IMPROVING PROGRESSING CAVITY PUMP PERFORMANCE

THROUGH AUTOMATION AND SURVEILLANCE

K. A. Woolsey, SPE, KUDU Industries Inc. Copyright 2010, Society of Petroleum Engineers

kudupump.com
Abstract
To extend the run life of the pump while producing all
available fluid is the goal of all PCP operators. The primary
challenge is to do so without starving the pump and
causing damage to the stator. The petroleum industry has
been searching for years to find a reliable way to control
progressing cavity pumps for pump-off. Several methods
have been used, from monitoring torque to manual fluid
levels. To date, none of these have been commercially
successful. A method for controlling these wells has
been developed combining wedge meter flow technology
and microprocessor control of both electric motors using
variable frequency drives and hydraulic motors using
proportional control valves. This method has proven to
Introduction
The acceptance of progressing cavity pumps in the oil and
gas industry has grown throughout the world. One of the
major concerns has always been causing stator damage
if the well is pumped off. The most common prevention is
to ensure that there is a substantial amount of fluid level
above the pump. Operators taking manual fluid level shots,
and adjusting pump speed has been the most widely used
method to maintain a safe fluid level. With advancements
in fluid flow measurement and proven algorithms, the PCP
Pump off Control for
Progressing Cavity Pumps
Two main objectives were defined when the theory of the
PCP Controller was first introduced. The first objective
was to reduce premature pump failure. The most common
failure is stator damage due to pump off. Pump off is
defined as a lack of fluid entry into the pump. This causes
a lack of lubrication to the stator resulting in extremely
high temperatures being generated. The high temperature
ultimately burns the elastomer in the pump. The rubber
surface of the stator becomes hard, brittle, and cracked. In
severe circumstances, the stator contour is completely torn
up producing rubber at surface. This may be caused by one,
or a combination of the following, problems; plugged pump
intake, poor inflow, or production rates exceeding inflow.
be accurate and reliable, extending the run life while
producing all available fluids.
Combining this automated technology at the well with
a web based system that feeds back real time data to a
dedicated SCADA host allows PCP technical experts to
diagnose problems, and operators to respond quickly to
changing well conditions.
This presentation discusses the advances in automation
and optimization of progressing cavity pumps. The method
will be explained and data will be presented of field study
results showing actual well tests.
controller has eliminated this concern, while producing
all the available fluid from the well bore without
damaging the pump.
With this automated technology and a web based
SCADA system we were able to monitor several data
trends and discover additional control algorithms.
Continued development of these algorithms
is ongoing.
The second objective was to automatically optimize the
well. There are several problems associated with trying
to maintain a safe fluid level with the use of manual
fluid level equipment. Fluid levels are only an indication
of how much fluid is over the pump at the time the fluid
level is taken. There are a large number of misinterpreted
fluid levels due to surface and rod noise as well as foam.
Downhole anomalies such as high liner tops, bad dog legs,
or other non standard configurations will result in false
fluid levels. It is extremely time consuming to shoot fluid
levels, adjust speed, allow the well to stabilize and shoot
the fluid level again. This manual process is often not a
quick enough reaction to account for changes in inflow.
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By optimizing the well, we not only eliminate the fluid
level monitoring problems above, we also increase
overall production. This is accomplished in several
ways. First, by keeping the fluid at or near the pump
Development of Theory and
Control Algorithms
The primary control algorithm of the PCP Controller is the
production control algorithm. Its purpose is to optimize
production of the well without causing pump off. The
patented control algorithm varies the speed of the pump
in steps while measuring the amount of fluid production
from the pump. As long as sufficient fluid is available at
the pump intake to completely fill the pump cavities, a
linear relationship occurs between fluid production and
pump speed. The special hunting algorithm continuously
looks for the most production. The controller continues
increasing the pump speed in user-defined steps,
measures production rate at each step after the settling
time, and establishes a speed/rate relationship.
A description of the production control algorithm
is as follows:
The PCP Controller begins an operating cycle at a user-
defined startup speed. When the well is first started at
the suggested start up speed, for example 150 rpm, the
initial well state is the settling period. This is the period
of time that the production from the well is allowed to
stabilize after any speed change. For our purpose we
will use three minutes for the settling time.
After the three minute settling time the controller goes
into sampling period. This is the period of time that
the production from the well is measured and a flow
rate is established. For our purpose we will also use
three minutes for the sampling time. The flow rate that
is established is total fluid in barrels per day for that
period. The pump is then sped up between the hard set
minimum speed change and the maximum allowable
speed increase that is preset. The well is then placed
back in the settling period again.
After the three minute settling period and the three
we are maintaining the lowest bottom hole pressure
promoting the most fluid inflow. Second, by being able
to pump over capacity the system is able to make a quick
recovery from downtime.
minute sampling period, the algorithm looks at the
flow rate and determines if it satisfies the minimum
production increase requirement that was preset at
commissioning. For this purpose we will use 5%. If the
production increase is greater than 5% the speed of the
pump will be increased a percentage of the previous
production increase while remaining within the minimum
and maximum speed change window and the hard set
minimum speed change. This process is repeated until
the minimum production requirement is not met, or the
pump reaches the maximum speed allowed. At that
time the pump speed is reduced to a value between the
maximum and minimum speed decrease window that is
preset at commissioning. See Figure 1.
After the well is ramped down in speed the settling
and sampling periods are again observed and the
production still needs to meet the minimum production
requirement. There is a number of consecutive speed
ramps allowed that are configured at commissioning
before the challenging algorithm is implemented. For
this purpose we will use three. After the well is ramped
down in speed three consecutive times and the minimum
production requirement is not met, the pump is sped up
the hard set minimum speed change, and the settling
and sampling periods are again observed. If the minimum
production requirement is met then the pump continues to
be sped up and the production is tested. If the minimum
production requirement is not met then the pump will be
ramped down again and the process continues.
The PCP Controller also has secondary control algorithms
that monitor the following:
A polished rod torque value either from the electric
variable speed drive analog output, or hydraulic
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 pressure from the hydraulic pump to the hydraulic
motor. This value is used to protect the rod string and
pumping equipment. Two violation settings are provided
for torque with the option of programming the well
to either shut down or slow down when the limit is
exceeded. The torque limiting violation is used to limit
the rod torque. The current torque is compared to the
specified limit value to detect if the pump is beginning
to show evidence of stalling or fluid starvation that
can cause friction between the stator and elastometer,
thus increasing the torque. Torque is monitored every
second, and once it is violated, the PCP Controller will
decrease the speed by the specified torque limiting
speed value, and continue reducing speed until the
minimum operating speed is reached. In this state,
the PCP Controller either operates in a downtime or
violation minimum running speed mode. The Critical
Torque violation is used to either shut the well down or
run in minimum speed when in a high torque situation.
The current torque is compared to the specified limit
value. This is an instantaneous action that reduces the
speed to the minimum operating speed or shuts the
well off depending on the action selected.
A current flow rate value either via the wedge meter or
another trusted flow measurement device. Two violation
settings are provided for flow rate with the option of
programming the well to either shut down, or slow
down when the limits are exceeded. A low production
fluid rate limit is specified defining the minimum
amount of fluid production allowed. Production for
the current sampling period is compared to this value
to detect a fluid starvation/dry pump condition. This
feature also helps to detect (at the rate of one-minute
resolution) if something is wrong with the production
transmitter. When a violation occurs, the PCP Controller
decreases motor speed by the value specified. At this
state, the PCP Controller either operates in a downtime
or minimum running speed mode.
A low pump efficiency limit is specified defining the
minimum efficiency the pump is allowed to operate at.
Production for the current sampling period is compared
to this value to detect low pump efficiency. When a
violation occurs, the PCP Controller decreases motor
speed by the value specified. At this state, the PCP
Controller operates in either a downtime or minimum
running speed mode.
All secondary control features slow the pump when one or
more set point limit is violated. If the monitored variable
continues to be in an alarm condition when a programmed
minimum speed is reached, the PCP Controller will stop
the well to prevent damage to the pumping equipment.
After proving the initial production control algorithm it
became evident that the flow meter was a critical part
of the complete system. Although exact accuracy was
not necessary, repeatability was critical. Many types of
meters were tested, however, the wedge meter proved
to be the most reliable when measuring flow at the
wellhead. Working in conjunction with the wedge meter
manufacturer many improvements were made and this
device is now the meter of choice for most applications.
See figure 2.
Combining this automated technology at the well with
a web based system that feeds back real time data to
a dedicated SCADA host allows PCP technical experts
to diagnose problems, and operators to respond quickly
to changing well conditions. See figures 3 & 4. Utilizing
statistical process control the SCADA host allows
operators to determine when changes in field conditions
occur. By monitoring the difference between the maximum
allowable working speed of the pump and the current
speed we can immediately determine if the well is
optimized. Automatic reaction to changing field
conditions prevents pump damage. See figure 5. This
has shown significant results in increased production,
and pump run life, as well as a reduction in maintenance
and down time, thus providing better cost/time
management for operations.
Continued improvement with customer input has driven
development of additional algorithms that make producing
wells with a high sand content much easier. See figure
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6. With additional equipment at surface, this technology
has successfully performed automated flushes of large
Field Study Results and Historical Data
1. A 15 well pilot project started in January 2007 included
the host SCADA system and the PCP VFD Combo unit
complete with wedge flow meters. The results showed
an increased average oil production from 120 m3/day,
to 145 m3/day. An unexpected benefit of increased
average gas production from 19 to 23 dec/day was also
noticed. This showed an estimated payout in 120 days.
See sample well from this project on graphs 1 & 2.
2. A single well pilot started July 2008 was chosen due
to its extreme production difficulties For the first six
months prior to the installation of the PCP controller,
this Bakken zone well had four pump changes due
to sand and inflow issues. The well produced a total
of 2711 m3 with an operational cost of $198,000.00.
On July 1st, 2008 Kudu installed a 300TP1200 pump
and added the hydraulic PCP controller with wedge
flow meter. For the next six months the well produced
19,779 m3 with no work overs. The pump ran for 14
months before it needed to be changed out due to wear
and tear from abrasion. The hydraulic control system
expertly maintained speed changes using PID loop
amounts of sand without operator intervention. See
figure 7.
control on the proportional valve without adding heat to
the system. See graph 3.
3. A single well pilot started in Dec 2009 was chosen by
the producer because they were unable to keep the well
running. Before optimizing the well the concentration
was on producing the sand that was preventing the
well from running. Once this was achieved we were
able to increase fluid production. By bringing the well
on slowly, limiting the maximum speed over four stages
the sand was cleaned up to a very manageable level and
the revenue for the well was increased from $ 0/day to
$7,798/day with an oil gain of 19.4 m3/day. See table 1.
4. A single well pilot started in Sept 2009 was chosen due
to the short run life of the pumps. Prior to installing the
PCP controller the pumps were being replaced every
3 to 4 months. A new pump was installed at the same
time the PCP controller was installed. This pump has
been producing since Sept 2009 and the most recent
test showed a pump efficiency of 74% with an oil gain
of 1.84 m3/day, increasing oil revenue by an average of
$925.00/day. See graph 4.
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GRAPH 1: Example 1 Results

GRAPH 2: Example 1 Results

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GRAPH 3: Example 2 Results

TABLE 1 Example 3 Results

Nov 26-Dec 26/09 Dec 27-Mar 15/10 Mar 16-Apr 15/10 Apr 15-May 15/10 May 16-June 15/10
Pre-controller #1 Post-controller #1 Post-controller #2 Post-controller #3 Post controller #4
Hrs On 744 741 744 744 744
m3 Oil/Day 0.00 0.99 1.29 10.19 19.40
m Sand/Day
3
0.000 0.006 0.000 0.000 0.000
m H2O/Day
3
48.97 38.45 108.95 139.40 144.30
m3 Oil/Day 0.00 0.99 1.29 10.19 19.40
$/Day $ 0.00 $ 398.11 $ 517.41 $ 4,097.81 $ 7,798.80
$/Month $ 0.00 $ 12,341.40 $ 16,039.80 $ 127,032.00 $ 241,762.80

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GRAPH 4: Example 4 Results
Conclusion
The PCP controller has proven to be a successful and
viable well manager for progressing cavity pumps,
in meeting the objectives originally set forth. Overall
productivity has been increased for the well and for the
entire field by increasing daily fluid production, recovering
more quickly from downtime, and enhancing cost and time
management for operations. The PCP controller meets
Acknowledgements
I would like to express my gratitude to Lufkin Automation
and Theta Oilfield Services Inc. for their product
and exceeds the goals and expectations of maximized
production, minimized downtime, reduced equipment
failures, and extended equipment run life. By eliminating
the need to continuously monitor fluid levels and manually
adjust pump speed, operators are able to concentrate on
other tasks. Secondary control features allow protection
from over pressure, high torque, and sand plugging.
information and equipment used in this paper, as well as
IHS for the Accumap production and well data provided.
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FIGURE 1: Minute by Minute Production, Speed, and Torque Trends

FIGURE 2: Wedge

FIGURE 3: XSPOC Group Status Screen

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FIGURE 4: Well Status Screen

FIGURE 5: Minute by minute production and speed trend showing automatic reaction to
increased flow line pressure.

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FIGURE 6: 7 Day trend data showing automated sand handling

FIGURE 7: Trend data showing automated flush technology

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