General Guidelines for Failure

Analysis Of
Downhole Progressing Cavity
Pumps
 Table of Contents

Section 1………………………..Introduction

Section 2……………….……….Component Description

Section 3………………………..General PC Pump Theory

Section 4………………………..Failure Modes

Section 5………………………..Root Causes

Section 6…………………….….Possible Solutions

Section 7………………………..Technical Support

 Introduction

This Failure Analysis Guide is intended to give a general

outline of common failure modes of Progressing Cavity
Pumping Systems along with their respective root causes
and possible solutions.

In order to properly understand some of the failure

modes covered herein and their respective root causes
and solutions, an understanding of progressing cavity
technology is crucial. It will be done by first reviewing the
basic progressing cavity pump components followed by
some basic progressing cavity pump theory.

This guide is not intended to give final answers on

progressing cavity pump component failures but should
help in evaluating whether further investigations are
necessary.
 Component Description
The basic progressing cavity pump components consist
of a rotor and a stator the configuration of which is given
below.

The Progressing Cavity Pump (PCP) is a rotary positive

displacement pump consisting of two (2) components. A
single external helical rotor rotates eccentrically inside an
internal double helical stator of the same minor diameter
and twice the pitch length.

The rotor cross-section is that

of a circle the centers of which
lie along a helical path. The
centers of the rotor cross-
sections are off set from the
axis of the rotor. This is what is
known as eccentricity.
The stator is molded from an
elastomeric material that is
permanently bonded inside a
steel tube. The cross-section is
that of two semi-circles
connected by two parallel
straight lines. The centers of the semi-circles also lie
along a helical path. The minor diameter is equal to that
of the rotor.
 Progressing Cavity Pump Theory
As the rotor rotates within the stator, its circular cross-
section at any point along the length travels back and
forth across the stator opening in one revolution.

This unique geometrical motion is

based upon the concept of a
hypocycloid. A hypocycloid by
definition is the curve traced by a
point on the circumference of a
rolling circle inside a fixed circle
that is twice the diameter. This
path is always a straight line.
To look at this in terms of a rotor and stator, the centers
of the rotor cross-section when viewed axially give us the
rolling circle. The centers of the
semi-circular portion of the stator
cross-section when view axially,
give us the fixed circle. You can
see this in the following diagram
at the right.
The pump generates pressure
due to interference fit between
the metallic rotor and the
elastomeric stator (shown in red).
This line of contact is called a
seal line. One complete sealed
cavity (or 360º rotation of the
stator helix) will generate a given
amount of pressure. By increasing the number of sealed
cavities, you increase the pump’s pressure capabilities.
 Failure Modes
The rotor of a progressing cavity pump consists of (2)
two parts; 1) the rotor base metal and 2) the coating
(hard chrome plating). The stator of a progressing cavity
pump consists of (3) three parts; 1) a steel tube, 2) a
bonding system (glue) and 3) an elastomer contour.
Under certain circumstances, failures may occur which
are related to one of these two components.

General stator description

There are a whole host of failure modes that could be
seen on both the rotor and the stator however this
section is intended to cover some of the more common
failure modes and is not meant to be all encompassing.

The following rotor and stator failure modes will be

covered -

Rotor Failure Modes:

Abrasive Wear
Acid Attack
Fatigue Failure
Pitting Corrosion
Improper Rotor Spacing

Stator Failure Modes:

Run Dry
Hysteresis
Abrasive Wear
Swell
Gas Permeation / Explosive Decompression
Delamination
Bond Failure
ƒ Bond to tube
ƒ Bond to elastomer
 Rotor Failure Modes

The following failure modes can occur on a progressing

cavity pump rotor:

Abrasive Wear: Abrasive wear occurs when the hard

chrome plating on the rotor becomes worn. This wear
can be just on the surface of the chrome or down to the
base metal. In either case, the original rotor profile is
changed. This change in profile can affect the pump’s
performance in that the interference fit between the rotor
and stator is no longer what it was initially. Acute
abrasive wear where the hard chrome plating is worn
down to base metal can go as far as permanently
damaging the elastomer. Abrasive wear usually occurs
on the crests of the rotor however in acute cases, it can
occur on other sections as well.

Acid Attack: Acid attack occurs when the pH of the

produced fluid drops below 6.0 resulting in a complete
stripping off of the hard chrome plating on the rotor. This
usually occurs when an operator decides to acidize their
well while leaving the pump in the well. Once the hard
chrome plating has been stripped from the base metal,
the resulting surface finish is very rough. This rough
surface will eventually result in the elastomer wearing
and a drop in production.

Torsional or Fatigue Failure: A fatigue failure is the result

of a material undergoing cyclic stresses and ultimately
failing. Fatigue failures are progressive and begin as
small stress cracks that grow under the cyclic stress. A
progressing cavity pump rotor is rigid and as such any
unnecessary side-loading or locking up of the pump can
result in the rotor failing. The natural movement of the
rotor is eccentric in nature and if a rotor is not inserted
adequately during the initial installation, the portion of
rotor outside the top of the pump can experience a higher
than designed eccentric motion. This excessive motion
will raise the cyclic stressed in the rotor and can result in
a fatigue failure. Any damage to the rotor surface can
reduce the cross-sectional area of the rotor. This
reduction in area will increase the load at that point
creating a stress riser.
Another failure mechanism of a rotor is torsional fatigue.
This type of failure can occur is if the pump locks up for
any reason (e.g. solids, elastomer failure). Under this
situation, a portion of the rotor locks up while the
remaining portion of the rotor wants to keep rotating. As
the rotor is not that flexible, the portion of the rotor that
continues to move twists off.

Pitting Corrosion: Pitting corrosion occurs when some

initial damage occurs to the hard chrome plating thereby
allowing corrosive attack to the base metal. This initial
damage is usually a chemical attack associated with the
produced media (oil, water and gas). Despite the hard
surface and relatively low coefficient of friction, hard
chrome plating is porous and under the right conditions
components of the produced fluids enter these pores and
begin to corrode the base metal under the chrome. Once
a sufficient amount of the base metal has been eroded
away under the chrome, the chrome in that area will pop
off leaving a pit.
In the most severe case of pitting corrosion, a fatigue
failure can occur once the cross-sectional area is less
than the minimum acceptable area for the stresses seen
within the rotor body.

Improper Rotor Spacing: Improper rotor spacing is not a

material or application related failure but a failure due to
improper installation procedures. For a given set of well
conditions, the sucker rods will stretch a given amount.
This stretch is dependent upon the rod size, total
dynamic head and the effective cross-sectional area of
the pump. If the proper amount of stretch is not
accounted for, the rotor placement within the stator could
either be too high or too low. In either case, excess
stresses are placed on the rotor and sucker rods and
may result in a torsional fatigue failure of either the rotor
or the sucker rods.

In the case of being set too low, if a torque anchor is not

used the additional torque of the rotor running on the tag
bar could result in the stator/tubing unscrewing.
 Stator Failure Modes

The following failure modes can occur on a progressing

cavity pump stator:

Run Dry: A pump that has run dry has its elastomer hard,
brittle and extensively cracked. In an extreme run dry
condition, the stator contour will be completely gone.

Hysteresis: Hysteresis is the result of over-pressuring the

elastomer. Hysteresis occurs in the minor diameter of the
stator (thicker section of rubber). It can occur for a variety
of reasons but all as a result of the over-pressuring.
Although it is a normal process that occurs as an
elastomer ages, its occurrence can be premature based
upon several factors. These factors are –

Pump setting depth beyond the pump’s

rated pressure.
Resulting TDH is beyond the pump’s rated
pressure.
Improper rotor insertion resulting in less
pressure available.

During normal operation, the heat that is generated in the

minor diameter areas of the pump due to the flexing of
the rubber is dissipated by the produced fluid moving
through the pump. However when excessive heat is
generated by over-working or over-pressuring the
elastomer as would be the case in the above situations,
the elastomer is working harder than it is designed for
and thereby fails prematurely.
The produced fluid passing through the pump is not
adequate to dissipate the heat built up in the minor. This
heat build-up reduces the elastomer’s strength and
ultimately its ability to generate the necessary pressure.
The following three (3) images depict the stages of
hysteresis occurrence -

Abrasive Wear: Abrasive wear occurs when the

elastomer is worn from the presence of abrasives in the
produced fluid. As the percentage of abrasives increases,
the chances of prematurely wearing the seal lines that
are formed by the interference fit between the rotor and
stator also increases. The hardness and angularity of the
pumped abrasive can also affect the wear rate.

The total differential pressure seen across the pump as

well as the pump’s rotational speed play a key role in
how abrasives affect the elastomer.
As a result of the elastomer wearing, the slip within the
pump increases and as a result, the production will drop
off.

Elastomer Swell: Elastomer swell can occur either when

the stator elastomer is affected by production fluids or
treatment chemicals that are incompatible with it
(chemical swell) or due to an increase in temperature
(thermal swell). Chemical swell is generally caused by
the elastomer coming in contact with high API gravity
crude oils or incompatible treating chemicals; both of
which have a fairly high percentage of aromatics.
Aromatics include benzene and compounds that
resemble benzene in chemical behavior. The presences
of these aromatic compounds cause the stator elastomer
to expand and swell. This expansion results in an
increase in the interference fit between the rotor and
stator thereby in an increase in operating torque as well.
Chemical swell is generally permanent and non-
reversible once the source of the swelling has been
removed.
Thermal swell on the other hand is purely due to an
elevation in temperature resulting in the elastomer
expanding due to this increase in temperature. This
expansion also results in an increase in the interference
fit between the rotor and stator thereby in an increase in
operating torque as well. Thermal swelling can be
predicted and is not permanent. Once the temperature
decreases the thermal expansion of the elastomer also
decreases.

Gas Permeation / Explosive Decompression: Gas

permeation occurs when gas; under pressure; enters the
elastomer matrix and expands due to a pressure drop.
When the gas expands, it often results in blisters or
bubbles forming within the elastomer. This pressure drop
can be the result of the events such as the fluid level
equalizing in the wellbore after a shut down or from the
pulling of the pump.
The expanding gas within the elastomer matrix can
sometimes expand to the point that the elastomer
ruptures. This is called explosive decompression.

The rapidly decompressing of the gas entrained within

the elastomer matrix tears and chunks the elastomer
when it expands.

Delamination: The word delamination contains the word

lamination which means “in layers”. In elastomeric terms,
this means that the elastomer had not knit through its
cross-section resulting in layer-like striations within the
elastomer. This is often the result of temperature
fluctuations during the injection process. These
laminations or layers create weak areas within the
elastomer and are a prime location for gas that has
permeated into the elastomer to gather. When a pressure
drop occurs, the gas that has entered these laminated
areas expands thereby tearing these weak areas.
Visually looking at the laminated areas, the internal
surfaces of the laminations are smooth; unlike a torn
surface where the surfaces are rough and jagged.
Bond Failure: A bond failure occurs when the bonding
agent that keeps the elastomer in the stator tube fails.
This can occur at two interfaces. The first interface is
between the bonding agent and the elastomer.

In this instance, there is no elastomer left on the stator

tube but there is bonding agent. A view of the backside of
the elastomer will show it to be smooth. The stator tube
will also be smooth with a gray or black color.

The second interface is between the bonding agent and

the stator tube. As in the above instance, there will be no
elastomer left on the stator tube however the stator tube
will be clean and clear of any bonding agent. A view of
the back side of the elastomer will show it to also be
smooth.
 Root Causes
Although there are generally a host of conditions that can
and do contribute to each and every failure, there is often
one primary mode that dominates the list. One mode of
failure is the underlying cause of the failure upon which
the other modes depend. This section will attempt to
shed some light on the root causes for the failure modes
outlined in the previous section.

Rotor Failures

Abrasive Wear: Abrasive wear is the result of pumping

too high a percentage of abrasives (i.e. formation sand,
frac sand, coal fines, etc.) for the given pump speed and
pressure rating. Although progressing cavity pumps can
handle sand and abrasives much better than other
methods of artificial lift, the pump speed and differential
pressure across the pump need to be considered.

Acid Attack: Acid attack is caused by the pH of the

produced fluid going too acidic or too basic. Generally
this is the result of the operator acidizing the well without
pulling the pump. The acid used is often hydrochloric or
hydrofluoric acid which will strip the chrome plating off of
the rotor.

Torsional or Fatigue Failure: Torsional or fatigue failures

are a result of a material undergoing cyclic stresses. In a
rotor, these stresses are often the result of the pump
locking up or improper rotor spacing. When the former
occurs, sudden locking up of the pump on a rigid shaft
(rotor) results in a torsional failure. In the later case, a
rotor that is improperly spaced also places additional
stresses on the material. If the rotor is landed too low, the
rotor could run on the tag bar, and thereby cause the
same stresses as if the pump locked up. If the rotor is
spaced too high, the portion of the rotor that is outside
the stator can experience undue bending stresses (as a
result of the eccentric motion) and fail due to fatigue.

Pitting Corrosion: Pitting corrosion is the result of the

underlying base metal being attacked resulting in the
formation of pits followed by the flaking off of the hard
chrome plating. This is usually related to improper
handling in the field thereby damaging the chrome plating
allowing access to the base metal however in some
cases, the porosity of the chrome will allow corrosive
fluids to access the base metal as well and the same
process occurs.

Improper Rotor Spacing: Improper rotor spacing is

always caused by the initiator. That is, the person who is
installing and spacing out the pump.

Stator Failures

Run Dry: A run dry condition is generally caused by the

well pumping off. The lack of fluid entry into the pump
causes a lack of lubrication within the stator resulting in
extremely high temperatures being generated. This high
temperature ultimately “burns” the elastomer at the seal
lines. On occasion, very high percentages of free gas at
the pump intake can result in the same run dry situation.
Hysteresis: Hysteresis is the over-pressuring of the
elastomer. This is generally the result of one of the
following –

Total Dynamic Head is beyond the pump’s

rated pressure.
o Set too deep
o Producing pressure + wellhead pressure
higher than rated pressure.
Improper rotor spacing (rotor spaced too
high resulting in not enough pressure capacity.)

Abrasive Wear: Abrasive wear is caused as a result of

pumping too high of a percentage of abrasives for the
given pump geometry, differential pressure and operating
speed. A pump with a large swept rotor angle (SWA)
tends to allow sand to settle within the cavities allowing
the abrasives to wear the elastomer. Excessive pressure
per sealed cavity also increases the abrasive effect on
the elastomer. The pump’s operational speed also affects
the rate at which the abrasive particles pass through the
pump. To high of an RPM will wear the pump faster.

Elastomer Swell: Elastomer swell is the result of the

elastomer being incompatible with the produced fluid or
treating chemical or related to thermal expansion.
Swelling from the produced fluid is from the aromatic
content of the fluid and will usually reach equilibrium after
a specific period of time. Chemical swell from treating
chemicals (e.g. corrosion, scale or paraffin inhibitors) on
the other hand will not usually reach equilibrium and will
continue to swell until the stator opening is completely
closed.
Thermal swelling of the elastomer is due to the
temperature that the elastomer at its setting depth.
Thermal expansion can be pre-determined.

Gas Permeation / Explosive Decompression: Gas

permeation is the direct result of gas permeating into the
elastomer matrix. This can be a result of the specific gas
composition combined with the permeability of the
particular elastomer. Under the right circumstances (e.g.
temperature and pressure), gas can permeate into the
elastomer matrix. When a pressure drop occurs (e.g.
shut down or pulling), the gas that had permeated into
the elastomer rapidly decompresses resulting in
explosive decompression. This is evident in the
blisters/bubbles that form within the elastomer.

Delamination: Delamination is the result of improper

“knitting” of the elastomer during the injection process.
This can often be due to temperature fluctuations across
the stator tube / core cross-section. During the injection
process, cooler spots will cause portions of the elastomer
to cool prematurely allowing hotter elastomer to pass
over it thereby forming layers or laminations.

Bond Failure: Bond failures occur as a result of a failure

between the bonding agent and the stator tube or
between the bonding agent and the elastomer. It is most
often a manufacturing defect occurring during the
elastomer injection process however there are instances
that the bond can be affected as a result of elastomer
damage.
 Possible Solutions

Without a complete understanding of all of the

circumstances surrounding a given event, it is impossible
to come to a conclusion not only on what the root cause
of the problem was, but also what course of action to
recommend as a possible solution. This section will
share some of the most commonly recommended
solutions for the problems discussed in earlier sections.

Rotor Failure Solutions

Abrasive Wear: Adding additional seal lines (or stages)

will reduce the pressure per sealed cavity thereby
reducing the effect of abrasives on the rotor. Running a
pump with a larger displacement per RPM will lower the
required pump speed and thereby reduce the particle
velocity within the pump.

Acid Attack: If the well is to be acidized, pull the rotor

before conducting the acid job. Swab the well until the pH
pf the fluid after the acid job is back to its original level. If
the well fluid’s normal pH is normally acidic, a stainless
steel chrome plated rotor should be used.

Torsional or Fatigue Failure: If the torsional or fatigue

failure is the result of an elastomer issue, the solution lies
with the elastomer selection (see section on Elastomer
Swell). If the failure is due to improper spacing of the
rotor, being sure that the rotor is properly spaced within
the stator should eliminate this problem.
Pitting Corrosion: Pitting corrosion can be minimized by
knowing the fluid composition prior to selecting the
equipment materials of construction. This will allow for
the proper selection for the rotor material. Proper
handling of the rotor during shipping and installation will
also minimize damage to the hard chrome plating
thereby eliminating places for the corrosive pitting to
initiate.

Improper Rotor Spacing: This can be eliminated by being

sure to space the rotor out properly based upon the
Rotor Pullback curves in the LIFTEQ Technical Manual.

Stator Failure Solutions

Run Dry: Monitoring the producing fluid level will ensure

that the well will not pump off resulting in a run dry
condition. If the run dry is a result of high percentages of
free gas, lowering the pump setting depth or running a
gas anchor will limit/eliminate the gas entry.

Hysteresis: As hysteresis generally occurs via an over-

pressuring of the pump, there are a few solutions that
can be offered. The first consideration should be to be
sure that the pump has the correct pressure capabilities
for the operating conditions is installed. By installing a
pump with higher pressure capabilities, the pressure per
sealed cavity will be reduced thereby reducing the over-
pressuring of the elastomer. This should include the
wellhead pressure. If the over-pressuring was due to the
improper spacing of the rotor, be sure that the rotor is
completely engaged in the stator thereby using all of the
pump’s pressure capability.

Abrasive Wear: When abrasion is a problem, pump

speed is generally the first thing to consider. By installing
a pump with a higher production capacity, the pump
speed will be reduced for the same production rate while
reducing the particle velocity within the pump. In addition,
increasing the pump’s pressure rating will lower the total
differential pressure across the pump thereby decreasing
the effects of the abrasives.

Elastomer Swell: Proper evaluation of the well conditions

(e.g. APIG, bottom-hole temperature) will allow for better
application of the elastomer minimizing or eliminating the
occurrence of elastomer swell.

Gas Permeation /Explosive Decompression: Proper

evaluation of the well conditions (e.g. APIG, bottom-hole
temperature, % free gas, gas composition) will allow for
better application of the elastomer and placement of the
pump intake in the wellbore thereby minimizing or
eliminating the occurrence of gas permeation.

Delamination: Since delamination is generally a

manufacturing issue, there is not much to do to resolve it
aside from an evaluation of manufacturing processes.

Bond Failure: Although bond failures are generally

manufacturing related, it can occur due to an
incompatibility of the elastomer with the well conditions.
The solution would be to check the compatibility of the
elastomer with the well fluids.
 Troubleshooting Diagnostic Table
Perceived Problems Possible Causes
1. No Production 2, 3, 4, 5, 7, 16, 18, 26, 28, 29, 35
2. Production Drops off 3, 4, 5, 7, 8, 9, 10, 11, 14, 16, 17, 21, 27, 28, 29
3. Intermittent Production 4, 5, 7, 8, 14, 15, 17, 27, 28, 29, 34
4. Pump Will Not Start 6, 7, 8, 12, 17, 20, 24, 26, 29, 32, 33, 34, 35
5. Motor Stalls @ Pump-up 8, 11, 12, 20, 24, 25, 28, 29, 32, 33, 34, 35
6. Motor Overheats 6, 8, 11, 12, 15, 18, 20, 24, 26, 28, 32
7. Pump Consuming Excessive Power 8, 11, 12, 15, 18, 20, 28, 33, 34
8. Excessive Noise & Vibration 2, 3, 4, 6, 8, 9, 11, 14, 15, 17, 18, 19, 20, 26, 28, 31, 33, 34
9. Wear on Pump Elements (rotor or stator) 1, 11, 15, 18, 27, 28, 34
10. Excessive Packing Gland Wear 1, 12, 15, 25, 27, 30
11. Packing Gland Leakage 13, 25, 27, 30
12. Pump Locks Up 9, 11, 12, 20, 26, 27, 28, 29, 33, 34, 35
List of Causes Plan of Action
1. % Abrasion Above Max Recommended 1. Select Correct Rotor Fit, Decrease Pump Speed
2. Sucker Rods Parted 2. Fish Parted Rod & Replace
3. Tubing Parted 3. Fish Parted Tubing & Replace. Tighten Adequately
4. Inadequate Fluid (reservoir or completion related) 4. Reduce Pump Speed or Put on a Timer
5. Hole in Tubing or Collar 5. Replace Tubing or Collar
6. Motor Supply or Wiring 6. Check Electrical Supply & Wiring
7. Pump Intake Blocked 7. Pull Up Rotor, Circulate Well
8. Fluid Viscosity Above Design Point 8. Decrease Pump Speed
9. Fluid Temperature Above/Below Design Point 9. Select Correct Rotor Fit
10. Fluid Viscosity Below Design Point 10. Increase Pump Speed
11. Discharge Pressure Above Design Point 11. Check Flowline for Blockages or Partially Closed Valve
12. Packing Gland Too Tight 12. Adjust Packing Gland (see Drivehead Manual)
13. Packing Gland Not Tight Enough 13. Adjust Packing Gland (see Drivehead Manual)
14. Excessive Free Gas @ Pump Intake 14. Install Gas Anchor, Reduce Speed or Lower Pump
15. Pump Speed Above Design Point 15. Decrease Pump Speed
16. Pump Speed Too Low 16. Increase Pump Speed
17. Drive Belts Slipping 17. Check Belt Tension & Adjust as Necessary
18. Incorrect Rotor Setting 18. Check & Adjust Rotor Spacing
19. Drive Mounting Insecure 19. Check & Tighten All Mounting Hardware
20. Drivehead Bearing Wear/Failure 20. Remove Drivehead. Replace or Overhaul
21. Worn Pump (rotor/stator) 21. Replace Worn Components
24. Low Voltage 24. Check Voltage/wiring Sizes
25. Abrasives in the Packing Gland Area 25. Check Packing Type & Condition
26. Failure of Drive Arrangement 26. Check & Replace Failed Drive Components
27. Incompatible Treating Chemicals 27. Re-check Materials of Compatibility with Chemicals
28. Pump Discharge Blocked or Valve Closed 28. Relieve Pressure. Clear Blockages
29. Stator Worn/Damaged 29. Replace worn Parts
30. Packing Gland Destroys Packing 30. Check Polished Rod for Excessive Wear & Replace
32. Motor is Too Small 32. Check & Re-calculate Motor Size
33. Incorrect Rotor Spacing 33. Re-space Rotor
34. Stator Elastomer Swollen 34. Re-evaluate Well Characteristics & Elastomer Selection
35. Pump Sanded In 35. Pull Rotor up, Circulate & Re-Set Rotor
 Technical Support

Contact Information

Ken Saveth
Sr. Applications Engineer
(918) 461-9186 - Office
(918) 510-1490 - Cellular
Ken.saveth@weatherford.com