Progressive cavity pump main problems
Focus on the main problem working with PCP pumps
Progressive cavity pumps are notable for their effectiveness in transferring viscous and abrasive fluids with constant pressure and uniform flow. However, like any machinery, they can encounter some issues. Here are some potential problems with progressive cavity pumps:
- Internal parts wear: Internal parts, such as the rotor and stator, are subject to wear over time due to rotational movement and direct contact with the fluid. This can lead to efficiency losses and decreased performance.
- Overheating: In situations where the pump is overloaded or the pumped fluid is too viscous, overheating can occur. This can damage internal parts and reduce the pump’s lifespan.
- Blockage or obstruction: Solid particles in the pumped fluid can cause blockages or obstructions in the system, compromising flow and damaging the pump’s internal parts.
- Seal leakage: Seal leaks can occur due to seal wear or damage to the rotor and stator. This can lead to fluid losses and compromise the overall efficiency of the pump.
- Cavitation: If the fluid pressure drops below its vapor pressure, cavitation can occur. This can damage the pump’s internal parts and affect its ability to pump fluid effectively.
- Corrosion: If the pump is exposed to corrosive fluids, internal metal parts can corrode over time, compromising structural integrity and reducing pump performance.
- Speed control issues: Some progressive cavity pumps are controlled by drive systems that may encounter speed control issues, leading to unwanted variations in flow and pressure.
- Sedimentation or scaling: If the pumped fluid contains sediment or solid material that can deposit on the pump’s internal walls, scaling can occur, negatively impacting performance and requiring additional maintenance.
- Fluid shortage: If the pump is started without fluid to pump, significant damage can occur to internal parts, especially the rotor and stator. Contact between metal surfaces without lubrication can cause overheating and premature wear.
- Risk of catastrophic damage: If the pump runs dry for a prolonged period, significant wear can occur, leading to catastrophic damage to internal parts, necessitating complete pump replacement.
To prevent fluid shortages, it’s important to implement fluid level monitoring systems or pressure switches that halt pump operation when the fluid level drops below a critical point. Additionally, training personnel on the importance of regularly checking fluid levels and intervening promptly in emergencies is crucial.
Addressing these issues requires proper preventive maintenance, regular performance monitoring, and correct pump selection and installation to suit the specific application requirements.
PCP Pumps
Flanged industrial series ideal for heavy duty applications.
It is the best solution for the industrial sector for pumping a vast range of fluids; available with UNI, DIN and ANSI flanged and GAS BSP threaded connections.-See pump detail
Standard model equipped with hopper and auger feed screw to move the product to the hydraulic part. Suitable to convey the Bentonite and Drilling Mud, as well as Cuttings.-See pump detail
Vertical Series developed for pumping from tanks and wells immersed directly in the product to be pumped. The length can be adapted to suit the installation requirements. The stainless steel version (AISI 304 or AISI 316) is supplied with a stator jacket as standard to prevent corrosion of the stator. Two standard configuraions are available: the short version and the long version with split casing and bottom mounted guiding cone –See pump detail
DV SERIES (long vertical)
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Order Original spare parts with NOVA ROTORS manufacturing quality.
For all products we are able to send worldwide with short delivery times – the right partner for the global players.
Despite production site in Italy we are able to delivery on all five continents (please request with delivery transport cost included), we are the deal partner, for companies operating globally as well. Our specialists are happy to provide consultation and support with trouble shooting and part identification for all our pump models.
APPLICATIONS
DH-Pump
DH pump for conveying cuttings at the drilling mud handling skid.See pump detail
DN Pump
DN pump used for transferring the drilling mud to the high pressure pump.See pump detail
DN Pump
DN pump used for recovering the mud.See pump detail
Oil/ Water Separation
DN-Pump
DN pump to feed the separator. The gentle handling of Novarotors-Pump ensures high efficiently of separator.
Novarotors Pumps do almost no damages to the oil droplets
DN-Pump
DN pump used for tansferring the oil from the separator.
SPE (Society Petroleum Engieneers) Paper SPE 18204 compares how different pump types damage oil droplets when put through them. Ranking found
1)PCP
2) Lobe pumps
3) Sliding Vain
4)Centrifugal
5) Twin screw
- Progressing Cavity Pump(PCP)Extremely LowBest performance. Gently transfers fluid with minimal disruption, keeping droplet sizes large for highly efficient downstream separation.
- Lobe PumpLow Good alternative. Smooth positive displacement mechanism preserves most droplet structures.
- Sliding Vane PumpModerate Acceptable, but begins to induce noticeable droplet breakage under higher pressures.
- Centrifugal PumpHigh Poor. High-speed rotating impellers create aggressive turbulence and shear forces, shattering droplets and emulsifying the fluid.
- Twin Screw PumpVeryHighWorst performance. Intensely shears the fluid, creating tiny micro-droplets that are incredibly difficult for standard separators to remove.
Progressing cavity pumps (PCPs) are widely used in oil and gas processing because their gentle, low-shear transfer method helps prevent the formation of tight oil-water emulsions — a common challenge in downstream separation.
Why PCPs Improve Oil Separation
Low-Shear Action
Unlike high-speed centrifugal pumps, which break oil into fine droplets and generate stable emulsions, PCPs move fluid at low internal velocities. This preserves larger, natural droplet sizes and makes the fluid far easier to treat downstream.
Higher Separator Efficiency
Gravity separators, hydrocyclones, and skim tanks all rely on droplet size to work efficiently. Larger, non-emulsified oil droplets separate from produced water significantly faster than finely dispersed ones, reducing residence time and improving overall separation performance.
Steady, Pulse-Free Flow
Thanks to their positive displacement design, PCPs deliver a smooth, consistent output. This stabilizes the feed entering separation vessels, avoiding the flow surges that can disrupt separator performance.
Key Operational Advantages
Reliable Multiphase Handling
PCPs are well suited to handle mixtures of crude oil, produced water, sand, and gas, maintaining volumetric consistency without vapor-locking — even under variable process conditions.
Excellent Solids Tolerance
The rotor-stator geometry allows abrasive particles, such as sand, to pass through without damaging internal clearances or compromising droplet integrity — a key advantage in upstream production environments.
APPLICATIONS
Open Drain / Closed Drain Pumps
DV-Pump
DV pump for Open Drain application. Novarotors Pumps are able to handle very low NPSHa application, vertical pumps have a NPSHr of 1.2m or less.
DN Pump
DN pump used for closed Drain Application. Also the horizontal pumps can be sized to handle a NPSHa of 1 .0m.
DV Pump canned
A canned DV pump designed for very low NPSHa.The NPSHr can be designed for 0.5m upon request.
APPLICATIONS
Crude Oil Transfer Pumps
DN-Pump
DN pump Installation for crude oil transfer. These pumps mostly are located somewhere between in the field, at booster station or just as stand-alone unit, transferring the crude oil down stream.
SN Pump
SN pump for Russia. They handle the various viscosities. Due to the slow shaft speed the reliability and lifetime of the wear components rises up.
JN Pump
MOL pumps transferring the Oil from the Gathering station.
Multiphase Boosting Pumps
JN-Pump
JN pump Installation for Multiphase Boosting. The single well boosting increases the production and reduces the well head pressure.
JN Pump
The JN Pumps, installed in Algeria, have to be controlled auto remote, it is an unmanned station in the desert. Failure is not an option.
JN Pump Skid
Multiphase Pump Skid including liquid hold-up tank and injection pump, suitable for Multiphase transferring with heavy oil, suitable to handle poor gas slugs of 30 minutes and more, manual or auto remote controllable.
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