SPE-173959-MS

Production Optimization using Insert Progressing Cavity Pumps (I-PCP)

and Hydraulic Equipment for Heavy Oilfields in Mexico
L. Jimenez Carreno, and C. Yudiche Barbosa, Weatherford de Mexico; B. Villalobos Ramirez, DIAVAZ Group

Copyright 2015, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Artificial Lift Conference — Latin America and Caribbean held in Salvador, Bahia, Brazil, 27–28 May 2015.

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
Implementation of compatible production technologies for extraction of heavy oil using progressing
cavity pump (PCP) systems in three different oilfields: Altamira, Ebano, Panuco & Cacalilao; located in
Northeastern Mexico. The optimization process was accomplished thru implementation of Insert Pro-
gressing Cavity Pumps (I-PCP) and hydraulic driveheads, in areas without electric power network, and
high restrictions of well service rigs.
The project started with conventional PCP, and a second phase achieved an important operational
improvement thru I-PCP and surface systems with smaller internal combustion engines in response to the
operator’s request for less fuel consumption. In 2008 January a conventional PCP was installed in the
Franco Española-66 well (60 BFD & 1000 m lifting capacity), successfully operating for 2 years.
Subsequently between 2008 and 2009, 32 additional PCP were installed, but the operator company had
serious restrictions for optimization programs because of unavailability of well intervention rigs.
In response for January 2010, an I-PCP was installed in the Altamira-1022 well (189 BFD & 1500 m
lifting capacity), for extraction of heavy oil (10-13 °API); the favorable results led to installation of over
200 additional PCP systems in shallow wells (⬍450 m). At the same time, 80 power generators as surface
equipment were installed in Ebano field; this due to the absence of electricity in the area. Those generators
used 4.3 and 5.7 liter internal combustion engines. Those wells had low gas-oil ratio (GOR), therefore the
use of natural gas obtained from annulus (casing-tubing) was not an option, so an outsourcing of Liquefied
Petroleum Gas (LPG) was required. Considerable financial costs for high daily gas consumption were
caused by this situation.
Facing this condition, the first hydraulic surface equipment with smaller capacity (3.0 L) was installed
for January 2012, showing a decrease in gas consumption and lower costs. Likewise, the new application
was focused on shallow wells, during next two years, in which all of the initial engines were replaced.
This PCP optimization process showed several positive economic impacts:
● Decrease of intervention rig frequency regarding former PCP systems installed, which demanded
pulling of production tubing string.
● Saving in time and cost in front of PCP failures due to lower operating time using flush-by units,
in comparison with bigger intervention rigs; i.e., workover or maintenance rigs.
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● Lower deferred production levels were obtained.

● Additional cost saving associated to the consumption of LPG.
Implementation of this PCP process as artificial lift system for heavy oil wells achieved important
improvements regarding operational performance and well productivity.

Introduction
The optimization process using I-PCP, and hydraulic driveheads in areas with no electrification, was
focused on Ebano field because the potential of those installations was there; in cuantitative terms:
Altamira (20 wells), Ebano (176 wells), and Panuco-Cacalilao (17 wells).
Ebano is an oilfield located at Mexico northeastern near to Mexico Gulf, the first commercial well “Pez
No. 1” was perforated in April 1904 (the oldest one in Mexico); it is a mature oilfield characterized by
heavy oil, and production pumps seated in vertical zone (300-400 m), therefore named shallow wells.
Based on that the implementation of an operation model based on high viscosity and shallow wells, in
surface and subsurface, has been developed; and operator company always has searched for new
technologies or methods to assure required reliability for the field. The following figures (1,2, and 3)
summarize the main characteristics of Ebano field.

Figure 1—Ebano Oilfield Overview.

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Figure 2—Average Daily Production (BOD) in Ebano Oilfield.

Figure 3—Range of Characteristics in Ebano wells.

Statement of Theory and Definitions

Since the first efforts to apply progressing cavity (PC) pumping as method of artificial lift in the early
1980’s, they have experienced a gradual increase in the petroleum industry, and today there are more than
100,000 wells worldwide operating on-shore and off-shore with these PC systems. That is mainly because
overall efficiencies of 50% to 70% are evidenced, which is higher than any of the other artificial lift types.
Conventional PC pumps are installed by running the stator assembly on the bottom of the tubing string
and rotor on the bottom of the rod string, however the insert or insertable progressing cavity pumps (I-
PCP) have the entire pump assembly installed via the rod string and landed inside the tubing string
enabling the pump to be pulled and rerun via the rod string; both of them incorporating a torque anchor
or no-turn tool to prevent back-off of pump components.
The primary advantage of I-PCP system is the elimination of costly and time consuming tubing pulls
to change worn or damaged pumps or to switch to different pump sizes/configurations as downhole
pumping requirements change. Another potential benefit is avoiding the need to pull and rerun downhole
instrumentation with tubing. Note that because the entire pump assembly must fit within the production
tubing there is a limitation in terms of the compatible pump models for a given tubing size which in turn
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reduces the maximum rate and volume that can be produced relative to conventional tubing deployed
systems.
The I-PCP can be installed in different tubing sizes (2-7/8”, 3-1/2”, 4-1/2”, 5-1/2”), and using two
separate methods. The conventional method is through the use of a Pump Seating Nipple (PSN) in the
tubing string and corresponding set of seating rings in the pump assembly. The second method is through
the use of an anchor which allows I-PCP to be run in wells either not equipped with a PSN, or when the
PSN is at the wrong location or its specifications are unknown. The seating rings can be configured as top
or bottom hold down.
The system is run and deployed by lowering to the target position (PSN or anchor landing depth).
Retrieval of the I-PCP is done by pulling the rod string upwards to remove the seating rings from the PSN,
or unseating the anchor if it was used. Once at surface the I-PCP can be inspected and normally redressed,
if required, on the well site and rerun. I-PCP systems have application for a wide range of requirements
depending on displacement capacity and lifting neccesary; Figure 4 shows these ranges for different
tubing sizes.

Figure 4 —Available Ranges of Volume & Lift Capacity for I-PCP.

Related with surface equipment for PC systems, the basic functions of a surface PC drive are:
● Suspend the rod string and carry the axial loads.
● Deliver the torque required at the polished rod.
● Rotate the polished rod at the required speed in a safe manner.
● Provide for safe release of the stored energy during shut-downs.
● Prevent produced fluids from escaping the system.
To achieve those functions, PC drives typically comprise thrust bearings, a transmission system (fixed
gear or sheaves & belts), braking mechanism (or recoil control system), and a stuffing box. They are
designed for applications where a large range of horsepower and polished rod speed are required; and two
main configurations are identified based on prime mover used: Electric Motor, and Internal Combustion
Gas Engine; the last one aka Hydraulic Equipment.
The Hydraulic Equipment basically consists of a hydraulic motor, and is powered by a hydraulic skid
unit (skid). The skid has an electric or gas prime mover which drives a hydraulic pump. Fluid flow from
SPE-173959-MS 5

the pump then drives the hydraulic motor on the drive, which in turn, drives the rod string. The hydraulic
power unit is completely assembled with an enviro-skid, tank, pump, hoses and oil. The pressure
compensator on the pump is preset to requirements for automatic torque control. The speed control is
easily adjustable in the field with a turn of a knob, located on the pump.
For backspin control a backspin retarder is built into every hydraulic power unit with a check valve in
the hydraulic lines on the pressure side of the motor. When the drive is turning in the forward direction,
the check valve is forced open by fluid flowing into the motor. When the drive spins in reverse, the check
valve is forced closed and drains the fluid at a slow, controlled rate of speed. In order to ensure that there
is no loss of suction in the motor the backspin speed is very slow.
These units can be driven optionally through belts and sprockets, and the hydraulic motor mounted on
a slide frame or on a wellhead frame with a detachable stuffing box. The hinged belt guard on the drive
completely encloses the belts and sheaves but provides easy access and maximum safety. The drive unit’s
hollow shaft is coupled to the polished rod through a polished rod clamp. Inside the drivehead, large roller
bearings support the rod string and fluid column. A sturdy wellhead frame supports the assembly with a
variety of stuffing box options available.
All drivehead assemblies must be are equipped with a polished rod and booth guards as standard safety
equipment. See the Figure 5 for a broad understanding.

Figure 5—Typical PCP Surface Hydraulic Equipment.

Description and Application of Equipment and Processes

In Ebano field the I-PCP design was moved away from a bottom hold down configuration because there
was the risk of solids being produced fall down between the stator and the tubing wall, decreasing the
chances of successfully pulling the pump to surface. In a top hold down installation that type of issue is
drastically reduced, although there is still a chance that it will be stuck downhole due to solids however
it will be because the solids have accumulated above the pump discharge.
In those cases solids can be removed with flushing activities, or if there is access to coil tubing unit,
and the pump surfaced without pulling the tubing. In the bottom hold down application always the tubing
string has to be removed to surface the pump, at margin of quantity of solids being produced, even if it
is a trace amount, it will fall out of solution and accumulate over time.
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Accordingly, PCP well planning in Ebano field included installation of PSN into all of the wells at
initial completion. The PSN and seating rings were located at the top of the assembly, reducing the chance
of sand packing in the annular space between the pump and the tubing. Besides a special rotor design was
used to allow flushing without an extended flush tube, makes it easier to handle and install, while
providing ability to flush sand from the pump and pump intake without unseating the pump or pulling the
tubing.
The rotor features a unique shaped tip which mates with a floating ring at the top of the insert assembly,
acting as a no-go. When these two components make contact, the entire assembly can be pulled along with
the rod string. When a flush is required, the rotor-end is positioned between the upper top of the stator and
the floating ring chamber, in a 4’ (1.2 m) extension tube or orbit tube, extending the rest of the rotor into
the production tubing. Once the rotor is positioned, fluid can be flushed around the rotor and through the
stator. Other advantage is this specific configuration reduces the length of the assembly during running
and pulling when compared to other insert PCP designs. See details in Figure 6.

Figure 6 —Typical I-PCP Configuration used in Ebano field, (ⴙ flushing position).

The elastomer used for I-PCP installed in Ebano field was an improved version of traditional high
nitrile elastomers, wich had better resistance regarding high water cuts, gas, and explosive decompression;
with a superior performance in gassy applications containing CO2 and/or involving chemical products
where other elastomers experienced chemical swelling; those all advantages keeping mostly the resis-
tances concerning solids, H2S, and maximum fluid temperatures.
The PC Pumps have demonstrated effectiveness as the best artificial lift system installed in Ebano
oilfield, in that way the applications validated so far have been insert PC Pumps (I-PCP), driveheads with
hydraulic skid, and energy generator sets with 3.0 liters combustion engines in surface. I-PCP improved
working time because the stator and rotor can be reemplaced with versatile units called flush by units,
decreasing intervention rig costs, and optimizing production time; i.e., selection of I-PCP models based
on characterization of fluids, and pressure load. Surface equipment (hydraulic or electric) using 3.0 L
engines minimized the consumption of LPG which represents a proper selection of PCP surface
equipment in agreement with maximum torque and horsepower requirement.
Graphics 7, 8, and 9 show all pumps run and their average performance. Conventional PCP were the
first installed (2008-2009), I-PCP from 2010-2014. In total 383 pumps historically installed in Ebano
field.
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Figure 7—Types of PCP installed in Ebano Oilfield.

Figure 8 —PCP Models installed in Ebano Oilfield.

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Figure 9 —Run Life by l-PCP Models installed in Ebano Oilfield.

The nomenclature of pumps used is in accordance with ISO rules where the first number represents
nominal displacement capacity expressed in m /day/100rpm (or Bbl/day/l00rpm), and the second number
the maximum operating lift in m (or ft) as dimensional units.

Results and Conclusions

The insertable PC pumps (l-PCP) provided in Ebano field have been focused on reduction in well
servicing time and costs, allowing pump volume / lift changes without having to pull tubing. Those pumps
use PSN and seating rings located at the top of assembly, reducing the chance of sand packing in the
annular space between the pump and the tubing.
The l-PCP mostly used in Ebano field because good performance for displacement and lifting
requierements have been 11-1800, 14-1200, 17-1000 y 30-1500 models; i.e., cost/benefit, which even
represent the pumps currently requested by the operator oil company and are considered for their
production optimizacion plans.
The first observable positive impact was reduction about 40% of intervention rig annual frequency in
PCP systems previously installed, conventional pumps, which demanded pulling of production tubing
string. In the Figure 10 the evolution of some representative PCP wells over the time can be observed
relating to service units utilized for well interventions.
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Figure 10 —Sample of PCP Well Services in Ebano field.

In economic terms, the well interventions aimed at changes on installed artificial lift systems had 90%
approx. of money saving because the service cost of flush-by unit was about US$6,100/service by
comparison with US$42,675/day using a traditional rig (maintenance or workover); in addition the
intervention time for pulling and running was 1-2 days for a flush-by unit, versus 3-4 days for the second
case.
Besides, getting lower production losses associated to minor off-line well times was a parallel and very
important achieved benefit. Those benefits by lower costs and deferred production were observed with
higher impact when well programs included extra operational activities such as bottom sand cleaning,
redesigns or re-completions. Figures 11 and 12 illustrate a representative example of optimization level
achieved in Ebano field, wells Ebano-1042 and Ebano-1043, where the cost difference between a
conventional PCP and I-PCP system after two well services can be noticed.
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Figure 11—Cost Comparision of PCP & I-PCP Well Services in Ebano Oilfield.

Figure 12—Cost Impact by Production Loss of PCP & l-PCP Well Services in Ebano Oilfield.

And fewer than 33% of oil production loss (50 BOPD; US$ 87.7 Bbl lifting cost) during their
interventions, planned only for PC pump replacements but one of them (Ebano-1043 well) including
change from conventional PCP to I-PCP in the second well service.
The optimization process also included energetic improvement at surface which was obtained with the
implementation of smaller combustion engines as prime movers for PCP systems, changing from 4.3 &
5.7 to 3.0 Liters combustion engines in surface, and achieving inferior daily LPG consumptions. As
example, Figure 13 shows detailed requirements for one typical operative month (March 2013) regarding
gas demand in hydraulic skid and genenerator set (GenSet), with differents engine capacities (5.7L, 4.3L,
3.0L); clearly evidencing that 3.0L engine was the most economical option.
SPE-173959-MS 11

Figure 13—Daily Gas Consumption for Different Surface Equipment in Ebano Oilfield (March/13).

Figure 14 is a good example of optimization process implemented at surface level, showing monthly
and annual costs for PCP equipment installed in two Ebano PCP wells; where the cheapest configuration
was systems using hydraulic skids with 3.0L engine, and a cost savings of 28.5% was recorded. There are
similar data for other periods, equipment, and wells under the same optimized operational conditions.

Figure 14 —LPG Monthly Cost & Annual Saving for Representative Ebano PCP wells.

And Figure 15 represents the comparision between the two years with higher PCP well population
because completion campaign in Ebano field, 2012 and 2013, and the associated costs to LPG consump-
tions.
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Figure 15—Annual Saving for Ebano PCP wells.

Lastly, the following are potential opportunities of improvement to Ebano field in the future, keeping
the focus on getting better performances, higher run life, reduction of intervention cost and downtime:
● Evaluation of new available elastomer, which represents the next generation of high nitrile
elastomer with upgraded properties to wear, higher temperatures, gassy applications containing
CO2, and explosive decompression compared to the current elastomer; in addition the bonding
system reacts better with their elastomer components resulting in higher bond strength.
● Consider the operational accesability of I-PCP as production system for well programs including
chemical stimulations.
● Intallation of I-PCP along with continuous rod deployed by a flushby unit equipped with injector.
● Running of downhole monitoring equipment (sensor / gauges) which can remain in place during
pump servicing.
● Implementation of I-PCP anchors throughout the accomplishment of proper field trials and
respective widespread increase, which allows I-PCP redesigns (relocation in depth) or runnings in
wells either not equipped with a PSN or when the PSN is at the wrong location or its specifications
are unknown.

Acknowledgedments
Authors are thankful for the opportunity to prepare this paper from the Operator Oil Company of Ebano
field, and their involved representative who provided valuable information.
Likewise thanks to Weatherford Int. for all support and encourage about it.

References
Soltys, T., Svitich, J. 2008-2014. Progressing Cavity Pumps Training Documents. Weatherford
International, Global Product Line Manager, Edmonton, Alberta, Canada.