SPE

SPE 18873 The Progressing Cavity Pump: Principle and Capabilities

by K.J.Saveth and S.T. Klein,Robbins & Myers Inc. SPE Members

Copyright 1989, S@ety of Petroleum Engineers, Inc. This paper was prepsred for pres.ntstion at the SPE ProductionOperations Symposiumheld In Oklahoma City, Oklahoma, March 13-141989. This papar was wlected for presentationby an SPE Program Committee foliow@grwiaw of informationcontained in an abetract submittedby the aumor(a). Contentsof the paper, as prewntad, have no! been reviewed by the society of Patroleum Engineers and are subjectto correctionby the author(s).The material, as prawnted, does not necessarilyreffacr any positionof the Societyof PetroleumEngineers, its officers,or members. Papers presentedat SPE meetingsara subjeotto publicationraview by Editorialcommittees of the Soclafy of PafrofeumEnginwre. Permission copyia restrictedtoan abstractof notmorethan 300 worda.Illuafrafiis may notbe copied.The abstractsf?outd onfainconspicuous to o ackn&e@mant of where and by whom the paper is presented. Write PublicationsManager, SPE, P.O. Sox 83S836, Richardson,TX 7S083-3S36. Telex, 7309S9 SPEDAL.

the stator helix, and the pumps rotational speed. The stators elastomeric gear lends itself .wel to 1 The progressing cavity (PC) pump has been used as a use in a wide range of applications. A single fluid transfer pump for many years. From various particular pump size can easily be adjusted to handle industrial applications to surface transfer of varying production rates. With present lift oilfield fluids. Within the last several years the capabilities from 4000 feet (1219 m) and capacities progressing cavity pump has been widely used as a to 1000 BFPD (159m3/day), the areas for progressing method of artificial lift for the oil and gas cavity pump usage is ever expanding. Compared to industry. The use of progressing cavity pumps as a other methods of artificial lift in similar . means of artificial lift has numerous advantages over applications, the progressing cavtty pump is normally other artificial lift methods. Through years of the more efficient means of artificial lift. The research and development in progressing cavity pump low initial investment, ease of installation and design, the production and lift capabilities are minimal maintenance are other advantages the expanding to cover a wide range of applications. progressing cavity pump has over other methods. With various elastomeric materials available, a wide PROGRESSING CAVITY PRINCIPLE range of well fluids can be handled efficiently using the progressing cavity pump. The ability to pump abrasive fluids lends itself well to many of the The progressin cavity pump consists of a single viscous sand laden crudes found throughout the world. helical gear (rotor! which rotates inside a double With present lift capabilities from 4000 feet and helical elastomeric gear (stator) of the same minor capacities to 1000 BFPD, the progressing cavity pump diameter and twice the pitch length. See Figure 1. is ever expanding and becoming a viable alternative As the rotor rotates eccentrically within the stator, for wells utilizing artificial lift. a series of sealed cavities form 180 degrees apart which progress from the suction to the discharge INTRODUCTION ends of the pump. As one cavity diminishes, another is created at the same rate resulting in a constant The most coinrronrogressing cavity design is one p non-pulsating flow.3 The total cross-sectional area of a single helical rotor rotating eccentrically of the cavities remains the same regardless of the inside a double threaded helical elastomeric stator position of the rotor in the stator as shown in of twice the pitch length.3 The number of seal lines Figure 2. The progressing cavity pump overcomes determines the pressure capabilities of the pump and pressure because it has a complete seal line between is one of the determining factors of the slip the rotor and stator for each cavity. The pressure experienced within the pump. Fluid viscosity and the capabilities in the pump are based on the number of compression fit between the rotor and stator are the stages and,the number of times the seal lines are two other determining factors for slippage. repeated. Normally astage is designed and Theoretical displacement at zero psi is directly manufactured to be 1.1 to 1.5 times the pitch length proportional to the cross-sectional diameter of the of the stator. The reason for this is to insure a rotor, the rotors eccentricity, the pitch length of proper seal between the rotor and stator to achieve the desired psi/stage rating in order to sustain a desirable operating life. Figure 3 shows this relationship between the rotor and stator pitch References and figures at end of paper. lengths. By increasing the number of seal lines or ABSTRACT **

&

,,..

r~...--...=

-.

,,J

...!~

.,

,.,w,~,w

,,

VSAy..

,,

,,

=w

*,

stages the pressure capability of the pump is increased moving through the pump. For each rotation of the rotor, the fluid moves one pitch length of the stator. allowing it to pump from deeper depths. As pressure The longer the pitch length, the higher the velocity increases for the same number of stages and speed ;~l;~sfluid through the pump. Velocity is found as the flow rate decreases. The reduction in flow rate : caused by pressure higher than atmospheric is called slip. V= (Ps)(N) . . . . . . . . . . . . . . ...(5) All rotary positive displacement pumps experience some slippage as a result of differential pressure The flow formula, Q = (A)(V) can now be used substituting the known values to obtain the following between the suction and discharge ends. The amount of equation: slip is determined by the pressure and is independent of speed. It is however dependent upon the number of Q= (4 EDROT)x (Ps) x(N)..... . ...(6) seal lines or stages, the viscosity of the fluid being pumped, and the compression fit between the rotor and stator. The curve in Figure 4 graphically shows the MATERIALS OF CONSTRUCTION definition of slip. Figures 5 and 6 show the effects of fluid viscosity and compression f~t respectively on The continued development of materials of construction of the progressing cavity pump lends to slip. In Figure 5 one can see the effects of fluid its adaptability to a wide range of well conditions. viscosity in relation to slip and flow. The higher The stator consists of a steel tube with an elastomer the viscosity, the lower the slip at any given pressure. This is due to the fact that the increased permanently bonded inside. The elastomer is molded in the configuration of a double helix. The rotor is viscosity will tend to resist flow in any direction. normally tooled steel and chrome plated. The The higher viscosity fluid will not flow easily into the cavity causing cavitation to occur, thus a decrease elastomeric stator and the chromed rotor provide increased abrasion resistance beyond that of other in displacement per revolution. This decrease in flow conventional pumps lending itself well into the cavity is evident in the lower flow rate at to wells that have sand production or fluids with D psi for the higher viscosity fluids. The higher viscosity fluids do create increased frictional line abrasive characteristics. The solids tend to imbed losses in the production string and flowline. This rather than abrade while the elastomeric gear temporarily deforms to allow the particles to pass causes higher line pressure which in turn will bring about higher differential pressure and additional through the pump. Some areas that the progressing slip. Figure 5 shows the effectof rotor/stator fit cavity pump provides superior service is in coalbed on slip. As the compression fit between the rotor gas production where coal fines and frac sand are and stator decreases, the slip within the pump being moved along with produced water. Also in heavy increases with an increase in differential pressure; oil production where formation sand is often moved By design, the compression fit is constant and changes along with the oil. With various elastomeric only from wear of the stator and/or rotor or swell of materials available, a wide range of well fluid the elastomer. characteristics can be handled efficiently using the progressing cavity pump. Elastomers have been The pump is theoretically pulsationless in that developed for wells having highlyaromatic crudes, it has a constant cross-sectional flow area with a high brine content, Iron sulfide, hydrogen sulfide constant velocity resulting in constant positive or other fluid characteristics. An elastomer has displacement flow calculated as: also been developed for high temperature environments such as those encountered in steamflood or huff and puff operations. Q = (A)(V) . . . . . . . . . . . . . . . . . (1) The cross-sectional area can easily be determined by calculating the cross-sectional area of the opening and subtracting the cross-sectional area of the rotor. The dimensions of the in Figures 7, 8 and 5. By circle and rectangle which area, the remaining cavity AROT=area of,a circle= rotor and stator are shown obtaining the areas of the make up the cross-sectional area can be determined. COMPARISON OF EFFICIENCY Although low initial investment, ease of installation and minimal maintenance are advantages the progressing cavity pump has over other artificial lift methods, compared to other methods in similar applications, the progressing cavity pump is normally the more efficient means of artificial lift. For example, to.show the increased efficiency of the progressing cavity pump over other means of artificial lift we have sized three systems for the well conditions shown in Well #1 in the Appendix.1~2 For these parameters a 14 Stage 6 progressing CavitY PUmP running a 510 RPM and a DH30 drive head were selected.1 An operating horsepowerof 25was obtainet from Figure 11. The brake horsepower or operating horsepower was obtained from the performance curve and is the sunwnationof the frictional horsepower plus the calculated hydraulic horsepower (7). The horsepower breakdown at a given speed is shown in Figure 11. phyd = ~. =j2916)(l169\=

llDRoT2 . . . . . . . . . . (2) 4 DROT . .

q

AST8=area of a circle + =fiDR~T2+4E arga of a rectangle

(3)

4CAV=ASTA-AR0TUnDR~T2+$ E DROT-nDR~T2=4 E DROT . . (4)

This shows that the area of the cavity depends upon the size of the rotor diameter and eccentricity. The length of the cavity is determined by the pitch of the stator as shown in Figure 10. The pitch length of the stator determines the velocity of the fluid

19.9Hp

. . . . . (7)

1714

.-

SPE 18873

Kenneth J. Saveth The hydraulic horsepower (H h ) as calculated in Equation (7) is 19,9 Hp. Wit [ Ugth the hydraulic and brake horsepower known, the system efficiency ::ng~ calculated as shown in Equation (8) and is . . Figure 12 shows the graphic comparison for efficiency and horsepower for the progressing cavity pump, the plunger lift system and the electric submersible pump system. CONCLUSIONS

2 .

The efficiency of the system can now be derived through the following equation: es Hphyd (100) = 19.9 (100) = 79.6% . . . . . . . (8) pb 25

The efficiency loss through the DH30 drive head bearings, gears, sheaves and belts is considered negligible therefore the totalsystem efficiency of the selected 14 Stage 6, DH30 progressing cavity pump system under conditions given in Well #1 is 79.6% or 80% . For comparison the plunger pump system that was chosen for this application is a 456 pumping unit with a 2 3/4 diameter plunger running at 15 strokes per minute (5PM) and having a stroke length of 86.4,5 The nameplate horsepower (Hp ) and system efficiency were derived using a cNEbination of the polished rod horsepower (PRHP) calculated from Equation (9); the nominal horsepower rating and the hydraulic horsepower (Hphyd) from Equation (7). PRHP= (F3 ) xSkrx ~) SxN x2.53x10-6 . . . (9)4*5

The progressing cavity pump by design can handle a wide range of applications due to its simplistic design and expanding development in materials of construction. The single helical metal rotor, turning in the double helical elastomer stator with no internal valving gives the PC pump its many advantages. The constant cross-sectional area of the pump cavity theoretically yields a non-pulsating flow. Gaseous, sandy and viscous crudes do not adversely affect the operation of the pump. The progressing cavity pump is normally a comparatively lower initial investment, it is easier to install and requires minimal maintenance. These factors, as well as the overall systems high efficiency, clearly indicate that the PC pump is a viable choice of the many methods of artificial lift. The three pumping systems sized for Well #1 parameters in the Appendix clearly show the progressing cavity pumps advantage in both system efficiency and required horsepower. It can be clearly seen that the progressing cavity pump has many advantages over other artificial lift methods and its range of applications is continually expanding. NOMENCLATURE

= .1484426
= 26.5

54728.27

86

15

2.53

10-6

ro derive the Hp the nominal HP rating for the lumping unit is ~~ed to calculate a % unit nominal horsepower Pating at 20 5PM as done in Equation 10.6 PRHP Nominal Hp 26.5 T = % Unit Nominal Horsepower Rating at 20 SPN = . . ..(l(J)

= 28% . . . . . ........

Q=
P= ACAV = ASTA =

F1OW

GPM)

Inter Fig. 2.24,6 Efficiency vs. Polished Rod {orsepower as Percentage of Unit Nominal Horsepower /sting at 20 5PM to obtain a surface efficiency of !2%.6 Assuming a cyclic load factor (cLF) of 1.375 or NEM4 D electric motors, the HpNp is calculated :0 be 50.6. pN = PRHP CLF =~26.5)(1.375) ~urf~ce E{$ici~ncy .72 = 50.6 Hp . .

Pressure (psi) Area of Cavity Area of Stator Area of Rotor Center L Eccentricity (inches) Diameter of Rotor (inches) Pitch ofStator (inches) Fluid Velocity Number of Revolutions Brake Horsepower Hydraulic Horsepower System Efficiency Polished Rod Horsepower

(11)

AROT=
%= E= DROT = Ps =

With both the hydraulic and nameplate horsepower olown, a system efficiency can be calculated. !s = ~ pNP

(loo)

= 19.6
G

(100) = 38.7% . . . . . . (12)

For the second system comparison, an electric wbmersible pump was sized. A 153 stage Esp system fasselected utilizing manufacturers published iterature.7 The performance curve of the selected. 53 stage ESP shows a horsepower requirement of ).28 hp/stage. By using Equation (13), the required rake horsepower can be calculated. lpB = (Number of Stages)(Hp/stage)(Specific Gravity) = (153 stages)(O.28 Hp/stage)(l.08) =46.3 Hp . .(13)

v=
N= Hpb = phyd = es = PRHP =

A*.

Th@ Prnaressina . ... . - =. ---

..= Cavitv -, -- . .

Pumn -...r

Princinle r.- and Canahilitirx . ..-. ----r--.

-----

<LF
. -

1RR72
.,

I
HpNp = CLF = REFERENCES Nameplate Horsepower Cyclic Load Factor

1. 2.

MOYNO Technical Manual, Robbins & Myers, Inc. Kenneth J., Klein, Steven T., and Fisher, Kevin B.: A Comparative Analysis of Efficiency and Horsepower Between Progressing Cavity Pumps and Plunger Pumps, paper SPE 16194 presented at the 1987 Production Operations Symposium, Oklahoma City, Oklahoma, March 8-10. Dill~n, Michael L. and St. Clair, Kenneth A.: A Method for Predicting Flow Rate in Positive Displacement Rotary Pumps, Robbins & Myers, Inc. 1983. API RP1lL, Design Calculations for Sucker Rod Pumping Systems, (February, 1977); Supplement 1 (March, 1979). SPE Microcomputer Users Group; Disk #21, Release March 1, 1988. Brown, Kermit E., The Technology of Artificial Lift Methods, Volume 2A, Sections 2.841-2.845 1980. Reda Submersible Pump Catalog, TRW Reda Pump.

Saveth,

3.

4.

5.

6.

7.

APPENOIX Well #1 Parameters Pump Setting Depth . . 2700 Ft. (823 m) Total Production . . . 1000 8FPD (159 m3/D) Percent Water Percent Oil API Gravity . . . . 70% (700 8WPO)(111 m3/0) . . . . . 30% (300 80PD)(48 m3/D) . . . . . 27 API

Tubing , . . . . . . . 34 (8.89 cm) Casing . . . . . . . . 5* (13.97 cm) Flowline . . . . . . . 500 ft. of 2.o line 8ottom-Hole Temp. MCFPD GOR . . 100F (38C)

. , . . . . . . 7.5 MCFPD . . . . . ...-.25 . . . . . 0.8

Gas Gravity

No Sand Present

18873

1
MAJOR DIAMETER h :S

i
MINOR DIAMETER

~~
5TATCR ) MAJOR OIAMETER /

t
{ MINOR DIAMETER \ t

---.__

-_

THEORETICAL CAPACITY

~j

T SLIP

-i

P ROTOR/STATOR MAJOR ~MINOR FIGURE- I DIAMETERS GRAPHIC DEFINITION FIGURE-4 OF SLIP

CONSTANT CAVITY CROSS. SECTIONAL FIGURE-2

Q
AREA

P VISCOSITY EFFECT ON SLIP FIGURE-5

R-

I
ROTOR/STATOR PITCH RELATIONSHIP FIGuRE-3

P COMPRESSION FIT EFFECT ON SLIP FIGURE-6

S= N387~

I I

I STATOR PITCH FIGURE.10

ROTOR/STATOR CENTER LINE DIMENSIONS FIGURE-7

r-1
% ROTOR-,$: ~--2E

ROT

20 ---

RUNNING HORSEPOWER

r
E 1

% ROTOR X SECTION /0<__________ % STATOR o Soollioo 1500 2000 HEAD (FT. H20) 2800 ., ___+ _ 1 ::: o ~ HORSEPOWER 3000

@
ROTOR/STATOR ECCENTRICITY FIGURE- 8 DIMENSIONS HORSEPOWER BREAKDOWN FIGURE-II

00 80
60

EFFICIENCY

I
~fl .---:

50 40

HORSEPOWER .. .. . . .;?. ,... / // // 1 /

OROT

30 20 I

m R, 2 }A Im 6000 DEPTH(FT.) COMPARATIVE

[o
CROSS SECTIONAL AREA SCHEMATIC FIGURE-9

0+-.!
OEPTH(FT.)

PERFORMANCE DATA &19.4!Nw 14STAGE6 AT510RPM ----$56PUMPING UNITW/S6 / .- . . . ..CENT.C. STROKE, 2-3/4 PLUNGER 11.5 STAGLS AT15 SPM