KUDU Rodless PCP

with downhole electrical Permanent

Magnet Motor (PMM) drive
(design, benefits, applications)
 Rodless PCP
Design consideration
The downhole electrical PMM drive was developed and
manufactured by RITEK-ITC located in Moscow, Russia.

Since 2013, KUDU in partnership with RITEK-ITC offer Rodless

PCP system based on PMM drive in global market.
 History of innovation
1996 – work on PMM downhole drive technology began
1998 – first prototype of PMM drive was tested
2002 – first commercial PMM drive with ESP was installed
2003 – first commercial PMM drive with PCP was installed
2013 – total 2370 PMM drives in operation (1840ESP, 530PCP)

- Total PMM drives

- PMM + ESP
- PMM + PCP

Most of PMM drives installed in Russia

Benefits of Permanent Magnet technology

Permanent magnets applied in electrical machines have fowling benefits:

1. Increase in efficiency because there are no excitation losses or electrical
energy is not absorbed by the field excitation.
• Less temperature increase during motor operation
• Lower current value in power line (lower losses)

2. Higher power density and torque density.

• More power output from without increase in size (shorter motor)

3. Due to higher magnetic flax density in the air gap PM machine has better
dynamic performance.
• Accurate VFD speed adjustment
• Soft start
• Wider speed adjustment range
PMM vs. Induction Motor (design)

Induction Permanent magnet

(asynchronous) (synchronous)
motor motor)

Rotor
Rotor permanent
winding magnets

Control
PMM
Panel
 PMM vs. Induction Motor (design)

Induction Motor

Permanent
Magnet Motor
Cooper
Rods

Permanent
Magnets
 PMM vs. Induction Motor (parameters)

Parameter PM Motor Induction Motor

Efficiency 91% 84,5%

Power
Lower Higher
consumption

Shorter motor for the same Longer motor for the same power
Size
power rating rating

Increased run life for motor,
protector, cable
Equipment run
Improved thermal
life
characteristics in stator
winding
Reduction in run life and motor failuer
due to:
Low flow rate
Unstabale well inflow
Operation at high BHT

Soft start and VFD adjustable Routine motor shut down to prevent
Motor control
motor speed motor overheating (brining the well in
line)
 PMM vs. Induction Motor (parameters)

Motor Type
Parameter
Induction Motor PM Motor
ПЭД32-117 ВДМ30-117

Nominal Power, kW 32 30
Nominal Current, А 26 21
Idle Current, А 11,0 1,4
Motor Efficiency, % 84,5 91,3
Specific heat dissipation, kW/m² 5,5 3,2
Stator Winding operational temperature increase, оС 40 20
Required motor cooling flow, m/sec (no less) 0,08 0,06
Motor Length, mm 3798 1925

Note, compared motors for ESP application.

Two approaches in Electrical Submersible PCP

Regular induction motor with Direct drive based on

mechanical gear reducer PM motor technology
Benefits of direct drive in Rodless PCP
application
1. PMM technology utilization
• smaller dimensions (shorter)
• lighter
• low heat generation – extended motor run life
• low current & voltage in power cable – low losses, reliability
• flexible pump speed adjustment
• constant torque
• higher electrical efficiency

2. Eliminates mechanical gear reducer between motor and pump

• less moving mechanical part – more reliable
• no torque loses in gear reducer
 PMM vs. Induction Motor in Rodless PCP
application*

*Based on bench test results

 Rodless PCP completion

Rodless PCP system has completion similar to ESP

The difference in following components:

1. PMM downhole motor

2. Supporting unit and pump intake
3. PC pump
4. Special, PMM applicable, control panel
Rodless PCP – Surface Equipment

Control Panel Step-Up ESP Wellhead with

RITEKS-99 Transformer cable penetrator
Rodless PCP – Subsurface Equipment
Casing
Tubing to surface
Power Cable
Power Cable Clamps
Drain Valve

PCP

Motor Lead Extension

Pump Intake

Protector Supporting Unit

Permanent Magnet Motor
DH Permanent Monitoring Sensors

Motor Centralizer
Perforation Zone
 Permanent magnet motor (PMM)

Permanent magnet motor, manufactured by RITEK-

ITC, generate and transfer torque to PCP

Motor Specifications:
• Torque range up to 480 ft*lbs
• Max motor power – 40 kW
• Speed range from 90 to 900 RPM (at 60Hz)
• Motor OD – 4.6 inch
• Max length – 24.3 ft
• Max weight – 1124 lbs
• Max temperature - 150ºC
 Supporting unit-pump intake

Supporting unit –pump intake connects motor protector shaft with PCP rotor and
designed for:
• Support hydrostatic pressure load (axial load) through set of thrust bearings
• Pump intake
• Dump eccentric PCP rotor movement through flexible shaft assembly
• Connect PCP to downhole drive assembly

Rotor connection coupling

SPLINE- 7/8” (1”)
Coupling SU- Protector Flex Shaft Pin Coupling
Flex Shaft Connection 3 ½”EUE PIN
Supporting Unit
Pump Intake - slotted
 Control panel

Control panel (VFD based) controls PMM operation

and includes following features:
• PMM soft start
• “Manual” and “Automatic” modes
• Motor speed adjustment from 90 to 900RPM (at
60Hz)
• Maintaining set DHP (±500kPa) (with DHMS)
• Automatic restart
• Automatic motor reverse based on torque (flush
mode)
• PMM operation in set sequence
• Maintain motor speed setting (±2%)
• Real time operational parameter monitoring and
visual display
• Failure identification
• Operational data logging
• Remote well control (through MODBUS)
• Comply to IEEE519
Permanent downhole monitoring system

PDHMS consist of 6 downhole sensors

installed in one package at the bottom of
PMM to monitor following parameters:

• Casing pressure at PSD

• Casing temperature at PSD
• PMM housing oil pressure
• PMM housing oil temperature
• PMM vibrations (X,Y)
• Power cable resistance (conditions)

Note: signal from DHMS is transmitted through

power cable
Three phase electrical connection diagram

Power Supply Control Panel Step Up

(480V/60Hz) Transformer PMM
(PMM-VFD)
 KUDU Rodless PCP specifications:

Parameter Min Max Unit

Pump production rate: 5 1100 Bbl/d
Pump setting depth (1100 bbld): - 2600 ft
Pump setting depth (<120 bbld): - 8200 ft
Max downhole temperature: - 150 ºC
Pump speed range: 90 750 RPM
Casing size: 5 ½” >5 ½”
Pump series: 2 7/8” 3 ½”
Max Motor power: - 40 kW
Max Motor torque: - 480 ft*lbs
Max axial load: - 13200 lbs
Max Well bore deviation: - 90 ⁰
Motor OD - 4.6 inch
Available options for downhole drive:
1) Basic, with max temperature - 120⁰C
2) High temperature, max temperature - 150⁰C
3) Corrosion resistant, max temperature - 120⁰C
4) HT - Corrosion resistant, max temperature - 150⁰C
Rodless PCP
Benefits
 NO ROD STRING

• No restrictions to set PCP pump in wellbore with any deviation

• Increase in production (set pump dipper)
• Eliminates up to 50% of PCP failures
• Reduces torque and pressure losses in pumping viscous fluid
• Eliminates human error in PCP space out
 NO ROD STRING - no failures in tubing or
rod string
Based on industry reports 35-50% of failures in PCP application associated with
rods and tubing string

Source: CFER, PCP training guide

NO ROD STRING – lower torque and
pressure losses in viscous media
NO ROD STRING – lower torque and
pressure losses in viscous media
 Other Benefits

• Lower operating cost (lower power consumption and maintenance cost

for surface equipment)
• Wide range for pump speed adjustment from 90RPM to 750RPM (less
interventions to downside or upside the pump)
• Low noise generation in environmentally sensitive areas
• Could be used in offshore applications
• Equipment optimization (less capital cost)
• Production and reservoir management optimization (using DH sensors)
• No leakage at surface (no stuffing box)
• Eliminate restrictions for drilling deviated well bores
• Wells with scale, emulsion or wax problems
• Safety (no back spin)
Artificial lift technology comparisons
Conditions SRP PCP ESP ES PCP Rodless
(gear box) PCP

Heavy oil
Deviated wells
Sand
Production rate
Pump depth
Surface equipment
Wax
Emulsion
Scaling
High temperature
Power consumption
Cost
High GOR
Reliability

- Poor
- Fair
- Good
 Rodless PCP
Application Considerations
 Rodless PCP Equipment selection

• Equipment selection can effect performance and run life of whole system
• Information input (rate, depth, well conditions, fluid properties)
• Equipment selection
• System operational parameters
• PC pump is most critical component
- Pump model
- Pump elastomer
- Pump efficiency
• Required proper combination: PC pump – PM motor
• PM motor model selection based on required torque
 Technical specifications

Parameter Value

Max production rate*: 400m³/d (2,700bbl/d)

Max setting vertical depth*: 2400m (7,800ft)
Max downhole temperature: 150 ⁰C (300 ⁰F)
Max sand content: 5%
Min casing size: 139.7 mm (5.5 inch)
Max power capacity: 40 kW
Power supply requirements: 380 V,50 Hz or 480 V, 60Hz
Max axial load: 6000kg (13,200lbs)
Max well bore deviation: 90⁰
PM motor OD: 117mm (4.6inch)

* - based on combination pump - motor

Pump performance curves
 Performance of Rodless PCP

Company: Lukoil-Komi (Russia)

Number of Drives pulled after operation (since 2005): 2166

Max Runlife: 1608 days
Average Runlife: 255 days

Number of Drives currently in operation: 525

Max Runlife: 1396 days
Average Runlife: 418 days (from date installed)

Major cause of failure: PC pump (≈ 55%)

Motor could be reused after inspection.
 Rodless PCP application limitations

• Production rate limit due to max motor torque – 650Nm

• Pump setting depth due to SU max axial load capacity – 6000kg
• Max operational temperature - 150°C
• Fluid composition – high BTX content would affect elastomer
• High GOR – would affect pump elastomer and reduce efficiency
• High H2S and CO2 – can affect elastomer and motor seals
• High dogleg severity at pump set location – can affect motor bearings run life
• Could not be deploied in smaller than 5 ½” casing
• Unit should be installed above perforation depth to cool PM motor
• Very high sand cut (>5%) – no capacity to do flush by
Thank you for your attention.

Questions?