Field experience has shown that the run lives of progressing cavity pumps (PCP) vary considerably in heavy oil applications but, overall, they remain unacceptably short. In wells which produce sand, run lives may range from only a few weeks up to eighteen months with a typical average of six to twelve months depending on the field. The resultant equipment replacement and servicing costs contribute significantly to the high operating costs of heavy oil developments. This was the focus of a Request for Proposals (RPF) issued through the Petroleum Technology Alliance of Canada (PTAC) that was prepared by a heavy oil Producer Group in which they expressed their interest in sponsoring a joint industry project (JIP) focussed on identifying ways to significantly improve ("double") the average run life of PCPs.

While PCP systems have been in general use in heavy oil production for about 15 years, there is today still only a limited understanding of the downhole conditions and mechanisms which control pump performance and service life. Therefore, as a first step toward achieving the industry objective, it was necessary to acquire an improved understanding of the key failure mechanisms which are responsible for the variability in pump life.

This knowledge is required to ensure that efforts are directed toward the identification of solutions or new pump products which are appropriate in terms of resolving the conditions responsible for short pump life and high servicing costs in a large percentage of wells. This main objective was achieved through a combined field data gathering and synthesis effort followed by comprehensive analysis work using the database. Based on the information collected, the project also examined the possibility of achieving the desired average run life improvement through the implementation of better failure tracking systems, equipment or operational changes.

Contact: Paul Skoczylas, Project Manager

Tel: 780.450.8989 x299