Progressive Cavity Pump Research Articles

Алгоритм расчета напорных характеристик винтовых насосов

Алгоритм расчета напорных характеристик винтовых насосов

Online wear detection for joints in progressing cavity pumps

Abstract The wear and failure of pin joints integrated in coupling rods of process equipment can lead to unpredictable breakdown with severe consequences. We present a simple algorithm for a non-invasive online detection of wear in pin joints where a progressing cavity pump serves as an example. The algorithm only requires a pressure sensor and a binary speed signal of the motor. We verify the algorithm with a laboratory test setup and an embedded system. The results show that the proposed algorithm can reliably monitor joint wear during regular pump operation.

Guest Editorial: Artificial Intelligence in the E&P Industry: What Have We Learned So Far and Where to Next?

Artificial intelligence (AI) has captivated the imagination of science-fiction movie audiences for many years and has been used in the upstream oil and gas industry for more than a decade (Mohaghegh 2005, 2011). But few industries evolve more quickly than those from Silicon Valley, and it accordingly follows that the technology has grown and changed considerably since this discussion began. The oil and gas industry, therefore, is at a point where it would be prudent to take stock of what has been achieved with AI in the sector, to provide a sober assessment of what has delivered value and what has not among the myriad implementations made so far, and to figure out how best to leverage this technology in the future in light of these learnings. When one looks at the long arc of AI in the oil and gas industry, a few important truths emerge. First among these is the fact that not all AI is the same. There is a spectrum of technological sophistication. Hollywood and the media have always been fascinated by the idea of artificial superintelligence and general intelligence systems capable of mimicking the actions and behaviors of real people. Those kinds of systems would have the ability to learn, perceive, understand, and function in human-like ways (Joshi 2019). As alluring as these types of AI are, however, they bear little resemblance to what actually has been delivered to the upstream industry. Instead, we mostly have seen much less ambitious “narrow AI” applications that very capably handle a specific task, such as quickly digesting thousands of pages of historical reports (Kimbleton and Matson 2018), detecting potential failures in progressive cavity pumps (Jacobs 2018), predicting oil and gas exports (Windarto et al. 2017), offering improvements for reservoir models (Mohaghegh 2011), or estimating oil-recovery factors (Mahmoud et al. 2019). But let’s face it: As impressive and commendable as these applications have been, they fall far short of the ambitious vision of highly autonomous systems that are capable of thinking about things outside of the narrow range of tasks explicitly handed to them. What is more, many of these narrow AI applications have tended to be modified versions of fairly generic solutions that were originally designed for other industries and that were then usefully extended to the oil and gas industry with a modest amount of tailoring. In other words, relatively little AI has been occurring in a way that had the oil and gas sector in mind from the outset. The second important truth is that human judgment still matters. What some technology vendors have referred to as “augmented intelligence” (Kimbleton and Matson 2018), whereby AI supplements human judgment rather than sup-plants it, is not merely an alternative way of approaching AI; rather, it is coming into focus that this is probably the most sensible way forward for this technology.

Исследования изменения свойств бутадиен-нитрильных эластомеров для скважинных винтовых насосов

Исследования изменения свойств бутадиен-нитрильных эластомеров для скважинных винтовых насосов

Improved accuracy and precision of bioprinting through progressive cavity pump-controlled extrusion

3D bioprinting has seen a tremendous growth in recent years in a variety of fields such as tissue engineering, drug testing and regenerative medicine, which has led researchers and manufacturers to continuously advance and develop novel bioprinting techniques and materials. Although new bioprinting methods are emerging (e.g. contactless and volumetric bioprinting), micro-extrusion bioprinting remains the most widely used method. Micro-extrusion bioprinting, however, is still largely dependent on the conventional pneumatic extrusion process, which relies heavily on homogenous biomaterial inks and bioinks to maintain a constant material flow rate. Augmenting the functionality of the bioink with the addition of nanoparticles, cells or biopolymers can induce inhomogeneities resulting in uneven material flow during printing and/or clogging of the nozzle, leading to defects in the printed construct. In this work, we evaluated a novel extrusion technique based on a miniaturized progressive cavity pump (PCP) which allows precise control over the volumetric flow rate by positive displacement. We compared the accuracy and precision of this system to the pneumatic extrusion system and tested both systems for their effect on cell viability after extrusion. The PCP achieved a significantly higher accuracy and precision compared to the pneumatic system, while maintaining good viability. These improvements were independent of the bioink composition, printing speed or nozzle size. This study demonstrates the merit of precise extrusion-process control in bioprinting by PCPs and investigates their influence on process-induced cell damage. PCPs are a promising tool for bioprinting and could help provide standardized and validated bioprinted constructs while leaving the researcher more freedom in the design of the bioinks.

Geometrically Calibrated Network Models for Progressive Cavity Pump Design

Summary Linear network models are promisingly simple progressive cavity pump design tools. Current linear network models are difficult to use in the design process because they require calibration against experimental data or computationally intensive simulation. In this paper we present new approaches for implementing linear network progressive cavity pump models and provide new methods to accurately and quickly estimate the values of each resistor in the model from pump geometry for both laminar and turbulent flows. This paper also argues that sealing-line flow transitions from laminar to turbulent at orders of magnitude smaller Reynolds numbers than described in the literature thus far. We propose a new hypothesis for the point of transition to turbulent performance.

Modeling the performance of progressive cavity pump under downhole conditions

Progressive Cavity Pump (PCP) is a common artificial lift method for high viscosity liquid production. In elastomeric stator PCP, the clearance between the metal rotor and elastomeric stator prevents mechanical friction but also causes reverse flows phenomenon known as slippage. This clearance is a key parameter in modeling pump performance. Currently, existing PCP slippage models are developed for single-lobe, constant clearance, at surface operation. This study experimentally and theoretically investigates the effect of downhole condition on behaviors of elastomeric stator. An analytical model for stator deformation based on Hooke's Law and composite cylinder theory is proposed. The proposed model is coupled with a developed analytical model for PCP performance at surface conditions to introduce, for the first time, a comprehensive model applicable for multilobe PCP operating at downhole conditions. The coupled model is validated against experimental data of PCP characteristic curves for different stator materials. Using the model, sensitivity analysis of design parameters (initial pump clearance, stator thickness, material stiffness, number of lobes) on pump performance is carried out. The findings of this study can aid manufacturers and operators in optimizing PCP design and operation.

Profiling of the flat-tool for manufacturing worms with circular eccentric profile by cold forming

The incremental pumps are encountered in pharmaceutical and cosmetics industries. One of the most representative categories of these pumps is formed by the progressing cavity pumps. The helical surfaces with circular profile, eccentrically positioned relative to worm axis, are frequently used in their rotors construction. In this specific case, the constructive dimensions of the worms allow their manufacturing by cold forming, with flat-tools similar to screwing dies. In this paper, an analytical algorithm for profiling such flat-tool is proposed. The algorithm starts from the analytical definition of the helical cylindrical surface with constant pitch of the generated worm, and it lays on the “Minimum distance method”. The equations of the gearing surface between worm and flat-tool are found, and, based on this, the active surface of the tool is determined. A MatLab application developed for implementing the profiling algorithm is presented. The results obtained after running the application in the case of a particular generated surface are also included.

PCM buys Halliburton Energy Services' Europump business

PCM Artificial Lift Solutions Inc has acquired Halliburton Energy Services Inc's Canada Progressive Cavity Pump Business Line known as Europump.

PCM and Bolland form JV in Argentina

Progressive cavity pump manufacturer PCM and Argentinean oil services company Bolland y Cía SA have signed an agreement to set up a 50/50 joint venture headquartered in Argentina.

Study on Speed and Clearance Optimization of All-Metal Progressing Cavity Pumps: Experiment and Simulation.

The stator and rotor of an all-metal screw pump are made of metal; so the matching method of the all-metal screw pump cannot be like that of the traditional rubber screw pump, and a certain gap must be reserved. If the gap is too small, it will affect the normal operation of the pump. If the gap is too large, the pump leakage will also become larger, affecting the efficiency of the pump. In this paper, the method of numerical simulation is used to optimize the gap of the pump. At the same time, it is found that the optimal gap of the pump is closely related to the viscosity of the fluid transported by the pump, and different viscosity fluids have different optimal speeds. The speed and clearance of the pump are optimized through numerical simulation to ensure high pump efficiency while taking into account energy saving and avoid the waste caused by excessively high speed. Finally, the relevant research results of numerical simulation are verified through experiments, and it is found that the experimental results are in good agreement with the simulation results, which also proves the accuracy of the numerical simulation results.

Production Data Analysis and Sonolog for Determining Artificial Lift Design and Well Characteristic

Tarakan Field, North Kalimantan is a part of PT. Pertamina EP Asset 5. The Tarakan Field has 5 structures in the form of Pamusian, Juata, Sesanip, Mangatal, and Sembakung. The Tarakan Field has 57 production wells and 6 injection wells. The wells at Tarakan field are produced with artificial lifts in the form of Sucker Rod Pump (SRP) totaling 25, Hydraulic Pumping Unit (HPU) totaling 11, Electric Submersible Pump (ESP) totaling 19 and Progressive Cavity Pump (PCP) totaling 2. The determination of artificial lifts is carried out by the design of well characteristics and production history. The design at Tarakan Field was carried out with an artificial lift in the form of ESP (Electric Submersible Pump). ESP is used according to reservoir and formation characteristics in Tarakan Field.
 Water Control Diagnostic Plot is a method used to analyze the effect of control on produced water. Water Control Diagnostic plot is plot between WOR and WOR derivative vs time. The plot was carried out on a log-log scale. The plot on the Water Control Diagnostic Plot is then analyzed against the graph created by the KS Chan. So from the analyzed plot, it is found whether or not there is a problem in the well at Tarakan Field. The results of the graph analysis on the well at Tarakan Field on the chart show that the field does not indicate a problem.
 
 Keywords: chan plot; design; esp; production

High-Density Polyethylene Liner Safeguards Against Corrosion and Wear

This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper SPE 199000, “High-Density Polyethylene Liner: Successful Alternative Against Corrosion and Wear Problems in Production Tubing of Mature Fields in Colombia,” by Gloria Isabel Duarte Poveda, Miguel Mateus Barragán, and José Alexander Estévez Lizarazo, Ecopetrol, et al., prepared for the 2019 SPE Latin American and Caribbean Petroleum Engineering Conference, Bogota, Colombia, 5-7 June. The paper has not been peer reviewed. Production tubing in mature fields in the Magdalena Department’s Middle Valley in Colombia has shown a run life between 180 and 300 days, with failures mainly caused by corrosion and abrasive wear or friction mechanisms. Extended use of high-density polyethylene (HDPE) liner in flow and collector lines with corrosion and abrasion problems has resulted in positive results. The complete paper presents the results of evaluation of laboratory and demonstration trials of HDPE liner to mitigate premature failures and prolong the run life of production tubing. Introduction Root-cause analysis determined that failures in production tubing in the mature Casabe and Cantagallo fields could be the result mainly of corrosion by the multiphase fluids transported or as the result of wear mechanisms caused by contact between the internal wall of the tubing and the sucker rod in artificial-lift systems. To solve this problem, HDPE liner was evaluated in the laboratory and implemented in a pilot-scale test. Results proved its ability to absorb abrasion impact from sand particles and resist CO2 corrosion. After 12 months in service, the HDPE liner demonstrated its compatibility with aggressive fluids, remaining thermally stable with no structural variation and absence of swelling, softening, and blistering. After 6 years, the pilot remained failure-free and operationally active. On the basis of these results as well as other research in the literature, HDPE liner was proposed as a downhole alternative to prolong run life of critical wells in the Casabe field. To this end, HDPE lining for carbon steel tubing was developed and manufactured in Colombia through an engineering process that included materials specification, prototype design, mechanical stress analysis, laboratory tests in simulated downhole conditions, redesign of the prototype, and optimization of the production process. To validate the technology, the downhole HDPE liner was installed in three producing wells with progressive-cavity-pump (PCP) artificial-lift systems and a run life of approximately 300 days. After 400 days of service, well intervention was performed not related to tubing; the tubing had not experienced damage and was reinstalled, with a three- to sixfold run-life increase. HDPE Liner Technology HDPE is known for its ability to inhibit corrosion, improve flow fluid because of a lower friction coefficient compared with carbon steel, and resist abrasive wear because of high tenacity properties. The HDPE (PE-100) is used in contact with multiphase fluids (water/crude oil/gas) with maximum service temperature of up to 60°C, depending on the manufacturer. According to laboratory tests, the resistance of HDPE to abrasive wear and corrosion is approximately three times that of carbon steel.

ВЛИЯНИЕ ГЕОЛОГО-ТЕХНИЧЕСКИХ И ТЕХНОЛОГИЧЕСКИХ ПАРАМЕТРОВ НА НАГРУЗКИ И УСТАЛОСТНУЮ ПРОЧНОСТЬ В ШТАНГОВОЙ КОЛОННЕ ВИНТОВЫХ НАСОСОВ

Актуальность исследования обусловлена необходимостью повышения надежности и ресурса штанговых винтовых насосных установок, используемых для осложненных условий эксплуатации скважин, поскольку они имеют низкую надежность в сравнении с электроцентробежными насосами, что ограничивает их применение. Винтовые насосные установки используются в скважинных условиях, характеризующихся высокой вязкостью откачиваемой пластовой жидкости (более 30 мПа·с) и высоким содержанием механических примесей в ней (коэффициент взвешенных частиц более 500 мг/литр). Опыт эксплуатации винтовых насосных установок показывает, что надежность насосных установок зависит в первую очередь от надежности штанговой колонны. Помимо крутящей нагрузки, необходимой для передачи вращения от асинхронного двигателя к винтовому насосу, погруженному на расстояние более одного километра от устья скважины, штанговая колонна испытывает растягивающие нагрузки от веса насосных штанг и осевой нагрузки винтового насоса, а также изгибающие нагрузки, вызванные пространственным искривлением ствола скважины. Цель исследования заключается в оценке влияния различных факторов эксплуатации на нагрузки, действующие на колонну насосных штанг в процессе эксплуатации скважины, а также на усталостную прочность насосных штанг. Методы: методика расчета штанговых колонн винтовых насосных установок с учетом осевых, крутящих и изгибающих нагрузок, учитывающая процессы трения штанговой колонны о насосно-компрессорные трубы, возникающие от Эйлеровых сил прижатия штанг к трубам из-за пространственного искривления ствола скважины, реализованная на языке программирования Python; факторный анализ нагрузок, действующих на привод насосной установки. Результаты. С помощью программного обеспечения, реализованного на языке программирования Python, произведены расчеты, показавшие влияние различных осложняющих факторов на величину нагрузок на штанговую колонну. Показано влияние нагрузок вследствие воздействия геолого-технических и технологических параметров на усталостную прочность насосных штанг. Разработанное программное обеспечение позволяет учесть степень влияния осложняющих факторов на стадии подбора компоновки винтовой насосной установки, а также в процессе эксплуатации и тем самым существенно увеличить межремонтный период работы штанговых винтовых насосных установок.

Viscous flow simulations through multi-lobe progressive cavity pumps

Computational fluid dynamics (CFD) simulations of multi-lobe progressive cavity (PC) pumps are limited in the literature due to the geometric complexity of the pump, which places numerous restrictions on the grid generation process. The present study attempts to alleviate such restrictions by developing a detailed numerical procedure for the numerical simulations of multi-lobe progressive cavity pumps. The profile equations for the multi-lobe configuration at any section at each instant of rotation are presented. A structured grid generation method is developed to generate mesh files required for CFD simulations of multi-lobe PC pumps. Results from the present procedure are validated against single-lobe PC pump numerical results available in the literature. Finally, a numerical parametric study is carried out to investigate the effect of the number of lobes, the stator pitch, the circular fillet and clearance on the volumetric efficiency of PC pumps with viscous oils.

Risk assessment of PCP lift system using a fishbone diagram and MICMAC method

Hydrocarbons demand by industrialized and developed nations and the oil prices conditions last few years; many companies have turned again to fields that were not previously considered attractive to produce, to identify them as an alternative to meet that demand. This research shows the identification of a condition, which should be taken into account to produce a mature field by progressive cavity pumping (PCP) artificial lift system, an evaluation with the MICMAC method and the identification of the key variables to achieve the development in this practice. The results make possible to identify highest influence elements, which can guide intervention strategies and form the basis to formulate guidelines and policies for the PCP implementation. The results allow us to conclude that pressures and mechanical designs in field wells should be the guidelines for optimum production, the market rate improvement, and the reservoir productive life.

A Seamless Transition Scheme of Position Sensorless Control in Industrial Permanent Magnet Motor Drives With Output Filter and Transformer for Oil Pump Applications

This article proposes a position sensorless control scheme for the induction and permanent magnetic low-voltage (LV) motor drives with an output filter and transformer for an electric submersible pump (ESP) and progressive cavity pump (PCP). The proposed sensorless strategy covers the full-speed range for ESP drives. An open velocity loop, current regulated sensorless controller is utilized to drive induction and permanent magnet motors (PMMs) during starting and at low speeds. A field-oriented controller (FOC) that utilizes an estimated rotor position based upon motor back electromotive force (EMF) is utilized to drive the motor at higher speeds. A seamless transition between controllers for the two operational modes, i.e., low-speed control and high-speed control, is proposed in this article. With velocity mode control over the full-speed range and mode control hysteresis, a smooth transition between open loop and EMF-based observer control can be achieved. The sensorless control scheme presented in this article has been implemented in a commercial drive for an ESP (deep well) application.

Analyses of Electric Submersible Progressive Cavity Pumps for Production of Heavy Oil Reservoir in the Niger Delta

A new artificial lift pump technology has emerged to increase the production of heavy oil in order to meet up high global demand for energy. The technology is a hybrid of two principal artificial lift pumps for lifting crudes. The hybrid called electric submersible progressive cavity pumps integrates the applicability and usefulness of electric submersible pump and progressive cavity pump. This gives it enhanced performance and more adaptability to varied reservoir conditions. This technology has the advantages of sample technology and management convenience. Electric submersible progressive cavity pump (ESPCP) is suitable for the viscous crude containing sand and high gas oil ratio oil extraction. In this paper, developing history of ESPCP is introduced and the structure and principle are analyzed. The advantages of ESPCP are compared with other oil extraction technology. In addition, the technical applicability of this new technology in the Niger Delta heavy oil fields and economic evaluation of the ESPCP were evaluated. The result of this research work showed that ESPCP showed better performance when compared with ESP and PCP making it a choice pumping system to replace the traditional gas lift predominant in the Niger Delta artificial lift operations.

Application of machine learning methods to assess progressive cavity pumps (PCPs) performance in coal seam gas (CSG) wells

In Queensland, progressive cavity pumps (PCPs) are the artificial lift method of choice in coal seam gas (CSG) wells, and this choice of artificial lift production stems from the ability of PCPs to better manage the production of liquids with suspended solids. As with any mechanical pumping system, PCPs are prone to natural wear and tear over their operational life, and with the production of coal fines and inter-burden, the run life of PCPs in CSG wells is significantly reduced. Another factor to consider with the use of PCPs is their reliability. As per the CSG production data available through the Queensland Government Data Portal, there are approximately 6400 wells operational in the state as of December 2018. This number is expected to grow significantly over the next decade to meet both international and domestic gas utilisation requirements. Operators supervising these wells rely on a reactive or exception-based approach to manage well performance. In order to efficiently operate thousands of PCP wells, it is pertinent that a benchmark methodology is devised to autonomously monitor PCP performance and allow operators to manage wells by exception. In this study, we will cover the application of machine learning methods to understand anomalous PCP behaviour and overall pump performance based on the analysis of multivariate time-series data. An innovative time-series data approximation and image conversion technique will be discussed in this paper, along with machine learning methods, which will focus on a scalable and autonomous approach to cluster PCP performance and detection of anomalous pump behaviour in near real-time. Results from this study show that clustering real-time data based on converted time-series images helps to pro-actively detect change in PCP performance. Discovery of anomalous multivariate events is also achieved through time-series image conversion. This study also demonstrates that clustering time-series data noticeably improves the real-time monitoring capabilities of PCP performance through improved visual analytics.

Progressive cavity pump tubing drain valves: operator-savings illustration

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.