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Progressing Cavity (PC) Pump Design Optimization for Abrasive Applications

Article · March 1997

DOI: 10.2118/37455-MS

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SPE 37455

Progressing Cavity (PC) Pump Design Optimization for Abrasive Applications

R & M Energy Systems, a Unit of Robbins and Myers Inc.
Author: Majid Delpassand
Copyright 1997, Society of Petroleum Engineers, Inc.
lining (stator).
This paper was prepared for presentation at the 1997 SPE Production Operations As the rotor turns inside the stator, fluid moves through the
Symposium, held in Oklahoma City, Oklahoma, 9–11 March 1997.
pump from cavity to cavity. As one cavity diminishes, the
This paper was selected for presentation by an SPE Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as opposing cavity increases at exactly the same rate which
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
results in a pulsationless positive displacement flow through
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at the pump. The cavities are separated from each other by a
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper series of seal lines which are created between the rotor and
for commercial purposes without the written consent of the Society of Petroleum Engineers is stator. The pressure capability of a pump is a function of the
prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300
words; illustrations may not be copied. The abstract must contain conspicuous number of times the progressing seal lines are repeated. PC
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435. pump manufacturers rate the pressure capability of a pump as a
function of the number of pump stages. Although somewhat
Abstract arbitrary, each stage is between one to one and a half of a
The progressing cavity (PC) pump is well established as the stator pitch length and is capable of handling 100 psi
pump of choice for handling abrasive solids. PC pump design differential. If cavity pressure increases beyond the seal limits,
can be optimized to achieve the best wear performance the seal lines will open, and fluid will “slip” from one cavity to
available for a given size. The wear optimization of the PC the other at a very high speed. The PC pump slippage is
pumps is achieved through geometric design for minimum generally a function of pressure differential across the pump
internal fluid velocities and by selecting proper materials of and it changes depending on the compression fit of the rotor
construction. and stator.
Wear causes PC pump failure by gradually reducing the
volumetric efficiency and increasing pump slippage. This Flow Rate. Pump flow rate is a function of design parameters
paper focuses on the parameters that influence pump wear, such as stator pitch (Ps ), rotor diameter (D), and pump
describes wear mechanisms, reviews design techniques for eccentricity (Ecc). Equation 1. defines this function:
wear optimization , and presents field data to support some of Q = K*PS*4*Ecc*D*N
the claims. where:
Q ≅ flow rate
Background
N ≅ number of revolutions per unit time
Pump Design Parameters. Figure 1. shows the cross section
of a progressing cavity pump. K ≅ conversion factor

Cavity DD Equation 1.
Ps Ecc
Fluid Velocity. Nominally, for each rotation of the rotor, fluid
will move one pitch length of the stator. Therefore, fluid
nominal velocity in the axial direction of the pump is defined
by Equation 2:
Figure 1. Equation 2. Assumes that the fluid particles travel along a
Definitions: Vfluid= C*Ps * N
Ps ≈ Stator Pitch Where:
D ≈ Rotor/Stator Minor Diameter Vfluid ≅ nominal fluid velocity
Ecc ≈ Rotor Eccentricity N ≅ number of revolutions per unit time
A progressing cavity pump consists of a helical steel rotor C ≅ conversion factor
which turns within a stationary tube with a helical elastomeric Equation 2.
2 SPE 37455

straight line. In reality, fluid does not travel in a straight line Figure 3.
and calculation of the maximum velocity must consider the
longest fluid path along a circular helix defined by the stator
pitch and diameter. The theoretical maximum velocity within a
PC pump is therefore defined by Equation 3.

VMAX= C*N*(Ps2 + ∏2 (D + 4Ecc)2)1/2

where:
VMAX ≅ theoretical maximum velocity
C ≅ conversion factor

Equation 3.
Wear Phenomenon Figure 3. Deep grooves on the rotor crest resulting from
Abrasive wear of PC pumps is one of the most common modes
extreme abrasive conditions
of failure in down-hole applications. High speed particles
(sand) traveling through pump cavities abrade both rotor and Pump Rotational Speed and Number of Stages. Equations
stator. This causes the seal lines between the rotor and stator 1., 2. and 3. show that PC pump internal velocity and flow rate
to become less effective and results in higher pump slippage. increase as pump speed increases. As these parameters
The increase in the pump slippage will reduce pump increase, the rate of particle impact to the rotor and stator
volumetric efficiency and will gradually destroy the pump. increases which will accelerate rotor and stator wear. In
There are many factors that contribute to rotor and stator general, the more abrasive the fluid, the slower the pump must
wear. Among the most important are particle size, operate. The amount of wear in an abrasive application is
concentration and hardness, pump rotational speed and number closely proportional to the speed squared of the pump. One
of stages, and velocity of the solids traveling through the detrimental effect that speed reduction may have on pump life
pump. may best be shown by the performance curves of Figure 4 for a
speed A and B where B is one half of A.
Particle Size. There is little or no uniformity in the size of
sand grains that find their way into the pump. Coarser grains
(less than 20 mesh) can do more damage to the PC pumps
compared to finer powder-like sands (higher than 100 mesh .)
However, high concentration of very fine powder-like sand can
also abrade rotors and stators. Larger sand particles can not
easily pass through the pump seal lines. These particles are
often partially embedded in the inner surface of the stator
(Figure 2.) and continually rub against the rotor during pump
operation.

Figure 4. Effect of wear on progressing cavity pump

performance
Since wear is assumed proportional to speed squared, it
Figure 2. Particles embedded on the stator surface would take four times as long for a pump to wear at speed B
The rubbing of the rotor against the sand particles compared to the same pump running at speed A. Although it
combined with the high speed impact of hard particles with the would take almost four times as long to reach the same amount
rotor contribute to the formation of wear patterns similar to of wear at half the speed, the reduction in the volumetric
SPE 37455 PROGRESSING CAVITY (PC) PUMP DESIGN OPTIMIZATION FOR ABRASIVE APPLICATIONS 3

efficiency1 would be doubled. In most applications, this effect describes flow rate as a function of pump rotor diameter (D),
will negate the usefulness of the longer life expected by speed eccentricity (Ecc), and stator pitch (Ps). Flow rate can also be
reduction. To compensate for this effect, using more pump described by Equation 4.
stages for an abrasive application is recommended. This helps
maintain high volumetric efficiencies under pressure at even Q = Acavity * Vfluid
the lower speeds, reducing the effect of wear on flow rate and Where:
thereby increasing the time between pump replacement. Acavity ≅ Area of the pump cavity cross
Therefore, abrasive wear of PC pumps can be improved by section or (D*4Ecc)
decreasing pump rotational speed and by increasing the Vfluid ≅ Nominal velocity of the fluid and
number of pump stages. particles inside the pump
Equation 4.
Sand Concentration. Most wells produce some amount of Equation 4 illustrates that pump cross sectional area (Acavity)
sand for varying periods of time which reduces rotor and stator must be maximized in order to minimize fluid velocity for a
life of a PC pump. Sand cuts of 10 to 30 percent by volume desired pump flow rate. Figure 5. shows the relationship
are considered to be heavy sand concentrations. In general, between pump design parameters and Acavity . From Figure 5.,
wear is directly proportional to the number of particles that the maximum possible pump cross sectional area and therefore
come in contact with the rotor and stator. Therefore, in the minimum pump internal velocity is achieved when the ratio of
absence of other failure mechanisms and for otherwise rotor diameter to pump eccentricity (D/Ecc) is equal to 4.
identical operating conditions, change in wear life is
proportional to the change in sand concentration. 100
Particle Hardness. The degree of particle hardness also
80
affects rotor and stator wear. If sand grains are harder than the

% MAX FLOW
surface of the rotor, shear on the rotor surface will cause 60
abrasion. Generally, rotor wear is accelerated as the particle
hardness increases. Some times, the affect of rotor wear is 40
accelerated when corrosion induced rotor surface cracks are
20
also present. For example, in sour wells, the effects of hard
iron-sulfide particles are accelerated due to rotor surface 0
corrosion cracks induced by the presence of H 2S. 0 2 4 6 8 10 12

D/E
Particle Velocity. Velocity of the solids traveling through the
pump is the most important parameter that causes rotor and
stator wear. Particle speed within a PC pump can be separated Figure 5. Relationship between pump design parameters
into two categories: 1) predictable pump internal velocity and and PC pump maximum possible flow rate
2) unpredictable particle speed due to pump slippage. To 15
reduce wear in PC pumps, pump internal velocity and slippage
must be minimized. This can be accomplished through 12
geometrical design optimization and proper selection of the
9
Ps/D

pump for the application.

Pump slippage accelerates wear by causing fluid and 6
particles to travel at higher speed between rotor and stator seal
lines. Compression fit between the rotor and stator can be 3
optimized to reduce pump slippage and improve wear life. The 0
following paragraphs describe pump design optimization, 0 2 4 6 8 10 12
materials of construction, and pump selection techniques that
can increase pump life in abrasive applications. D/E

PC Pump Design for Abrasive Applications Figure 6. Stator pitch length which minimizes velocity
Wear in PC pumps increases as a function of fluid and particle Figure 6. describes a more complicated relationship between
speed within the pump. The goal for PC pump design the pump design parameters. This figure shows the stator
optimization is to minimize the particle internal velocity while pitch length (Ps) which minimizes the Vmax (Equation 3.) and
meeting pump flow and lift requirements. Equation 1. therefore provides the best wear performance for a required
pump capacity.
1
volumetric efficiency is defined as the flow rate at the Figure 7. further demonstrates the necessary relationship
pressure divided by the flow rate at zero pressure differential.
4 SPE 37455

between the stator pitch, pump eccentricity, and pump physical strength, tear resistance, and fracture properties. As
diameter to achieve lowest internal velocity. the hard particles stress the elastomer upon contact with the
stator, energy is either converted to heat or stored elastically in
3 the polymeric chains of the rubber. The elastic energy stored
INTERNAL VELOCITY ( V /

D/E=4
D/E=6 within the rubber becomes available as a driving force for the
2.5 D/E=10 rubber fracture propagation. Once the fracture has occurred,
tear properties of the rubber will control fracture propagation
2
Vmin)

within the rubber.

1.5 The elastomer for PC pumps used in abrasive applications
must be soft enough to allow the passage of large particles
1 through the seal lines without damaging the rubber. Optimum
hardness range of the elastomer for maximum life in abrasive
0.5
applications is between 50 to 65 durometer (shore A.) In
0 2 4 6 8 10 12
addition, physical and mechanical properties of the rubber
Ps / D must be optimized to allow hard particles to imbed inside the
rubber without allowing the small surface fractures to
Figure 7. Relationship between pump internal velocity propagate. As in design optimization, it is not always possible
and design parameters to select the most wear resistant elastomer for an application.
Pump design optimization is typically conducted using Figures For example, although the most abrasion resistant rubber
5 and 6 as the starting point. However, manufacturing compound is a high grade of natural rubber, its lack of oil
limitations, well casing size, pump pressure and flow resistance eliminates its use in oilfield applications. Stator
requirements often constrain pump geometrical parameters. elastomer selection must take into consideration other down-
For example, most PC pump rotors are designed with the D/E hole conditions such as temperature, water cut, aromatics
ratio of larger than four (4) to insure adequate rotor strength to concentration, or H2S presence. The abrasion resistance of a
meet torsional and bending stresses. Also, stator pitch is stator elastomer is some times compromised to meet these
typically lengthened beyond the optimized value to increase down-hole conditions.
the pump capacity per revolution (at the expense of higher
internal velocity.) Consequently, it is not always possible to Pump Selection
optimize a pump solely based on the wear performance, and Selecting a PC pump for an abrasive application involves
often pump wear resistance is compromised in order to meet several steps. First, the pump must be rated for the application
other design requirements. flow requirements. The user must then select a pump which
can produce the desired volume at lowest fluid internal
Materials of Construction for Abrasive Applications velocity and at lowest possible pump rotational speed. The
Rotor Coating. Rotor wear is the primary cause of pump user must also consider de-rating pump pressure per stage to
failure in abrasive applications. To date, the majority of PC maximize pump life for the application. Once these criteria are
pump rotors are hard chrome plated. Hard chrome is adequate considered, the materials of construction must be selected for
for medium to low abrasive environments. However, life of a maximum wear life.
chrome plated rotor can be reduced by as much as 50% in high Material selection can greatly influence the life of a PC
flowing wells that produce more than 10% sand. pump. To select the right material for an application, all down-
Alternative rotor coatings using thermal spray processes hole conditions which may contribute to rotor and stator
have been successfully used by PC pump manufacturers to failure must be considered. Materials for the pump must be
improve rotor life in abrasive applications. Field trials of these selected to achieve the best overall performance for the
rotors have shown to double or triple the life of chrome plated application. For those applications where abrasion is the
rotors in similar applications. The alternative coatings are primary concern, stator material must have superior wear
typically more expensive than chrome and operators must properties as described in the previous section. Hard chrome
carefully weigh the economic benefits of using these rotors for or other wear resistant rotor coatings must also be considered
their specific applications. to improve rotor life in abrasive applications. Selection of the
Stator. Elastomeric stators give PC pumps an advantage over pump material may also require an economic justification
other down-hole pumps in handling abrasive slurries. The since some of the alternative materials might be more
flexibility of the elastomer allows large abrasive particles to go expensive than others.
through the pump or to imbed rather than abrade the stator.
The PC pump stator elastomer can be optimized for best wear Field Results
resistance while meeting other mechanical and physical New elastomers and rotor coatings for abrasive applications
properties. have been studied in many different locations in Canada and
The elastomer wear resistance optimization involves the United States. Figure 8 shows the improvement in pump
creating a balance between the elastomer’s cross-link density,
SPE 37455 PROGRESSING CAVITY (PC) PUMP DESIGN OPTIMIZATION FOR ABRASIVE APPLICATIONS 5

life obtained using pumps optimized for abrasive applications

in the sandy (3 to 20 percent by volume) Lloydminster region
in Canada2.
SERVICE DAYS
400
350
AVG PUMP LIFE
300 WITHOUT
250 OPTIMIZATION

200
150
100
50
0
1 2 3 4 5 6 7 8 9 10

Figure 8. Improvement in average pump life of ten

different wells in Lloydminster Canada using more
abrasive resistant elastomer
Summary
Progressing cavity pumps can be optimized to provide longer
life in abrasive applications. Wear optimization of PC pumps
is achieved through pump geometric design, proper selection
of stator elastomers and wear resistant rotor coatings, and
proper sizing of the pump for the application. Down-hole
conditions such as concentration, size, and hardness of the
sand particles influence pump wear. PC pump life can be
extended by reducing particle velocity through the pump, by
running the pump at lower speed, and by adding more stages to
the pump. Field results show that the life of PC pumps can be
increased significantly if pumps are optimized for the abrasive
conditions.

Acknowledgments
Author wishes to thank Moyno@ Oilfield Products for the
opportunity to prepare this paper. Author also expresses
appreciation to Mr. Dave J. Bourke for providing valuable
technical comments.

2
The data was obtained in December 1996 and all of the
pumps shown in this Figure were still in operation.

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