Selecting the right progressive cavity pump size depends on the actual production and well conditions. Flow rate, differential pressure, fluid viscosity, sand content, operating temperature, casing size, setting depth, and pump speed all affect the final selection.

For heavy oil and sand-producing wells, these conditions can change during operation. Our progressive cavity pump sizing guide explains how production rate, sand content, well depth, casing size, and fluid properties are considered together when sizing a PCP for CHOPS applications.

How Does Flow Rate Affect Progressive Cavity Pump Size?

Flow rate determines how much fluid the pump needs to move. In a progressive cavity pump, displacement and rotational speed work together to provide the required production.

A simplified relationship is:

Flow ≈ Displacement per Revolution × Speed

Actual flow can also change with pressure differential, fluid viscosity, internal clearance, and operating conditions. We therefore use the required production range rather than a single flow value when selecting the pump.

Match displacement to the production range

We recommend defining:

• Minimum production

• Normal production

• Maximum production

The selected pump should cover this range without requiring continuous operation at an unsuitable speed.

How Does Pressure Affect Progressive Cavity Pump Sizing?

After establishing the required flow, the next step is to determine the lifting requirement. Differential pressure depends on pump setting depth, wellhead pressure, fluid density, tubing losses, and surface resistance.

A deeper pump setting or higher discharge pressure increases the required dynamic head. The selected pump therefore needs sufficient pressure capability at the required production rate.

Our IntelliCPCP® configurations provide rated dynamic heads from 1,000 m to 2,200 m, depending on the model, with specified pump setting depths from 800 m to 1,500 m.

Flow, dynamic head, and pump displacement need to be checked together before the final configuration is selected.

How Does Viscosity Affect PCP Sizing?

Fluid viscosity directly affects how the produced fluid moves through the pump. This becomes particularly important in heavy oil applications, where viscosity can change with temperature.

As viscosity changes, rotor-stator clearance also becomes an important sizing factor. Our progressive cavity pump system uses a conical rotor and stator with variable radial clearance, allowing the operating clearance to be adjusted according to fluid conditions.

Match clearance to fluid conditions

Lower-viscosity fluids generally require tighter clearance to limit internal leakage, while higher-viscosity fluids may require greater clearance to maintain fluid movement.

Temperature should be considered at the same time because changes in temperature can significantly affect heavy-oil viscosity.

How Should Sand Content Be Included in PCP Sizing?

Sand concentration and particle characteristics need to be included when sizing a pump for sand-producing wells.

Sand can affect:

• Rotor-stator clearance

• Pump wear

• Torque

• Sticking risk

• Operating stability

Different IntelliCPCP® configurations are designed for different sand conditions. The GLB258-17C is specified for sand content up to 3%, while the GLB311-12C is specified for 3–10%. The GLB258-25C and GLB322-20C are specified for up to 0.3%.

This means sand content should be matched to the applicable pump configuration rather than treated as a general value for every PCP.

What Pump Speed Is Suitable for Progressive Cavity Pump Sizing?

Pump speed determines how quickly the pump delivers its displacement. However, increasing speed is not always the appropriate way to increase production.

Speed also affects pump wear, torque, solids handling, and operating stability.

Balance displacement and speed

Our IntelliCPCP® configurations have a rated rotational speed of 200 rpm and a speed adjustment range of 0–200 rpm. The theoretical displacement at 100 rpm ranges from 37 to 46 m³/d across the specified configurations.

The required production should therefore be matched with an appropriate combination of pump displacement and operating speed.

Casing Size and Pump Setting Depth

The pump must fit the physical conditions of the well as well as meet the production requirement.

Casing compatibility

The specified IntelliCPCP® configurations apply to casing sizes of 5.5 inches and larger, with maximum downhole component outside diameters of 114 mm or 135 mm depending on the configuration.

Setting depth and deviation

Setting depth affects the required dynamic head and mechanical loading. The applicable IntelliCPCP® configurations support pump setting depths from 800 m to 1,500 m.

For deviated wells, rod-tubing contact and downhole loading also need to be considered. The specified configurations support wellbore deviation up to 80°, with dogleg severity below 2°/30 m.

Progressive Cavity Pump Sizing for Heavy Oil and Sand

Heavy oil and sand-producing wells require closer attention to viscosity, clearance, sand content, and temperature.

IntelliCPCP® is designed for ultra-heavy crude, conventional crude, sand-laden fluids, high-water-cut crude, and multiphase flow with associated gas. Its specified bottomhole temperature range is -10°C to 380°C.

For these applications, the pump configuration needs to match both the production target and the changing fluid conditions.

Our FERROXIS® all-metal conical PCP uses variable radial clearance between the rotor and stator. This lets you adjust clearance to operating requirements, which is especially important when fluid viscosity and sand conditions change.

Choosing the Right Progressive Cavity Pump

The final pump selection should bring together the main sizing parameters:

• Flow rate

• Differential pressure

• Viscosity

• Temperature

• Sand content

• Pump speed

• Casing size

• Setting depth

• Well deviation

Our progressive cavity pump solutions are developed around these operating requirements. For heavy oil and sand-producing applications, we can also combine pump configuration, clearance adjustment, surface drive, and control functions according to the well conditions.

The objective is to select a pump that can deliver the required production while remaining within a practical operating range.

Discuss Your Progressive Cavity Pump Sizing Requirements

If you are selecting a new PCP or replacing an existing system, we can review the available well data and help determine the appropriate pump configuration.

Please provide the production rate, differential pressure, fluid viscosity, temperature, sand content, casing size, setting depth, and other available operating data through our progressive cavity pump engineering support. These details allow us to assess the application and recommend a suitable configuration.