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Borets Progressing Cavity Pumping Systems Have Proved Their High Cost Efficiency & Operational Performance

Borets has supplied to LUKOIL-Perm more than 500 Permanent Magnet Motor driven Progressing Cavity Pumping systems (PMM - PCP systems). This result has confirmed once again the demand for these products from the Russian oil companies.

Reducing electrical consumption, improving artificial lift systems performance and cost efficiency of oil recovery are crucial tasks for the majority of operators. While selecting the optimal pumping equipment, LUKOIL-Perm engineers have measured kilowatt-hours consumed by different artificial lift systems under similar well conditions. The field tests have demonstrated that the Borets PMM - PCP system for lifting 1 m3 of well fluid consumes 5.3 time less kilowatt-hours than an induction motor driven ESP system, 1.5 time less kilowatt-hours than SRP and 1.2 time less kilowatt-hours than a rod driven progressing cavity pumping (PCP) system.

The high energy efficiency of the Borets PMM - PCP system is based on design features of its components. For example, PCP efficiency is 70%, that significantly exceeds the efficiency of the other pump types, and the permanent magnet motor consumes 10-15% less electricity compared to an induction motor, since PMM rotor comprises the permanent magnets. Besides, the capability of PCP system to operate without a gas separator in conditions up to 50% free gas at the pump intake ensures the additional electrical power saving. 

The average run life of the Borets PMM - PCP systems tested in LUKOIL-Perm field was 400 to 530 days depending on well problems (solids, paraffin, asphaltenes and etc.), and the maximum run life was about 1 100 days. The Borets PMM - PCP systems tested in the other oil producing regions demonstrated the similar run lives: Surgutneftegaz field – 1 400 days, oilfield in Serbia – more than 1 000 days, oilfield in Volga region - about 900 days.

The five years experience of the Borets PMM - PCP systems operation has demonstrated the reduction in lifting costs without reliability degradation and increase in run life due to:

 

continuous operation of low flow rate (4-20 m3/day) wells,
        which could not be reliably operated with ESP

elimination of a gas separator from the pumping system

decrease in scale inhibitor injection costs and elimination of dosing units

reduction of electrical consumption up to 30% compared to ESP system

reduction of installation time

pump flow rate control via rpm adjustment almost without head degradation.

 

The experience of the Borets PMM - PCP systems operation has proved that SRP wells conversion to ESP allows to decease lifting costs, improve reliability and increase pump setting depth.

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