Program

PCP Training
Basics in Progressing Cavity Pumping Systems
History, Features and Benefits

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 Concept originally develop by René J. Moineau

1930
May 13th, 1930: Moineau got his first patent

“Pompes Compresseurs Mecanique” (PCM) was formed in Vanves, France

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First licenses sold to “Mono Pumps Ltd.” in England and
“Robbins & Myers” in USA. Also, other technological and commercial
1940 agreements were signed with companies in Germany, Russia, China,
Brazil and Canada

PCP Concept started to be applied in double-rotor hydraulic motors for

1950 oilwell drilling, by reversing the pump function

First attempts to use PCP as a production method in Russia, setting it

with a dowhole motor running at 1450 RPM
1960
PCP Brief Historical Review

1970 First attempts to use PCP driven from surface using a sucker rod string in
heavy oil fields in Canada

Canada and Russia started to use PCP’s driven from surface as a massive
1980 production method to extract heavy oil and bitumen

Other heavy oil producer countries started to use the concept of PCP
(i.e. Venezuela, China)

1990

Estimate of about 15,000 installations around the world

2000
Estimate of over 40,000 installations around the world
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 PCP System Configuration
Standard Components

Surface Equipment Downhole Equipment

Belts & Sheaves

Tubing String

Surface Drive Sucker Rods

w/ Couplings
Electric Motor
Stuffing Box

PC Pump Stator

Pumping Tee

PC Pump Rotor
Polished Rod

Tagbar
Sucker Rods
w/ Couplings
No-Turn Tool

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Surface PC Drive

• 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 these functions, drives typically

comprise the following components:
• Thrust Bearing
• Transmission System (Fixed Gear or Sheaves & Belts)
• Braking Mechanism (or recoil control system)
• Stuffing Box

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Prime Movers

• Internal Combustion Gas Engine

• Excellent option for non-electrified areas
• Variable Speed Capability
• Can work with diesel, gasoline or natural gas
• Manual Operation
• High Maintenance required

• Electric Motor
• Low maintenance requirements
• Higher efficiency
• Low energy costs
• Easy operation and low noise
• High cost of operation if area is not electrified
• Variable speed can only be achieve by changing
sheave ratio, rewiring motor or using an
electronic speed control device

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Motor Controller

• Provide protection and/or control capability to

the system
• Fixed Speed Controller
• Typically designed for only-protection operation
• Can be operated by motor load or torque (torque
limiter)
• Some are capable to auto-restart
• Low cost alternative
• Variable Speed Controller
• Configured from basic speed variation to full
automation and control functionality
• Ability to admit external analog or digital signals
for additional “intelligence” (pressures,
temperatures, flow, etc.)
• Ability of remote communication and control
• Typically a high cost solution

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Surface PC Drive
Stuffing Box - Conventional Type

• Seals on the rotating polished rod to control fluid

leakage from the production system

• Conventional design that uses special packing

material (rope style) which compress against the
polished rod

• Requires regular inspection and

maintenance

• Flanged or pinned wellhead attachments

• Better suited for:

• All vertical, low to medium speed wells
• All low to medium abrasive wells

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Pumping Tee / Rod BOP

• Pumping Tee is a necessary device in

PCP installations to direct the flow
from the tubing string to the surface
pipeline

• Rod BOP is an alternative device that

could be used for safety purposes

• “Composite” Special design combines a

Pumping Tee and a BOP into one single
piece for simpler surface configurations

• Rod “Clamps” (as the WFT ‘Support

Clamp’ or the OilLift ‘Rod-Lock’) are
used to hold rod string axial load for
easy wellhead service and repair

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Sucker Rod String
General Features

• Transmits power (torque) from the surface

drive system to the downhole pump

• PCP applications subject rods to a

combination of torsion and axial loads
• Overall stress state is normally governed by
torsional component
• Cyclic bending loads can occur due to rod
rotation in areas of wellbore curvature
• Rod make-up is more critical due to the
constantly applied torsion load

• Sucker Rods are available in conventional

coupled configuration (solid or hollow) or
continuous design
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Pump Model & Geometries

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Rotor Geometries

60 82 88 107 140 200 500 615 820 1000 1010 1100

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Progressing Cavity Pump

• Consists of two key components:

• Rotor:
• Is a high strength steel piece covered
with chrome and externally machined
as a helix of “n” lobes.
• Only moving part.

• Stator:
• Generally made with elastomer (or
rubber) with and internal shape as a
helix of “n+1” lobes.
• Elastomer is permanently bonded to
the tube

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 Elastomer Properties Table

Elastomer Type

Characteristics Buna
High Nitrile Hydrogenated Viton
Soft Medium

NBRM 55
NBRM 70 NBRA 70 HNBR (P) FKM
Weatherford

NBRM 64
Elastomers

59O-55 59O 68A-1 45C (P)

366/55 366 356 HTR

G62A N080 G60

Mechanical Properties Excellent Good Good Poor

Abrasive Resistance Very Good Good Good Poor

Aromatic Resistance Good Very Good Good Excellent

H2S Resistance Good Very Good Excellent Excellent

Water Resistance Very Good Good Excellent Excellent

Temperature Limit ** 95°C (203°F) 105°C (221°F) 135°C (275°F) 150°C (302°F)
** The temperature at the pump must be 20-30°C (30-60°F) below this limit to accommodate the friction
heat generated by the interference fit
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PCP System Accessories

• Tag Bar Assembly

• Normally included as integral part of the stator, is required as a reference
to facilitate the installation and space-out of the rotor and sucker rod
string.
• Different configurations available:

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PCP System Accessories

• No Turn Tool (Tubing Anchors)

• Although it is considered an accessory, it is used
almost in all PCP installations. Cost is normally
not relevant.
• Avoid the rotation and consequent backing-off of
the tubing string when system is operating
(clockwise direction)
• Easy release in the opposite direction (counter-
clockwise) when system stops and back-spins
• Normally it does not provide axial anchoring of
the system, facilitating its removal when
required

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Conventional PC Pumping System Animation

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PCP Systems Advantages

• Produce high viscous fluids, large solid concentration

and moderate free gas
• Low internal shear rates limit fluid emulsification by
agitation
• No valves to clog or gas lock

• Low capital and power costs

• Relative low energy costs

• As a positive consequence of its high efficiency

• Simple installation and operation

• Low maintenance
• Only surface equipment routine maintenance is required

• Low profile surface equipment

• Good for visual impact environment

• Low noise level

• Good for urban and noise sensitive areas

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Low Wellhead Profile

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High System Efficiency

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PCP Systems Current Limitations

• Displacement Capacity up to 5,000 B/D (800 m 3/day)

• Maximum Lift Capacity of 9,800 ft (3,000m)

• Normal Maximum Operating Temperature of 205ºF

(95ºC)
• overheating due to friction effect should be considered
• Special designs allow to increase this limit to 302°F (150°C)
• If high water cut, maximum temperature would be 185°F
(85°C)

• Highly sensitive to fluid composition

• i.e. single ring aromatic content (BTEX - benzene, toluene,
xylene)

• Presence of free gas affect its volumetric efficiency

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PCP Systems Current Limitations (more)

• High risk of Stator failure when it runs without fluid

• Even for short periods of time

• Wearing between tubing and rod string

• Accentuated in highly deviated wellbores and/or when sand
is present.
• Problem could be minimized by using rod
guides/centralizers or continuous rods

• If stator fails tubing string has to be removed entirely

• The use of Insert PCP eliminates this problem

• Potential for vibration related problems under certain

combination of equipment and operating conditions
• Could be eliminated with proper system’s design and good
operating practices

• Limited experience in certain emerging markets

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General Application Parameter Range

Typical Range Maximum*

1,000’ – 5,000’ TVD 9,800’ TVD

Operating Depth
330 – 1,550 m TVD 3,000 m TVD

5 – 2,500 BPD 5,000 BPD

Operating Volume
1 – 400 m /day
3
800 m3/day

75 – 170 °F 300 °F
Operating Temperature
24 – 77 °C 150 °C

Dogleg Severity less than

Wellbore Deviation N/A 15°/100 feet
15°/30m

Corrosion Handling Excellent (regarding pump)

Gas Handling Good

Solids Handling Excellent

Fluid Gravity Below 45 °API (highly dependable on aromatics content)

Servicing and Repair Typically Requires Workover or Pulling Rig

Prime Mover Type Electric Motor or Internal Combustion Engine

Offshore Application Good

System Efficiency 50% to 75% (up to 90%)

© 2004 Weatherford. All rights reserved. * Requires Special Analysis 23

PCP Typical Ranges of Application
• HEAVY OIL
less than 18 API Gravity:
• 500 to 100,000 cps Viscosity
• 300 to 1100 Meters (1000-3500 ft)
• up to 500 m3/day (3,150 bls/day)
• Sand cuts up to 50%
• Water cuts up to 100%
• Low Aromatics, GOR
• H2S and CO2 possible
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• MEDIUM OIL
18 to 30 API Gravity:
• Less than 500 cps Viscosity
• 600 to 1400 Meters (2000-4500 ft)
• up to 500 m3/day (3150 bls/day)
• less than 2% Sand cuts
• Water cuts up to 100%
• Greater possibilities of aromatics,
higher GOR’s, H2S and CO2
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PCP Typical Ranges of Application

• WATER:
• LIGHT OIL
• Water Source Wells
over 30 API Gravity:
• Gas Water Separation
• Less than 20 cps Viscosity
• Coalbed Methane Extraction (CBM)
• Over 1000 Meters (3200 ft)
• Up to 800 m3/day (5000 bls/day)
• up to 500 m3/day (3150 bls/day)
• Depth 100 to 2100 m (300 to 7000 ft)
• Trace sand
• Negligible Aromatics
• Water cuts up to 100%
• High GLR’s
• High possibility of aromatics, High
• H2S and CO2 possible
GOR’s, H2S and CO2
• Mature steam drive operations

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 PCP Installations per Region (estimates)

Sources: Oil & Gas Journal 2003

Canada
WFT Regional Offices
23680
(still under revision)
56.4%

USA
3965
9.4%

South America
7060
16.8%

South Pacific
West Europe
300
115
0.7% Far East
0.3%
1805 East Europe
4.3% Middle East Africa
4320
420 320
10.3%
1.0% 0.8%
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PCP Installations per Applications (estimates)

Source: WFT Regional Offices

(still under revision)
Heavy Oil
29385
70.0%

Medium Oil
5030
12.0%

Coalbed Methane Water Source Light Oil

6180 380 1010
14.7% 0.9% 2.4%

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© 2004 Weatherford. All rights reserved.
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Alternative PCP Configurations
Insert PC Pumping System

Tubing

• Same operating principle as conventional

configuration but having the complete pump Pump Seating Nipple

run on the rod string

• The only device attached to the tubing Seating Mandrel Extension Tube

string is the pump seating nipple (PSN)

Pull Rod

• In case of failure, the complete pump can be

removed by pulling the rods PC Pump

• Models available to handle up to:(400rpm/80%)

• 224 Bls/day (25 m3/day) in 2⅞” tubing
• 600 Bls/day (70 m3/day) in 3½” tubing
Tag Bar

• 640 Bls/day (125 m3/day) in 4½” tubing

• 3200 Bls/day (635 m3/day) in 5½” tubing

No-Turn Tool
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Insert Animation

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