Electrical Submersible Progressive Cavity Pump (ESPCP) Application in Kulin Horizontal Wells

Abstract

Abstract The original Kulin Horizontal well project scope was to drill two horizontal wells and run Electric Submersible Progressive Cavity Pumps (ESPCP's). ESPCP is a combination of Progressive Cavity Pump (PCP) and Electric Submersible Pump (ESP) motor as a down hole fluid lifting system and is ideal for use in horizontal wells. With rod less system, it will eliminate friction loss at tubing and rod. The PCP has more resistance to sand production and provides high efficiency production of viscous fluid. The Kulin Horizontal Drilling project started in early 2002 and ended in February 2003. The first horizontal well was Kulin 082 (KL082) and the second well was Kulin 083 (KL083). After the wells were completed using ESPCP as artificial lift, the initial production for KL082 was 708 BFPD, 531 BOPD, 25% water cut and KL083 was 518 BFPD, 394 BOPD, 24% water cut. The initial production was above estimated initial production of 300 BOPD/well. The ESPCP's in both Kulin horizontal wells are installed in tangent sections with less than 2 °/100 ft build rate inside 9-5/8" production casing. The design threshold for ESPCPs is up to a maximum of 15°/100 ft build rate in the tangent section. The stator elastomer inside the PCP is operated at temperatures between 135°F and 150 °F and this is below the maximum temperature limitation for the elastomer. The flow rates, head and pump efficiency of the ESPCPs are controlled using surface mounted Variable Speed Drive (VSD). As of June 2004, the ESPCPs that are installed in both Kulin horizontal wells have been operating for over 450 days and 800 days respectively without any mechanical problem from pump or ESP failures. Both ESPCPs was down in period mid of June’04 until early August’04 when the Kulin field was shut down due to facility safety issue. The production rates from these horizontal wells are about 2.5–3.5 times greater than an average vertical producer in the field. This paper will discuss ESPCP design, installation and performance in the Kulin Horizontal wells.