod torque-off situations
by diverting fluid and entrained solids from the production
tubing to the annulus when flow to surface stops (i.e. when
the pump stops rotating or fluid production ceases). The PCP-
TDV with backflush capability is designed to allow the pump
rotor to be retracted and reset without running out of hole.
In addition, outer connections that form part of the tool are
locked together with locking plates to prevent back-off and
allow reverse torque. The design has a maximised bore-
through tool to allow a larger range of stators and, specific for
coal bed methane wells, an inclusion of a tubing pressure-
activated, single-use, locking piston to allow external pressure
to be subjected to the PCP-TDV without pumping being open.
The Zenith PCP-TDV is available in 2 7/800 and 3 1/200 sizes.
shows a diagram of the operational sequences of a PCP-TDV.
Case study 1
Introduction
A Latin American operator who was operating 14 PCPs was
experiencing problems caused by solids blockage and
subsequent pump damage. The effect of this untreated
situation was an increase in downtime and backflush costs.
The installation of the Zenith PCP-TDV in these 14 wells was
shown to improve the economics of the well operation through
the reduction of production downtime and reduction of cost of
backflush operations.
Study data
Refer to Table 1 for the cost of PCP backflushing for 14 wells.
Refer to Table 2 for the cost of lost or deferred production owing
to shut in pumps because of damage.

Journal compilation Ó APPEA 2020 CSIRO PUBLISHING www.publish.csiro.au/journals/appea

B The APPEA Journal
Fig. 1. Progressive cavity pump tubing drain valve (PCP-TDV) cut-away drawing.
Pump on
The valve is installed
above the pump stator
allowing passage of well
fluids upward through
production tubing to
surface.
!
!
Backflush
Retract rotor to clear the
stator then flush fluids and
chemicals down tubing
through stator.
On completion of
backflush, run rotor back
to depth. Pump operation
can recommence.
Fig. 2. Progressive cavity pump tubing drain valve (PCP-TDV) operation sequence drawing.
Results and conclusions
Table 1 shows a total cost of US$219 018 for backflush
activity. This is an average cost per well per year of
US$15 644.
Table 2 shows a total cost of US$388 710 in deferred oil
production (@ US$50/BBL). This is an average cost per well of
US$27 750.
The total estimated cost savings in the reduction of both
backflush activity and deferred oil production are US$607 728,
P. M. Smith
Pump shut down
Valve immediately shuts
off flow path through the
pump, opening annular
ports to divert fluid column
from upper tubing into
annulus along with any
solids.
Natural flow
Retract rotor to clear the
stator allowing natural flow
through stator and tubing
to surface.
To return to artificial lift
operation, run rotor back
to depth.
which is an average cost saving of US$43 409 per well. This
cost does not include the cost of installing PCP-TDVs.
There are additional savings from
(1) extended pump run-life, saving on equipment replacement
costs,
(2) reduced intervention, saving on manpower and human error
costs, and
(3) reduced risk, saving on environmental health and safety
expense owing to less intervention.
PCP-tubing drain valves: operator-savings illustration The APPEA Journal C

Table 1. Cost of pump backflushing Table 2. Lost production

The cost of backflush operations required to repair or clean pumps that The cost of lost production owing to pumps that are shut in. BBL, barrel;
are blocked because of solids BOPD, barrels of oil per day; PCP, progressive cavity pump

Well ID Flushes per Cost per Cost per Well ID BOPD Oil production Lost US$ per
month (avg) flush (US$) year (US$) lost per year due year @ US$50/BBL
to PCP shutdown
Well 1 1.11 2500 33 333
Well 1 163 2176 108 800
Well 2 0.71 2500 21 260
Well 2 148 1260 63 014
Well 3 1.07 2500 31 953
Well 3 58 736 36 809
Well 4 1.23 2500 36 986
Well 4 29 431 21 526
Well 5 0.94 2500 28 125
Well 5 53 591 29 531
Well 6 0.63 2500 19 014
Well 6 74 559 27 951
Well 7 0.45 2500 13 636
Well 7 110 601 30 027
Well 8 0.22 2500 6691
Well 8 191 512 25 615
Well 9 0.13 2500 3965
Well 9 194 307 15 344
Well 10 0.24 2500 7297
Well 10 55 160 8012
Well 11 0.23 2500 6818
Well 11 46 124 6218
Well 12 0.23 2500 6835
Well 12 43 117 5865
Well 13 0.09 2500 2628
Well 13 167 176 8782
Well 14 0.02 2500 477
Well 14 128 24 1216
Total 35 000 219 018
Total 1459 7774 388 710

Case study 2 Case study 3

Introduction
A second Latin American operator who was operating PCPs
was experiencing short run life caused by solids blockage
resulting in broken rods. The installation of the Zenith PCP-
TDV in these three wells was shown to improve the run time of
the PCPs. In addition, the number of flush interventions was
reduced.
Study data
Three PCP-TDVs were installed, one was pulled after 170 days
because of a failure where the PCP-TDV disassembled
because of torque and a failed bottom swivel. Changes were
made to the PCP-TDV design to prevent this occurring in the
future.
Well install date, pump run time (3 February 2020) and
expected run time were as follows:
(A) 1 December 2017, 794 days, 120 days
(B) 22 December 2017, 773 days, 120 days
(C) not known, 170 days, 120 days
Results and conclusions
The PCP-TDV extended the life of the PCPs to at least
twice that expected for two of the three wells and by
50% in the third well. These represent savings of two
work-overs per year, plus a significant reduction in flush
interventions.
Introduction
An Indonesian pump supplier running PCPs was experiencing
very short run life caused by sand falling into the pumps when the
pumps were shut in. The installation of the Zenith PCP-TDV in
the first trial well has proven successful.
Study data
One PCP-TDV was installed.
Well install date, pump run time (3 February 2020) and
expected pump run time were as follows:
(A) 1 April 2019, 308 days, 180 days
Results and conclusions
The PCP-TDV extended the life of the PCP in the trial well and
the trial continues. The pump supplier categorically states that the
life of the PCP has been extended and the trial to be a success,
even with a short run time to date.
Conflicts of interest
No conflicts of interest exist.
Acknowledgements
The author acknowledges the support of his colleagues at Baker Hughes in
preparation of this paper. No funding was provided specifically for this paper;
however; development of the PCP-TDV valve was funded by Zenith, a
subsidiary of Baker Hughes.
D The APPEA Journal P. M. Smith

The author

Peter Mark Smith holds a Bachelor of Business (Ag) from Curtin University, and a Master of Engineering
(Oil and Gas) from UWA. Peter is employed by Baker Hughes as a Sales Manager for Zenith Sensors and
Artificial Lift Equipment for AsiaPac and India. Peter’s previous experience includes product line manager
for wellheads, rod lift systems and flow measurement products. Peter is an author of two patents, a member
of SPE and a founding member of the Global Society of Peace Engineers.

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