SPE 136817

The Special Successful PCP Applications in Heavy Oilfield

Bingchang Wu, SPE, Xin Li, PCM Pompes

Copyright 2010, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Progressing Cavity Pumps Conference held in Edmonton, Alberta, Canada, 12–14 September 2010.

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 have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is 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 acknowledgment of SPE copyright.

Abstract
Due to some particular advantages, such as the maximum suitable artificial lift system for heavy and sandy wells, higher
pump efficiency and power saving, PCP (Progressive Cavity Pump) is becoming one of the popular oil artificial lift system in
recent years. PCP artificial lift technology is up to 12% all over the world averagely, and 50% in Canada. For normal heavy
oil (viscosity ≤1000CPo), the oil can be lifted to the surface only using conventional PCP system. But for the more viscosity
oil (viscosity ≥1000CPo), the viscosity and frictional resistance in the formation and annular (between tube and sucker rod)
will induce a very big difficulty for the oil flowing from the formation to pump depth and from pump depth to the surface, so
some assistant measures must be used with PCP system to lift the oil from downhole to surface.

For SAGD (Steam Assisted Gravity Drainage), CSS (Cyclic Steam Stimulation) and SFD (Steam Flooding Drive) wells,
steamed gas is assisted to decrease the oil viscosity to enhance its fluidity. PCM Vulcain™ (PCP with metal stator and metal
rotor) had been successfully applied in such kind of wells since 2007. And PCM PCP with 198 high temperature resistant
elastomer had been successfully used in 4 CSS wells. In addition, several high viscosity wells are producing with normal
PCM PCPs assisted with light oil mixing system, hot water injecting system and electricity heating system.

This paper will discuss the successful PCP artificial lift system applications with above 5 special assistant systems. This
paper will be a guider for such kinds of special PCP technologies to be spread and applied widely in the world.

Introduction
It is estimated that half of the world’s known oil reserves are made up of unconventional oil, viscous ranging from heavy oil
to nearly solid bitumen. These oils cannot flow unless they are heated. The oil viscosity is sensitive to the oil temperature and
decreases greatly with the oil temperature increasing. Thermal recovery methods, such as SAGD, CSS and SFD, are used to
inject heats into the reservoirs, decreasing the oil viscosity and enabling the oil to flow to the well.

For CSS, the initial operation fluid temperature is 200°C to 350°C, and then the fluid temperature decreases with the
producing of the well, until to the normal formation temperature. For SAGD and SFD, and the operation fluid will keep
almost the same high temperature 140°C to 250°C during the whole production period. Standard progressing cavity pumps
(PCP), sucker rod pumps (SRP) and electrical submersible pumps (ESP) are limited in terms of maximum operating
temperature. The PCM Vulcain™ and 198 high temperature elastomer are the pumps that can work efficiently at the high
temperatures of thermal recovery.

Some other assistant treatments are also used to decrease the oil viscosity along the tubing, thus the better fluidity can be got
from the perforation depth to the surface. Heating the fluid by electrically heated sucker rod system, injecting hot water, and
injecting light oil from surface to downhole are the suitable methods to decrease the oil viscosity.

The Theory of PCP System [1, 2]

PCP is known for their simplicity of design and operation. The heart of the pump is composed of two parts, the stator and the
rotor. The stator has a dual helical profile, while the rotor (which rotates inside the stator) has a single helical profile,
designed to mate with the stator profile. The rotating action of the rotor creates progressing cavities from suction side,
displacing the fluid through each successive cavity, until to discharging side(Fig. 1). PCPs are non-pulsating pumps and will
deliver a constant flow rate for a given rotor speed. In the conventional elastomer PCP, the part of the stator with the helical
profile is made of elastomer and is glued to an external metallic tube. The rotor fits the stator with negative clearance.
2 SPE 136817

The advantages of PCP system are: Easy flow-rate control (proportional to speed); accepting low or high viscosity; power
saving comparing other artificial lift methods; more energy efficient than other pump technologies; low net positive suction
head (NPSH) (i.e., operates with low bottomhole pressure); Non-shearing and no formation of emulsions; Easy initial startup
at higher viscosities; compact footprint.
Fig.2. is the typical diagrammatic sketch of surface and down hole PCP system.

Fig. 1 the structure and working principle of PCP

Fig.2 typical diagrammatic sketch of surface and down hole PCP system

1. PCM Vulcain™ (metal to metal PCP)

For the metal PCP, the stator is fully metallic and able to withstand very high temperatures. The metallic helical profile is
produced by hydro-forming. The stator is composed of three 9-ft-long elements welded together. Both rotor and stator are
specially coated for high temperature and wear resistance, but the rotor serves as a sacrificial element. Due to its patented all-
metal design, PCM Vulcain™ solves both sides of the equation by providing all the natural advantages and flexibility of
progressing cavity pump technology at extreme temperatures. The details lift property of Vulcain™ in bench test have been
presented in SPE paper 97796 [3].

1.1 Highlight of PCM Vulcain™

• Wide operating temperature range (up to 350°C)
• Easy to install, similar to conventional PCP
• A lifetime of 1 year minimum (8,000 hours)
• Ability to handle sand contained in oil (up to 2%)
Endurance, abrasion and coating improvements in the manufacturing process, providing superior performance and
resistance.

1.2 Completion Details

PCM Vulcain™ pump serials are available with a complete surface and down hole equipments and tools. More details see the
Fig. 3.
SPE 136817 3

Fig.3 surface and down hole completion parts for PCM Vulcain™ system

1.3 Application Statistics

The first prototypes were successfully tested on a high temperature loop made available by a major operator in 2007 [4]. And
many PCM Vulcian™ pumps were successfully applied in Canada in next 2 years [5].
To-date (January 2010), more than 19 systems are currently operating, of which all the pumps overcome 12 months
continuous run life. The life time record is today 33 months on a low pressure SAGD well in Canada (Fig.4). Table 1 is the
application parameter record where PCM Vulcain™ system successfully performed.

Fig.4 the life span of PCM Vulcian™ pump

4 SPE 136817

Table 1 the record application of PCM Vulcain™

Max CO2 33%
Max H2S 1.2%
Max DLS above pump 13.1 º / 100ft
Max DLS at pump depth 5º/100ft
Max Bottom Hole fluid temperature 210ºC
Max Bottom Hole steam through pump 320ºC
Max fluid temperature (running) 250ºC
Max running lifer 33 months
Max setting depth 860m (TVD) at 60º

2. PCM 198 High Temperature Elastomer PCP in CSS Well

2.1 The Property of 198 High Temperature Elastomer

Table 2 shows the property of 159 and 198 elastomer. Elastomer 159 is a conventional elastomer model and elastomer 198 is
a high temperature resistance model.

Table 2 property list of elastomer 159 and 198

2.2 CSS Well Conditions for the First Trial

The cycle of the steam injection stopped on March 16th, 2008, with steam pressure of 16.5 MPa, steam temperature 349°C,
steam rate15 ton/hr, steam dryness 63%, total steam injected 1500 ton. The well was closed for 5 days after the injection
completed, the actual measured temperature was 192°C, depth 1140 m. After this steam cycle, the daily fluid rate was
expected to reach around 30 tons/day.

2.3 Installation and Operation Summary

• Well Shu 1-39-036 Completion Diagram
PCM 198 Elastomer pump 200TP1200 wa selected for this trial. PCM VH60-8T drive head together with the 30 KW motor
is used to supply the surface power. The speed will reach 250 rpm when frequency is 50 Hz. Tubing size is O.D. 89.9mm.
Hollow plug-in sucker rod size is O.D. 36mm. The pump depth is designed at 850m.
• Well 1-39-036 data summary of operation
March 20th, 2008, 5 days after closure (after the steam injection), PCM 198 PCP was installed. March 22nd, 2008, well was
completed and started up successfully. Daily collection of the running data includes fluid production, speed, current,
wellhead temperature and dynamic level (Fig.5).
SPE 136817 5

Fig. 5 198 elastomer PCP operation data (first 60 days)

Fig.6 shows the downhole temperature distribution along the well body. The blue line is the static temperature, tested just
before the pump installation. The red line is the dynamic temperature during the first operating days calculated from the
temperature at perforated depth and wellhead.

Fig. 6 static and dynamic temperature distribution along the well body
After successfully running 12 month, the well turned into the next steamed gas injection cycle.

2.4 Second trial, Well Shu 1-39-38 with real time downhole monitoring
On August 28th, 2008, the second PCM 198 elastomer PCP was installed in Well Shu 1-39-38. The steam injection
parameters for this well were: injection pressure 14.6 MPa, injection flowrate 16 tons/h, steam dryness 72%, total steam
injection 1451 tons. Then the well was closed for 5 days to soak the high temperature in the formation.
In order to obtain the real downhole temperature distribution along the well, and since the temperature is decreasing with
time, a set of downhole temperature optical fiber was installed along with the PCP. The principle is Raman-scattering which
happen when the laser is spreading through the optical fiber, and then light with 2 different levels of energy (Stokes and
Antistokes) will be reflected. The temperature distribution data along the optical fiber can be calculated by contrasting the
strength of these 2 lights and can be shown directly in the computer. The advantage of this method is that continuous
temperature along the optical fiber can be measured, so the temperature at each depth along the well can be monitored. For
well Shu 1-39-38, the temperature data was gathered every meter with a precision ±1°C.
Before the next steamed gas injection cycle, this well has been normally working for more than 14 months, daily fluid
production 45 tons/day, daily oil production 15 tons/day, water cut 67%. With the downhole gauge, the measured
temperature at pump-depth before the pump start-up is 98°C. After the start-up, and having increased the frequency to 50 Hz,
the temperature at pump depth reached 155°C. After that, decreasing the frequency to 30Hz，the temperature gradually
decreased till 125°C.
6 SPE 136817

3. PCM PCP Application in Heavy Oil with Light Oil Injection

3.1 Oil property in PCP application block

Tuha block is a heavy oil block, average oil density is about 0.96g/cm3, oil viscosity is about 1~5.5×104 mpa.s, moreover the
formation depth (normally 2300~2700m) is deeper than normal heavy oil block. Table 3 shows the detail of oil and
formation. All these make it more difficult to lift the oil to the surface.

Table 3 Oil property in PCP application block

Formation Formation Formation Oil viscosity at Oil viscosity at
Oil density
Block depth pressure temp. 3 surface formation
(g/m )
(m) (MPa) (°C) (mpa.s) (mpa.s)
1# 2300 23.7 65.6 0.9668 35510 611
2# 2700 27.3 76.7 0.9629 12000 423

3.2 Technical Solution

The experiments in the laboratory showed that the viscosity of the heavy oil decreased when it mixed with kerosene. The
higher ratio of heavy oil to kerosene, the lower mixed viscosity can be got. When the ration is 1.0~4.0, the result is better.
When the ratio is 1.0, the viscosity of the mixed oil is down to 12 mpa.s (Fig. 7).

Fig. 7 the oil viscosity decreasing with the mixing ratio

Based on the experiment results and the unique advantages of PCP in the production of heavy oil, PCP with light oil injection
was selected as the main artificial lift technology in Tuha block. Considering the cost saving and sources, the light oil is used
to replace kerosene or other chemical agent [6] for mixing with heavy oil. The mixing ratio of heavy oil to light oil is 3.
The light oil was injected from wellhead to the annular between tubing and casing (Fig. 8), and mixed the heavy oil at the
depth between dynamic level surface (1600m~1800m) and pump depth (1900m~2030m). Then the mixed oil can be easily
lifted from pump to the surface.

Producing line

Injection line

Fig. 8 the surface equipments of PCP system

SPE 136817 7

3.3 The Operation Data

Until now, 6 wells were trialed and each of them gets the good results, high pump efficiency, high oil incremental and power
saving. Table 4 shows the operation details of the wells. And all of these wells are running well now.

Table 4 the operation data of PCP with light oil injection

pump pump total total oil power
speed liquid oil
well No. depth 3 efficiency running incremental saving / day
（rpm) (m /d) (t/d)
(m) (%) days (ton) (KW.H)

1# 2004 131 32 1 95 460 1429 69

2# 2005 104 21 12 85 178 767 46
3# 2021 165 29 13 74 227 1750 115
4# 2015 150 40 7.5 92 217 318 161
5# 1880 158 23 9.6 59 210 285 46
6# 1997 126 24 11 78 54 38 58

4. PCM PCP Application in Heavy Oil with Hot Water Injection

4.1 Oil property in PCP Application Block

Caogu1blocl belongs to a buried hill cavity and fractured heavy oil reservoir with strong bottom and edge water. The average
oil viscosity is 23900-50000 mPa.s at the surface, and the oil is very sensitive to the temperature. The viscosity decreases
50% for each 10°C fluid temperature increasing. 10 wells were selected for testing the formation temperature, and the result
showed the temperature is 40~48°C at the depth 840~950m. Table 5 shows the formation and liquid properties.

Table 5 oil property of PCP application with hot water injection

Formation Formation Formation Oil viscosity Oil viscosity
Reservoir Oil density
Block depth pressure Temp. 3 at surface at formation
type (g/cm )
(m) (Mpa) (°C) (mpa.s) (mpa.s)
1# buried hill 840-950 23.7 40-48 0.9668 23900-50000 2650-5500

4.2 The Exploration History and the Ddifficulties

• Stage 1: wells drilled and trial producing period (Sept. 1996 ~ Dec.1999)
36 vertical wells and 5 horizontal wells were drilled and put into production with beam pump during this period. All these
wells were operated with CSS assistant. The average flowrate per well is 37 m3/d, and water cut is about 75%。
• Stage 2: oil production descending period (Jan. 2000 ~ Dec. 2001)
4 horizontal wells were drilled and put into production during this period. But another 10 wells was closed because of the
high water cut (water coning) and only 35 wells worked at this stage with average flow rate per well was 28 m3/d, and water
cut was about 82%。
• Stage 3: low oil production period (Jan. 2002 ~ Dec. 2006)
Only 18 wells were operating during this period because of two high water cut, average up to 96.4%. And the average fluid
flow rate is 43 m3/d for per well.
During the first 3 stages, most of the wells are CSS wells.
• Stage 4: oil incremental by increasing flow rate (Jan. 2007 ~ now)
From this stage, CSS is stopped for most of the wells. Considering the too high average water (97.1%), so cold heavy oil
production was trialed by PCP. The purpose is to get more oil production by using increasing the flow rate for each well.
Table 6 shows the key information about different stages.

Table 6 operation information of different stages

Stage 1 Stage 2 Stage 3 Stage 4
CSS yes yes yes no
Total well 41 45 45 45
Qty of running well 41 30 18 30
Average flow rate of per
3 37 28 43 80
well (m /d)
Average oil rate of per
3 9.5 5 1.5 2.3
well (m /d)
Average water cut (%) 25 82 96.4 97.1
8 SPE 136817

4.3 PCM PCP Applications in Caogu1 Block

In order to lift the heavy oil with high water cut more easily and efficient, hot water injection from the well head to the
annular between casing and the tubing. 19 PCM PCPs were applied in this block from year 2008, and all of them work well
until now. Table 7 is the running data of some of the wells.

Table 7 operation data of some PCP wells in Caogu1 block

pump pump total
speed liquid water cut
Well No. depth 3 efficiency running time
（rpm) (m /d) (%)
(m) % (days)
1# 650 110 93 95 70 460
2# 650 120 99 40 69 178
3# 680 100 75 54 63 227
4# 660 100 90 80 75 217
5# 660 110 92 54 70 210
6# 680 170 140 50 68 54
7# 650 110 92 40 70 178
8# 650 120 95 54 66 227
9# 660 120 93 80 65 217

5. PCM PCP Application in Heavy Oil with Electrical Heating

5.1 System Introduction

Newly developed electric heating hollow rod drive PCP system adopts hollow sucker rod to drive the rotor [7]. The torsion
capacity of the hollow rod is almost twice as normal rod with the same cross section. By running integral cable into the
hollow rod, forming a circuit by the cable and the rod, making the rod wall heat by means of the skin effect, the crude oil in
the tubing is heated, thereby the flow ability of the oil is increased, and the frictional torque on the rod string is decreased.
Tests and applications show that the system is characterized by long heat section, uniform heating and adjustable heating
power. And it is especially suitable for the recovery of high viscosity, high condensation and high paraffin content crude oil.
The electrical parts can heat the whole fluid from the stator to surface. Normally 30~50°C can be increased to the fluid in the
tubing, and the viscosity of the fluid can be decreased 67%～80%. Fig.9 shows the sketch of the surface and down-hole
equipments of the electrical heating PCP system.

Fig.9 surface and downhole equipments of electrical heating PCP system

1. rod crossover 2. Hollow rod terminal 3. Hollow sucker rod 4. Tubing 5. Casing 6. Well head 7. Drivehead system 8. Cable
turning system 9. Input cable 10. Hollow polish rod 11. Output cable 12.secondary cable 13. Junction box 14. Solid sucker
rod 15. Rotor 16. Stator
SPE 136817 9

5.2 Oil Property in PCP Application Oil Block

This technology has its unique technology advantage for heavy oil with high paraffin content oil and high condensation oil.
More than 20 such kind of PCP systems were used in Dagang oilfield, Shengli oilfield and Huabei oilfield. Table 9 shows the
formation and oil property in Shengli oilfield.

Table 9 formation and oil property in Shengli oilfield using electrical heating PCP
Formation Oil
Formation Formation Paraffin Oil viscosity Oil viscosity
depth Oil density freezing
Block pressure temp. 3 content at surface at formation
(m) (g/m ) point
(MPa) (°C) (%) (mpa.s) (mpa.s)
(°C)
1# 840-950 23.7 50 0.9668 12~37 25 23900-50000 2650-5500

5.3 The Operation Data of Electrical Heating PCP System

Table 10 is the operation summary of electrical heating PCP system in Shengli oilfiled. The fluid of all the wells were heated
to around 50°C at the surface which kept the oil from freezing in the tubing and can easily produced to the surface.

Table 10 operation data of electrical heating PCP system in Shengli oilfield

Oil viscosity pump Heating Heating Well head
speed Flow rate
Well No. at formation depth cable depth 3 power Temp.
（rpm) (m /d)
(mpa.s) (m) (m) (KW) (°C)

1# 6616 1409 1200 100 12 63 49

2# 5507 1284 945 62 8 57 47
3# 6021 1437 1035 62 9 61 51
4# 357 810 800 120 5.5 41 46
5# 6034 1200 950 120 7 59 50
6# 10000 880 800 90 5.5 43 45

6. Well Candidate More Suitable for Each PCP Technology

How to select which PCP technology will be used in a block depends on the formation and oil property for each block. The
following table 11 shows the general standards more suitable for each technology.

Table 11 suitable well conditions for each PCP technology

Technology Suitable well conditions
1. Fluid Temp. 150~350°C 2. Pump lift head ≤ 1000m
Vulcain™ 3. Sand cut ≤ 0.5% 4. GOR ≤ 30% at pump suction
5. CSS, SAGD, and SFD wells
1. Fluid Temp. ≤ 150°C 2. Pump lift head ≤ 2600m
198 high Temp. elastomer PCP
3. CSS wells and hot water well
1. Fluid Temp. ≤ 120°C 2. Pump lift head ≤ 2600m
PCP system with light oil injection 3. Paraffin content ≤ 3% 4. Water cut ≤ 50%
5. oil viscosity sensitive to light oil
1. Fluid Temp. ≤ 120°C 2. Pump lift head ≤ 2600m
PCP system with hot water injection 3. Water cut ≥ 75% 4. Enough hot water source
5. Oil viscosity sensitive to temperature
1. Fluid Temp. ≤ 120°C 2. Pump lift head ≤ 2600m
PCP system with electrical heating
3. Paraffin content ≥ 3%

Conclusions
• Many successful applications show that all above 5 special PCP system technologies are fully feasible and successful to
heavy oil production.
• The above 5 special PCP system technologies are extensions to the conventional PCP system, and push the PCP system
technology to a wider application range.
10 SPE 136817

References
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production wells”, SPE 97796, 2005 SPE International Thermal Operations and Heavy Oil Symposium held in Calgary, Alberta, Canada,
1-3 November 2005.
4. J. Beauquin, F. Ndinemenu, G. Chalier, L.Lemay, L. Seince, and A. Damnjanovic. “World's First Metal PCP SAGD Field Test Shows
Promising Artificial-Lift Technology for Heavy-Oil Hot Production: Joslyn Field Case”, SPE 110479, 2007 SPE Annual Technical
Conference and
Exhibition held in Anaheim, California, U.S.A., 11–14 November 2007.
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6. Daqing Li, Xiuchao Wang, Zhensen, Chu. “PCP System Trial with Chemical Agent Injuction”. Special Oil & Gas Reservoirs [J], 2001,
No.4,Vol.8.
7. Jianping Lu. “The research on PCP Artificial Lift Technology with Electrical Heating”. Oilfield equipment [J], 1998, No.4, Vol. 27.

Acknowledgements
The authors would like to PCM for permission to publish this paper.