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.
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.
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.
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
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.