Rodless PCP Technology: From Theory to Reality; Analyzing One Year of Performance

Abstract

Abstract Oil producers have been utilizing Progressing Cavity Pumps (PCP) for decades, as it is the optimal method of artificial lift to effectively handle fluids with high solid content. These wells can be vertical, directional or horizontal, while the latter two optimize in-flow performance and maximize fluid rates. Conversely, these well-bore geometries create high contact loading between the rod and tubing, which ultimately leads to an increased and costly intervention frequency to repair failed rod and/or tubing. While there are several products that exist to prolong run-time in these environments (Endless Rod, Tubing Rotators, etc.), these failures cannot be entirely eliminated, and in some cases make these wells uneconomical to produce. The oil industry has been looking for an alternative to effectively and economically produce these troublesome oil wells. Many producers have been on a crusade seeking an alternative to a conventional rod driven PC Pump. This crusade has led to the development of a Rod-less PCP system, allowing the full benefit of the pumps ability to handle solids, while eliminating the primary cause of failure: the rod string. A major requirement to effectively operate a Rod-less PCP system is the ability to provide sufficient rotational torque. With this in mind, a team of industry professionals in their respective fields (Electrical Submersible Pumps, PCP, and Sensor-less Surface Control or SSC) began working cohesively to develop an all-inclusive system. The system provides full surface control and monitoring using the down-hole intake/discharge pressure gauges, a vibration sensor, and a motor winding thermocouple.