Products – PCP

Progressing Cavity Pump Systems

Increase efficiency with downhole, PMM-driven, PCP artificial lift solutions for horizontal, deviated, and challenging producers.

For well conditions that challenge conventional electrical submersible pump (ESP) or progressing cavity pump (PCP) systems, Borets offers a cost-effective alternative to increase well productivity and system run life.

Submersible PCP artificial lift systems are optimal where traditional rod-driven systems are limited by depth or where deviated or crooked wells have caused premature rod/tubing wear because 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; wells with a high gas-oil ratio (GOR); and wells with scale and high amounts of asphaltenes.

Borets’ extensive global manufacturing capacity includes 10 state-of-the-art plants that produce all major components of ESP, HPS, and PCP artificial lift systems. All facilities use advanced machining, assembly, and testing technologies to ensure production efficiency and the highest level of product quality.

PMM-PCP System

Applications

  • Deviated and horizontal wells
  • Low flow rate and unstable in flow wells
  • Heavy oil and viscous oil wells
  • Wells producing with higher solids volume or scale
  • High lift system adaptability to variable conditions

Benefits

  • Improved system reliability through the
    • elimination of rods and rod-wear associated failure
    • elimination of downhole gearbox and associated failure
  • Reduced OPEX through lower power consumption
  • Improved viscous or abrasive production in deviated wellbores
  • Reduced wellhead equipment footprint and environmental risk

Features

  • Low-speed, high-torque PMM
    • Speed range of 120-1,500 rpm
    • Torque up to 1,670 lb-ft
  • Independent thrust chamber to carry and equalize developed thrust load
  • Flush valve to reduce and smoothen starting torque impact on motor and system
  • Downhole monitoring sensor
  • Surface variable speed drive
  • Handles up to 50% free gas
  • Handles up to 0.6 g/l solids
  • No fluid emulsification

The PMM-PCP system effectively extends the application range of PCPs to highly deviated wellbores where this technology was not previously considered because of the well bore geometry limitations. In this manner, the Borets PMM-PCP system enables lower rate or more viscous fluids to produce from deviated wells with lower power consumption than historically deemed feasible with ESPs or conventional PCPs.

In one study, power consumption was directly measured on several hundred low flowrate wells, producing with different forms of artificial lift. Analysis showed that the Borets PMM-PCP system consumed the least power per unit volume of fluid lifted than the other forms of lift considered in this study.

Power Consumption

per 1 m3 of fluid produced

Wells producing large volumes of sand and abrasives, high-viscosity fluids, or high gas-to-liquid ratios are considered technically challenging for electric submersible pump (ESP) systems and even more so at lower flow rates. While more suited to these conditions, progressing cavity pump (PCP) systems encounter limitations to their application from well depth and deviation, resulting in inferior system run life and performance efficiency.

For these conditions, the Borets PMM-PCP system is a cost-effective lift system that overcomes such challenges to help increase well productivity and operational performance.

Operating conditions

Pump depth * 7,874 ft (2,400 m)
Water cut at pump intake up to 99%
Fluid specific gravity up to 1.4
Produced water pH *  6.0…8.5
Fluid viscosity * up to 1,000 cP
Solids content up to 0.6 g/l
Mohs’ hardness number up to 5
Free gas content at pump intake up to 50%
H2S content up to 0.125%
Fluid temperature * 80°С – 120°С

* depending on design

 

Borets PMM-PCP system is an electric submersible progressing cavity pump that incorporates a downhole permanent magnet motor (PMM). The downhole driven PMM-PCP system provides all the advantages of PCPs in viscous or abrasive fluids while eliminating the wear-risks associated with a steel rod string to surface.

Utilizing a low-speed 10-pole PMM to deliver sufficiently higher torque, the Borets PMM-PCP system also reduces downhole mechanical complexity by eliminating the need for a speed-reducing gearbox required by electric submersible PCP systems using downhole induction motors. Borets PMM technology is well proven to operate at lower current, increased efficiency, and reduced power consumption than an equivalent induction motor.

PCP Specifications @ 500 rpm

Low-speed PMM Specifications @ 500 rpm

PCP Pump Applications

Our submersible PCP applications use highly efficient progressing cavity pumps and are designed for wells where traditional rod-driven systems are limited by depth and rod and tubing wear. They’re also practical for 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 pump in wells where this technology was not an option due to wellbore geometry.

Advantages of Permanent Magnet Motors

The Borets PMM-PCP artificial lift system is a permanent-magnet-motor-driven electric submersible progressing cavity pump (ESPCP) that provides the benefits of a 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 reduced power consumption than historically deemed feasible with ESPs.

Thrust Chamber

Located below the flexshaft, Borets’ thrust chamber is designed to:

  • Absorb axial thrust from the 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.

Motor Seals

PCP system motor seals perform four basic functions:

  • Transfer power from the motor to the intake/pump
  • House a thrust bearing to absorb pump shaft axial thrust
  • Isolate motor oil from well fluid while allowing wellbore-motor pressure equalization
  • Act 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.

Our PCP system motor seals are highly configurable to address your operating needs:

  • Labyrinth and bag types
  • Elastomer options for temperature and corrosion concerns

Power Cable

Borets is one of few artificial lift equipment providers manufacturing the complete ESP system including the power cable. We have two in-house cable plants with the total capacity to make approximately 10,000 km of power cables annually.

Our PCP system power cable transmits three-phase surface electric power to the downhole motor. It also has:

  • Solid and stranded configurations: #1 through #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 of -40° F to 446° F (-40° C to 230° C)

It’s strapped or banded along the length of the tubing to provide support, and cable guards are used in deviated wells.