Progressing Cavity Pump Systems
Downhole, PMM-driven alternative lift solutions for horizontal, deviated, and challenging producers
For well conditions that challenge conventional electrical submersible pumps (ESP) or progressing cavity pump systems (PCP), Borets offers a cost-effective alternative solution to help increase well productivity and system run life.
Submersible PCP systems are considered where traditional rod-driven systems are limited by depth or where deviated or crooked wells have caused premature rod/tubing wear, as submersible PCP systems have no rods. They deliver the best performance in horizontal and deviated wells, low volume wells with unstable inflow, wells with viscous, abrasive fluids, high GOR, and wells with scale and high amounts of asphaltenes.
Borets extensive global manufacturing capacity includes 10 state-of-the-art plants that manufacture all major components of ESP, PCP, and HPS systems. All facilities make use of advanced machining, assembly, and testing technologies to ensure production efficiency and the highest level of product quality.
Borets submersible PCP applications utilize highly efficient progressing cavity pumps and are designed for wells where traditional rod driven systems are limited due to depth and rod and tubing wear and low volume wells where conventional ESPs have limitations such as low efficiency, plugging, and erosional wear.
By extending PCP application range, the system allows operators to take advantage of the efficiency and solids-handling ability of a PCP in wells where this technology was not an option due to wellbore geometry.
The Borets PMM-PCP system is a permanent magnet motor (PMM) driven electric submersible progressing cavity pump (ESPCP) that provides the benefits of PCP without the safety and abrasion risks associated with a steel rod string to surface.
The low-speed 10-pole PMM employs a rotor with permanent magnets made of sintered hard-magnetic materials. Magnets produce the rotor flux and so require less power for field generation. Increased efficiency and synchronous operation translate into reduced electrical loss, lower operating current, and less heat generation.
The Borets PMM-PCP system makes it possible to produce deviated wells at lower rates and lower power consumption than historically deemed feasible with ESPs.
Located below the flexshaft, Borets thrust chamber is designed to:
- Absorb axial thrust from PCP
- Isolate wellbore fluids from internal rotating components
- Facilitate torque transfer from motor seal to the flex shaft
- Equalize pressure inside the thrust chamber to that of the wellbore
- Contain special thrust chamber oil
PCP system motor seals perform four basic functions:
- Transfers power from the motor to the intake / pump
- Houses a thrust bearing to absorb pump shaft axial thrust
- Isolates motor oil from well fluid while allowing wellbore-motor pressure equalization
- Acts as a reservoir for thermal expansion and contraction of motor oil due to operating heat rise and thermal contraction of the motor oil after shutdown
Borets PCP system motor seals are highly configurable to address operating needs:
- Labyrinth and bag types
- Elastomer options for temperature and corrosion concerns
Borets is one of few artificial lift equipment providers manufacturing the complete ESP system including power cable. We have two in-house cable plants with total capacity to make approximately 10,000 km of power cables annually.
PCP system power cable:
- Transmits three-phase surface electric power to downhole motor
- Solid and stranded configurations: #1 thru #6 AWG sizes
- Round and flat profiles
- Galvanized, Stainless Steel or MONEL armor
- Specially formulated EPDM insulation for harsh conditions
- Lead sheath for high temperatures, H2S protection and gas migration
- Temperature ratings: -40 °F to 446 °F (-40 °C to 230 °C)
- Strapped or banded along the length of the tubing to provide support
- Cable guards are used in deviated wells