84137.
qxd 4/13/04 6:59 AM Page 56
Artificial Lift
New Approach for Modeling
Progressing-Cavity-Pump
Performance
The full-length paper introduces a new
approach for modeling progressing-cavi-
ty-pump (PCP) performance. Slip flow is
modeled as the result of rotor movement
and differential pressure between cavities.
The assumption was made that the slip-
page gap area depends on stator material.
A strong relationship between slippage
gap area and differential pressure is
demonstrated. Internal stator deforma-
tion is identified as the main parameter
necessary for predicting elastomer-stator-
PCP performance. Although the proposed
model is not able to fit data for all PCP
models, its results agree with documented
PCP-performance theory.
Introduction
PCP installations are designed by use of
pump characteristic curves usually obtained
from manufacturer’s catalogs. Previous stud-
ies with elastomer PCPs showed that sever-
al variables can affect pump characteristic
curves even in the low-slip region where dif-
ferential pressure is less than that required
for 80% volumetric efficiency. For a metal-
lic-stator PCP that works under permanent
slip conditions, it is well known that char-
acteristic curves are affected by viscosity
and gas handling. Previous studies show
that fluid viscosity can change the flow
regime inside the pump. It is well known
that curves presented by PCP manufactur-
ers and those resulting from experimental
data do not represent real pump perfor-
mance at downhole conditions. Models to
predict PCP performance must account for
stator-material behavior inside the pump
such as swelling and thermal expansion.
Internal Slip
Internal slip is the phenomenon that defines
PCP performance because it is a function of
PCP geometry, operating conditions, and
pumping-fluid properties. Internal slip is
transitory and not fully developed flow
through pump clearances, and it changes
instantaneously depending on the rotor
position. Current knowledge does not
define slip flow regimes resulting from
pump geometry and operating conditions,
and friction factor inside the pump is
56
unknown. An important simplification for
studying internal slip flow divides the slip
into a cross-sectional slip from cavity i to
cavity i-1 and a longitudinal slip from cavi-
ty i to cavity i-2 so that total internal slip
flow is the sum of these two components.
Experimental Data
Experimental data for metallic-stator-PCP
performance come from previous studies
where a test loop was designed to control
and record variables (i.e., suction and dis-
charge pressures and temperatures, differen-
tial pressure, and real pump capacity).
Viscosity ranged from 1 to 605 cp, and oper-
ating velocity ranged from 100 to 600
rev/min. Two metallic-stator pumps were
used, one with three stages and the other
with five stages.
Characteristic curves of capacity vs. dif-
ferential pressure demonstrate how pump
capacity is affected by variations in interfer-
ence. The difference in interference is intro-
duced by use of a smaller-diameter rotor.
A variation of 40% in the interference
value decreased pump capacity by approxi-
mately 80%.
In a metallic-stator PCP, a change in fluid
viscosity or interference value produces a
slope change in the characteristic curve. For
high-viscosity fluids, characteristic curves
show a linear relationship between differen-
tial pressure and capacity.
Unlike metallic-stator-PCP characteristic
curves which show that pump capacity
decreases linearly with the increase of differ-
ential pressure, elastomer-stator-PCP charac-
teristic curves show that capacity decreases
nonlinearly. An increase in fluid viscosity
expands the low-slip region, but the nonlin-
ear behavior of the characteristic curves is
the same. Data characterizing polytetrafluo-
roethylene (PTFE)-stator-PCP performance
obtained from its manufacturer showed the
pump capacity to decrease nonlinearly.
Experimental-Data Analysis
Characteristic curves for the three evaluat-
ed PCPs change as a function of fluid vis-
cosity, interference value, and stator mater-
ial. Fig. 1 shows a graph of volumetric effi-
ciency, ηv, vs. a dimensionless differential
This article, written by Assistant
Technology Editor Karen Bybee, con-
tains highlights of paper SPE 84137,
“New Approach for Modeling Pro-
gressive-Cavity-Pumps Performance,” by
Jose Gamboa and Aurelio Olivet,
GD Solutions C.A., and Sorelys Espin,
SPE, U. Simón Bolívar, prepared for the
2003 SPE Annual Technical Conference
and Exhibition, Denver, 5–8 October.
pressure for PCPs with metallic, elastomer,
and PTFE stators. These curves show that
PCP performance depends on the material
used to manufacture the pump. Similar
behavior has been observed in twin-screw
pumps where a polymer stator produces a
nonlinear performance curve because of
internal stator deformation and a metallic
stator performs linearly.
A simple approach for understanding
slip behavior inside a PCP was proposed in
1930. This approach models slip flow by
use of the Hagen-Poiseuille equation,
assuming a linear pressure profile and con-
stant slip flow along the pump and taking
the interference value and pump length as
the main geometric variables. This
approach matches experimental data for
metallic-stator PCPs but does not match
polymer-stator-PCP performance.
Variable Slippage Gap Area
To understand polymer-stator-PCP perfor-
mance, it is necessary to compare mechan-
ical properties of steel, elastomer, and
PTFE. Polymers deform more than steel
when stress is applied. The greater the
internal deformation of the stator, the
greater the internal slip flow.
Expressions to relate interference value to
differential pressure were introduced into the
previous simple approach. One expression
was linear and the other quadratic. With a
slippage gap area changing as a function of
differential pressure, the characteristic curves
have a shape similar to traditional polymer-
PCP characteristic curves. However, the
curves obtained from the simplified model
do not fit experimental data. To obtain a reli-
MAY 2004
84137.qxd 4/13/04 7:01 AM Page 57

ferential, internal slip

1.0 flow is subtracted from Autonomous
theoretical capacity. Ex- Well
0.8 perimental results have
shown that longitudinal
0.6 pressure distribution in
a PCP for an incom-
ηv

0.4
pressible fluid increases
a-well.com
linearly from the value
PTFE stator PCP
of suction pressure to
0.2 Elastomer stator PCP
the value of discharge I-Pump ESP Sensor
Metallic stator PCP
pressure. According to
0.0 the position of the rotor
0.0 0.2 0.4 0.6 0.8 1.0 proposed in this model, Driving down the cost of ownership for
∆P/∆Pmax
n+1 cavities exist in an ESP sensors I-Pump is the lowest
n-stage pump. There- cost, fully electronic, fully field service-
Fig. 1—Volumetric efficiency vs. dimensionless differ- fore, all differential pres-
ential pressure pumping a 42-cp oil. able ESP sensor measuring:
sures are equal to the
total pressure differen- well pressure (strain/ quartz)
able model, a methodology for defining the tial across the pump divided by n+2.
discharge pressure
relationship between slippage gap area and For a fixed interference value, pump
motor winding temperature
differential pressure must be found as a func- capacity decreases linearly as a function of
well temperature
tion of stator mechanical properties. differential pressure. Variable-interference-
value lines show a nonlinear behavior sim- vibration - x
New Approach ilar to polymer-stator-PCP performance. vibration - y
Internal clearances always exist in a metallic- The model was tested with experimental current leakage
or deformable-stator PCP. The model data for metallic-, elastomer-, and PTFE-
assumes that the rotor turns at the center of stator PCPs. Each surface system
the stator so that the distance between the Excellent results were obtained for the includes alarm, trip and
pump elements is always equal to one-half metallic-stator PCP with 42- and 433-cp VSD speed control.
the interference value. Hydraulic diameters fluids at various speeds. However, the
are calculated for the internal clearances. model was not able to reproduce experi- Autonomous eAmpChart

Slip components caused by differential pres- mental data for the metallic-stator PCP
Well

S
T
O

sure are calculated by multiplying the clear- with water. Polymer-stator-PCP behavior P

alarm

fault

ance area by the average speed of the flow could not be fitted with this model because a-well.com

passing through it. Average speed is obtained there were no accurate expressions to relate
by the Hagen-Poiseuille equation using geo- slippage gap area to differential pressure.
metric dimensions for each kind of clear- I-Pump Systems have years of data
ance. The friction factor for flow between Conclusions log capacity, multiple SCADA ports,
parallel plates is used. For slip components Analysis of experimental data shows that unlimited additional analogs/ relays,
caused by the rotor movement, average PCP performance is influenced by interfer- customisable control program, 3 phase
speed is calculated as the average speed for ence value, fluid viscosity, and internal monitoring, free internet access soft-
Couette flow between parallel plates, assum- deformation of the stator. Interference ware. Optional Motor Controller
ing stable and fully developed flow. value and fluid viscosity play a key role
upgrade.
Two cross-sectional slip components when the stator is made of a nondeformable
exist, depending on the velocity of each side material. Stator deformation greatly influ-
of the rotor. Once the expression for each ences pump performance for deformable What more could you want?
slip flow and its speed and differential-pres- PTFE- and elastomer-stator pumps.
sure component are defined, a mass balance The new approach for modeling internal
field-proven worldwide
for each of the cavities is determined. For a slip flow demonstrated that slip can be
three-stage PCP, four equations are written analyzed by applying steady-state-flow
for the volumetric-flow balances. theory for one specific rotor position. The
Assuming the total differential pressure in key to modeling PCP performance is defi-
the pump is known and establishing rela- nition of the gap area where fluid flows
tionships between differential pressures between cavities. JPT
between cavities, five more equations are
obtained. Once the equations for differential
pressure are solved, internal slip can be cal- For a limited time, the full-length paper
culated by adding all the entering or leaving is available free to SPE members at
slip flows in any cavity because mass bal- www.spe.org/jpt. The paper has not
44-141-552-2900
ance is conserved along the pump. To been peer reviewed.
obtain pump capacity at some pressure dif-
reception@a-well.com

MAY 2004