IPTC 10032

The Successful Application of 2000 PCP Wells in Daqing Oilfield

L. He, SPE, and C. Gang, SPE, Daqing Oilfield Co. Ltd.; W. Dingmin, PetroChina; and S. Guochen, SPE,
Daqing Oilfield Co. Ltd.
Copyright 2005, International Petroleum Technology Conference
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Abstract
With years of study and experiments, a complete series of
Progressive Cavity Pump (PCP) products has been developed.
Sets of down-hole pumps for various rates and lifting
capacities were developed for water-flooding, polymerflooding and ASP flooding areas according to the specifics.
One of the newest techniques, a hollow rotor PC Pump, has
been applied in more than 800 wells. It has proved to be an
effective way in removing the wax build-up and reducing
operation cost. Another specially designed product was the
sucker rod. By strengthening and redesigning the area
susceptible to failure, the new sucker rod prolonged the
running life of the lifting systems considerably. Also, a new
type of drive head with compact structure has been proved to
be more convenient in maintenance and more economic than
the traditional products. By means of completed monitoring
techniques including PC Pump testing equipment and
diagnosing software, PC Pump systems can be monitored in
real time. This decreased the frequency of failures and
improved the benefits effectively.
With more than 2000 PCP wells in Daqing Oilfield, the
capital and operating costs have reduced dramatically. The
PCP system, the most effective lifting method, has great
potential for Daqings Oilfield.
Background
Daqing Oilfield lies in the center of Songliang basin in North
east China. In the beginning stages, commingle water injection
and separate zone water injection technologies were used
which allowed the reservoir pressure to remain at a high level.
Therefore, by natural power the oil field produced for nearly
twenty years. To maintain the output, artificial lift
technologies were used from 1980s. Beam pumping system
was the most popular one. Up to the end of last century, the
number of beam pumping systems in Daqing reached over
20,000 wells. There were also about 2,000 ESP wells in
operation.

In 2000, the average water cut for the whole oilfield reached
nearly 90%. Huge operation cost was the most serious
problem for beam pumping system. In 2002, the total power
consumption of artificial lifting systems was nearly 10 billion
kWh, which was over one third of the whole oil fields power
consumption.
From 1990s, polymer flooding, APS flooding and other
EOR technologies were applied in Daqing oilfield. The
recovery of the oilfield improved considerably. On the other
hand, the failure rate for the artificial lift system increased
dramatically due to the changing properties of output. For
example, the beam pumping system in polymer flooding areas
decreased the average running life from more than 600d down
to 270d. Cost for overtime also increased by ten million RMB
per year.
As for ASP flooding area, the results were even more
serious. Due to high scaling in pumps and strings, the average
running life of the beam pumping system was less than 60d,
while the shortest running life was within a month. Artificial
lifting technology has become a bottleneck problem for
Daqing Oilfield in EOR period.
With this in mind, PCP system was chosen to be the first
alternative. It has lower investment and operation cost, higher
efficiency, and a high viscosity and sandy liquid production.
PCP Technologies in Water Flooding Area
Problems in Pilot Test. At first, Daqing oilfield was regarded
as the best place in China for the application of PCP lifting
system: all vertical wells, lower lift (less than 1000m), no
sand, lower oil gas ratio(less than 100), and no H2S. But due to
the limitation of manufacturing technology, PCPs were first
used only in small production rate wells whose production was
less than 30t/d. It was expected that PCP technology would be
successfully used in water flooding area in Daqing within five
years. But as of 1996, there were only 10 wells in the whole
oilfield. See Figure 1. High failure rate was the killer of this
new technology.
The main forms of the failures were pump and rod failures.
In most cases, the systems operating current increased
quickly which resulted in rods being broken frequently. Also,
upon examining the strings, they sometimes appeared to have
been twisted like a rope. Due to the severe deformation of
elastomer, pumps could not be reused after treatment.
Moreover, stators dropping out failure was also a concern.
Improvements of Elastomer. A special laboratory was
created to research the PCP system. Experiments indicated

that the problems mainly came from three things: (1) the
formula of elastomer didnt fit for the conditions of the
oilfield. The swelling of the stators was too high to keep the
pump operating normally. (2) Bonding technology in
processing the pump was not qualified and resulted in stators
dropping out failures. (3) The design parameters of the pump
were not the optimum. Therefore, the performance of the
technology was limited as well.
According to the above analysis, a series of experiments
were carried out in advancing elastomer formula, improving
the pumps processing technology, and optimizing the pumps
design parameters.
1.
Advancement of elastomers formula. The
elastomers formula was adjusted in the following three
respects:
(1) Adjusting the vulcanization system. Through the reselection and adjustment on sulfidizer and rubber activator, the
elastomers heat and aging resistance were improved
effectively.
(2) Improving the antioxidant. The major factors which
influence rubbers aging time include oxygen, heat, and
fatigue. When temperature rises 1, the oxidation rate will be
increased by 1 time. So its very important to select a proper
antioxidant for elastomer.
(3) Adjusting the strengthening agent to improve the
physical mechanical properties of the stator.
A new elastomer formula was developed after years of
study. Table 1 gives the performance contrast between the
previous elastomer and the new one. It obviously shows that
the physical mechanical properties of new formula elastomer
are much better than the previous one.
2.
Improvement of processing pump technology. A
series of innovative techniques were undertaken to improve
the pumps processing quality :
(1) Improving the force plugs centralization in the process
of elastomer injection. In the old elastomer injection process,
its not easy to put the stators force plug and outer barrel
exactly at the same axis, which often resulted in uneven
thickness of elastomer. In that case, the pumps operating load
would be unstable which decreased the pumps running life
and was easy to cause pump failure. Thus, a centralizing
treatment was added in the elastomer injection process, which
improved the stators quality effectively.
(2) Improving the bonding effect by spraying sand
technique. High stator drop out failure rate came from the
problems in stator bonding technology. Analysis indicated
that, there were some severe defects in stator bonding agent
and bonding process. After reselecting the bonding agent and
reforming bonding technology, the bonding strength increased
considerably.
3.
Optimization of pumps design parameters. PCP
design parameters mainly include: rotor/stator minor diameter
(D), rotor pitch (t), rotor eccentricity (e), stator-rotors fit (),
and steps(Z). And the optimization of these parameters were
carried out by the following two respects:
(1) Determining the optimization goals.
a. To get a larger flowing area. In order to get a larger
flowing within a limited casing inner diameter, the design
parameter should have the following relationship:

IPTC 10032

D + 4e + hmin < D0

[eq.1]
Where, hmin is the minimum value of stator mandrels
thickness. Then, for a given PCP series products, the
relationship of design parameters is showed as [eq.2]:
C = D + 4e
[eq.2]
In order to get the maximum of flowing area S=4eD, from

[eq.3] we could get D=4e:

S
=0
e

S
=0
D

or
[eq.3]
b. To get higher volume rate and a smaller flowing velocity.
During the process of rotation, lifting liquid on the edge of the
action line of rotor has the highest velocity:

v y max = n T 2 + (4e + D) 2

[eq.4]

Where the ratio of design parameters is:

T = 2 D
[eq.5]
c. To get a slower sliding velocity. Lower sliding velocity
between rotor and stator helps to decrease the elastomers
wear as well as prolong PCPs operating life.
When the flowing area is given, thus:
v max
=0
D

v max
=0
e

or
[eq.6]
The same result could also be deduced: D=4e.
(2) Analyzing the design parameters influence on PCP
performance. PCPs performance consists of three respects:
displacement, load, and mechanical efficiency. The
mechanical efficiency is calculated by the previous two,
therefore, PCPs performance is mainly reflected by its
displacement and load performance.
Eq.7 shows that PCPs displacement per rotation depends
on the value of design parameters. Table 2 gives three type of
PCPs displacement per rotation.
Q = 4eDTn
[eq.7]
PCPs loads consist of torque, axial force and cross force.
And rod strings operating torque mainly consists of rotors
operating torque and tilting moment. Figure2 shows that,
operating torque and tilting moment depends on e, D and t,
while tilting moment has no relationship with eccentricity (e).
PCPs axial force is one of the major factors in selecting rod
sting, while the rod strings oscillation mainly depends on the
cross force. Figure 3 shows that, axial force has no
relationship with pitch (t), and cross force is related to
eccentricity (e). Table 3 gives three PCPs specifications with
different interference between rotor and stator.
Pump failure rates decreased dramatically after taking the
above innovative from 1998. Till the end of 2001, the number
of small rate PCPs in Daqing Oilfield rose up to 448 wells; the
average running life reached 640d.
Hollow Rotor PCP Technology. Wax removal is necessary
for oil producers of Daqing Oilfield due to the high wax cut in
most areas. The most popular method in Daqing Oilfield is
water-flushing technique which injects hot water into casing
annulus from the well head of producers. Hot water was
generated from pump stations, and was sent to the producers

IPTC 10032

by flushing lines. Wax removal treatments were carried out in

a given period for different areas, depending on the wax
depositing rate in this area. Its easy to be implemented in
beam pumping system because it doesnt have any damage on
the lifting system as well as has no great effect on the
productivity. But as for PCP system, its very difficult to
effectively remove the wax deposited in tubing by means of a
high-pressured volume of water due to the interference fit
between rotor and stator. In order to improve the effect of
water flushing, in the past, the rotor had to been pulled out
from the barrel of the pump before flushing, and ran the rotor
back into the pump after the treatment. The process was time
consuming and expensive; moreover, due to rotors frequently
being pulled out and thrown back into the pump, the stator was
easy to be damaged which decreases PCPs running life
considerably.
A new patented technology, named hollow rotor PCP water
flushing technology, solved the problem effectively. In this
technology, the traditional solid rotor was replaced by a
hollow rotor, and a flushing valve was set above the pump. In
the process of wax removal, hot water flows downward
through the annular. At a higher flowing rate and pressure, the
flushing liquid easily would open the valve and pass through
the pump. See Figure 4. Moreover, PCP system could operates
during the flushing process, thus, some flushing water would
enter tubing with lifting liquid which would improve the wax
removal result as well.
Compared with solid rotor PCP, hollow rotor PCP
technology has many advantages:
(1) The water flushing liquids rate and pressure is much
higher which results in a shorter wax removal process and
better results as well. See table 4.
(2) The greatest benefit is that it neednt to pull out the rotor
from the pump or to shut off the system during the
process. The cost is cut down considerably due to the
creative reform compared with the previous method.
(3) This technology is more helpful in protecting the pump
and could improve the operating life effectively.
(4) Combined with a set of tools (eg. Packer, etc.), flushing
water could be isolated from the producing layer and will
not do harm to the reservoir. See Figure 5.
To date, there are more than 800 hollow rotor PCPs in
Daqing Oilfield.
PCP Technologies for EOR Process
Based on the improvements of small rate wells in water
flooding areas, another test pilot for EOR production was
carried out. From the end of 1998, the test pilots production
rate ranges from 50 to 200t/d. The initial results were exciting:
the pumps volume efficiency reached more than 60% on
average and running lives were near 300d, which was much
longer than beam pumping systems 30d.
With the increment of PCP number, the failure rate in high
rate wells rose up quickly. It was found that, the new problem
came from the original lifting systems inadaptability to the
new operating conditions. Hence, not only the significant of
pump needs to be adjusted, but also needs the design criteria
of the lifting system to be modified. Under the guidance of this
opinion, a series of new PCP products for EOR were
developed in the following years.

Two Novel Sucker Rods. Compared with beam pumping

system, the operating conditions of PCP string are quite
different. Apart from the axial load, a torque load is added
along the string in operation. Sucker rods in PCP wells were
originally designed for beam pumping systems which do not
take the PCPs operating conditions into account. That means,
the traditional sucker rods are used for enduring axial force
along the string. When an extra higher torque is added, which
is periodically, the string would tend to be broken on the
thread or the body. The following two novel sucker rod
designs solve this problem:
1.
Jaw-Clutch sucker rod for high rate PCP wells. In
this design, the torque of the string is added on the jaw clutch,
and the dragging force is added on the couplings thread
separately. Because the shearing strength of jaw clutch on
couplings is high enough as well as a hollow rod body design,
the string could operate in serious working conditions, such as
lifting high production rate, high viscosity liquid or sandy
liquid. See Figure 6.
When designing the shape of coupling, three candidates
were brought forward, see Figure 7. The Finite Element
Method (FEM) calculation indicated that design #2 has the
highest carrying capacity, and as the result, it was selected as
the optimum design. Stress concentration analysis is an
important part in mechanical design, so does in sucker rod
design. In the process of FEM calculation, it was found that
the fillet radius has great influence on the special rod
couplings stress concentration problem. Figure 8, and 9 show
that, an optimum fillet radius exists which could get the same
safety factor for both rod body and coupling.
2.
Tapered-thread sucker rod. Tapered thread is widely
used in drilling pipes due to its high strength characteristic.
Tapered-thread sucker rod, with a high strength rod body,
could operate in high torque conditions. See Figure 10. This
design fits for small production rate wells and gives better
operating conditions.
Up to date, there are 955 PCP wells using the both above
special sucker rods, which is 61.7% of the total PCP wells.
The average sucker rod failure rate decreased from 20% to
4%, and the operating life was prolonged considerably as well.
For example, N1-6-P34 is one of the PCP wells in an ASP
area. Before 1999, the rod failure rate was very high when
using a traditional sucker rod. The averaged failure rate was
once a month. After using jaw-clutch sucker rod, the PCP
system operated normally for 805 days. When the pumps was
pulled out at last, it was found that the whole rod string was
still in good conditions and had no deformation at all.
An Environmental, High Efficiency Drive Head. In the
beginning, the balanced-style drive head, showed in Figure 11,
was applied successfully in small production rate PCP wells in
water flooding areas. However, when this kind of drive head
was applied in high rate PCP wells in polymer flooding areas,
some problems emerged which limited the application
seriously:
(1) With the increment of rotating speed and of operating
load, the life of sealing materials decreased remarkably
from several months down to 1 or 2 weeks. Oil leakage
on the drive head was also very severe which polluted the
environment and increased the operating cost as well.

(2) High-power drive head had a huge volume and higher

barycenter. As a result, resonance of the drive head
enhanced the fatigue break rate of polished rod.
(3) Requirements needed for maintenance was higher.
The patented product, zero leakage drive head, see Figure
12, takes some completely new ideas to improve the efficiency
and environmental performance:
(1) It combines the oil-cup structure sealing with mechanical
sealing techniques which completely diminish the oil
leakage of PCPs on surface.
(2) The product also had the unique low profile design,
which avoids the damage of wellhead by resonance.
(3) The wellheads holding and sealing system made it easier
and cheaper for maintenance; it does not need a crane in
repairing the drive head any more.
(4) Modularization and standard design was used on all
elements of the driving system. Every element could be
replaced by another standard one, and that helps to cut
the maintenance cost to a very low level.
Due to its remarkable advantages in the environmental, high
efficiency, low operating cost, and easy maintenance, this
product has become the most popular drive head in Daqing
Oilfield in the past few years. Till the end of 2004, 1317 new
design drive heads have been applied in Daqing Oilfield. The
average operating life is more than one and a half years; the
longest one reached more than four years.
Wireless Testing and Analyzing Technology. Due to the
totally different operating status, the traditional dynamometer
testing and diagnosing technique in beam pumping system
couldnt be applied in PCP lifting system. For a certain years,
operators analyzed PCP lifting systems performance only by
producing rate, dynamic liquid level, and motors operating
current. And only a very few kinds of failures could be
identified in this way. In that case, a project was carried out
from 2000, aimed at developing a new testing technique which
could directly get the operating status of PCP system.
After years of study, a portable wireless testing system and
analysis software for PCPs were developed and put into
application, see Figure 13. The new testing system consists of
sensor, transmitter, receiver and processor. The later two
elements are integrated into a portable computer. The sensor is
set on the drive head permanently used for picking up
objective parameters of torque, axial load, and rotating speed.
See Figure 14. Because of its close packaging design, the
sensor can work in all weather. The working temperature scale
is very wide, ranging from less than -40 to above 70 . A
transmitter is installed in the process of testing, transforming
the objective parameters into electronic signals and
transmitting them in form of electromagnetic wave. The
signals are received and processed by portable computer. Then
the systems operating status can be identified by analyzing
the dynamic data of the lifting system, including strings
loads, dynamic liquid level, producing rate, current, etc. This
process is implemented by PCP trouble-shooting software. See
Figure 15.
The testing system has been installed in more than 100 PCP
wells. It has been proved that this technique is very effective

IPTC 10032

in diagnosing PCPs operating status, and its very helpful in

improving the lifting systems efficiency as well.
Ceramic Coating Rotor for ASP Flooding Areas. Scaling is
the main reason of pumping failures for beam pumping
systems in ASP flooding areas. Due to the systems
reciprocating lifting mechanism and the discontinuous flow of
producing liquid, scaling is easy to deposit in the space
between plunger and pump barrel which causes pump stuck
failures frequently. In some cases, when beam pumping
systems stop working due to power off or other issues, the
pump cannot start again unless work over treatment was taken.
Compared with beam pump and ESP, PCP has a better
performance in lifting ASP producing liquid. But, several
months later, scaling still will be found deposited on rotor
which decreases the pumping efficiency. In high scaling
period in ASP area, the operating torque and current of PCPs
would be unstable and varied in a larger scope. In some cases,
the rod string even operates discontinuously. This unsteady
state would accelerate the rods fatigue and its very harmful
to the system. As a result, a series of anti-scaling treatment
were carried out to improve PCPs operating conditions. And
ceramic coating rotor PCP is one of the most effective
techniques.
Its well known that ceramic is a kind of inert compound
whose surface energy is much lower than other material.
Therefore, scaling is hard to deposit on the surface of ceramic.
Through the experiments on 10 different ceramics, two of
them were selected for their lower surface energy and lower
friction coefficient under dry friction condition. These
characteristics help to slow down the accumulating rate of
friction heat and contact stress between coating and elastomer
as well as improve the running life of PCP.
In 2004, two ceramic coating rotor PCPs were applied in
ASP flooding areas, and the running life all reached more than
one year. More observations are still being noted for further
use of this technique.
Application Results
Till the end of October 2005, PCP lifting technology has been
used in more than 2000 wells in Daqing Oilfield. See Figure 1.
In water flooding areas, the average running life reached to
464d; the average pump efficiency was twenty per cent higher
than beam pumping system; and the system efficiency was
fifteen per cent higher. In polymer flooding areas, PCP wells
running life was 445d, which was 1.8 times longer than beam
pumping systems while the longest one was more than 10
times longer. In ASP flooding areas, the running life was 5
times longer, while the longest one was 26 times long as the
beam pumping systems.
Conclusion
(1) Large quantity of experiments and practice indicated that,
whatever flooding area it was used in, elastomers
compatibility to producing liquid was the prime problem
to be considered for PCP lifting system.
(2) Pilot tests showed that, due to the different working
conditions, high rate PCP producers have much more
difficulties in operation than the lower ones.

IPTC 10032

(3) Two novel sucker rod designs could ensure the PCP
systems operation effectively in large rate producers or
other complicated working conditions.
(4) Zero leakage drive head has remarkable advantages in
the environmental, high efficiency, and maintenance,
which has been widely used in Daqing Oilfield.
(5) The new wireless testing and analyzing technology has
been proven to be very helpful in decreasing PCPs failure
rate and improving PCPs management as well.
(6) PCP lifting technology is a systematic engineering, which
needs continuous development in every component and
matching technologies. Long terms of research and
development, large sum of investment, and the continuous
application in new techniques are the most important
experiences for Daqing Oilfield in applying more than
2000 PCP wells successfully.
Acknowledgements
The authors wish to acknowledge the contributions of
Production Engineering & Research Institute, No.1, No.3,
No.4 and No.6 oil companies of Daqing Oilfield Ltd., Co. for
providing large quantity of experiments and pilot tests results.
They would also like to thank Daqing Oilfield Ltd., Co. for
permission to publish the data in their study.
References
1. Wang Yan et al: Technology for Controlling Eccentric
Wear of Sucker Rods and Tubing in Pumping Wells
Lifting Fluids Containing Polymer, paper SPE 89927
presented at the SPE Annual Technical Conference and
Exhibition, Houston, Texas, 26-29 September, 2004.
2.

3.
4.

Godbey, J.K., and Dimon, C.A.: The Automatic Liquid Level

Monitor for Pumping Wells, SPE 6039 Journal of Petroleum
Technology (August 1977).
Cholet, H.: Progressing Cavity Pumps, Editions Technip,
Paris(1997) .
Klein, S.T. et al: Well Optimization Package for Progressive
Cavity Pumping Systems, paper SPE 52162 presented at the
1999 SPE Mid-Continent Operations Symposium, Oklahoma
City, March 28-31.

IPTC 10032

Table 1: The contrast of two elastomers physical mechanical properties

Physical mechanical propeties
Shore hardness A
Tensile strength at break
Elongation at rupture
300% elongation

Unit
Degree
MPa
%
MPa

Standard
655
12
50050
8.5

Elastomer#1
75
20.43
565.2
11.5

Elastomer#2
69
22.66
576.8
10.91

Peel strength

kN/m

61.2

cm /1.61km

3050
0.15

61.6

Abrasion wear
Break-off strength
variety
Air aging at
Break elongation
9024h
variety
Hardness variety

0.13

0.15

-16.74

-3.49

-12.24

-3.68

Degree

Volume variety (#120gasline+benzene

90peeling strength

<20

41.45

19.57

kN/m

16

19.6

18.62

Note: #1 is the previous elastomer, and #2 is the newer one.

Table 2: Three types of PCPs displacement

Model

e
(mm)

D
(mm)

2t
(mm)

V=8eDt
(mL/r)

GLB120-27

5.0

40

160

128

GLB500-14

7.5

44

400

528

GLB800-14

8.0

50

500

800

Table 3: Testing data of different fits between rotor and stator

Items
Rated lift (MPa)
Speed (rpm)
Volume efficiency at
6MPa (%)
System efficiency at
6MPa (%)
Torque at zero lift

Standards(0.30.7)mm
8
150

Fit=0.3mm

Fit=0.5mm

Fit=0.7mm

6
150

9
150

10
150

6090

36.17

76.43

83.37

50

30.70

76.43

83.37

35.66

52.06

78.60

Table 4: Wax removal results by hollow rotor and solid rotor technique
Well number #
X331607
N12215
P9546

Before treatment
After treatment
Before treatment
After treatment
Before treatment
After treatment

Rate

PCP
TYPE

t/d

Hollow
rotor
Hollow
rotor
Solid
rotor

4
9
5
7
3
5

Active
power
kW
4.44
2.65
4.22
2.76
3.33
2.26

Inlet
temp

Outlet
temp

Inlet
pressure
MPa

78

59

1.70

75

58

76

40

2.50

Time
h

IPTC 10032

2500
1627
1283

1500
778

1000
373

500

165

10

54

1991

1996

1999

0
2000

2001

2002

2003

2004

2005

Year
Figure 1.

PCP's Application in Daqing Oilfield

6000
5306.1

T Tz,N.m

Tz
4000

T
2853.2

2000

1018.4
415.0

672.2

0
GLB120-27

GLB500-14

GLB800-14

Figure 2. PCPs operating torque(T) and tilting moment(Tz)

70
63.66

60
Fc Fa kN

Number (wells)

2010
2000

Fc
Fa

50
40
30
20
10
0

44.82
25.60

16.30
21.12
12.80
GLB120-27

GLB500-14

GLB800-14

Figure 3. PCPs axial force(Fa) and cross force(Fc)

IPTC 10032

Rotor

Flusing

Flusing

liquid

liquid

Flusing
liquid

Stator

(a)

solid rotor PCP

Figure 4.

Figure 5.

(b)hollow rotor PCP

PCPs flushing channel

Hollow rotor PCP Water flushing tools

1
T

(a) Traditional sucker rod for BPL

(b) Jaw-clutch sucker rod for PCP
1-coupling 2-thread 3-tooth F-drag force T-torque
Figure 6. The loading status between a jaw-clutch sucker rods and a conventional one

IPTC 10032

#1 Design

#2 Design
Figure 7.

R1

Optimization of rod coupling shape

R2
Fillet radiuss optimization of rod coupling

Maximum stress(MPa)

Figure 8.

Fillet radius
Figure 9.

#3 Design

Tooths maximum stress via fillet radius

R3

10

IPTC 10032

(a)conventional rod thread

Figure 10.

Figure 11.

(b)tapered rod thread

Tapered rod thread and conventional rod thread

Traditional drive head

Figure 12.

Transmitter
Sensor

Computer

Figure 13.

Wireless testing system

New drive head

IPTC 10032

11

400
350

N.m,t,rpm
N.m,t,r/min

300

Torque
Axial force
Rotating speed

250
200
150
100
50
0
0

1000

2000

3000

4000

5000

6000

Time(1/30s)

Figure 14.

PCP rod strings loading curves by wireless testing system

Figure 15.

PCP trouble-shooting software