Copyright 2005, Society of Petroleum Engineers Inc.

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Abstract
The original Kulin Horizontal well project scope was
to drill two horizontal wells and run Electric Submersible
Progressive Cavity Pumps (ESPCPs). 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 ESPCPs in both Kulin horizontal wells are
installed in tangent sections with less than 2
o
/100 ft build rate
inside 9-5/8 production casing. The design threshold for
ESPCPs is up to a maximum of 15
o
/100 ft build rate in the
tangent section. The stator elastomer inside the PCP is
operated at temperatures between 135
o
F and 150
o
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 June04 until early August04 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.

Introduction
The horizontal wells were designed with 9-5/8 production
casing with a 8.5 open hole lateral section containing a 7
pre-perforated completion liner. The well KL082, is producing
from Duri E sand with 1,340 ft TVD sand depth and 393 ft
lateral length. The well KL083 is producing from Duri B
sand with 980 ft TVD sand depth and 1,214 ft lateral length. A
summary of reservoir properties at initial condition is listed in
table 1.
KL082 KL083
Porosity 33% 25%
Permeability 5000 md 2131 md
Sand Thickness 34 ft 18 ft
Reservoir Pressure 220 psi 235 psi
Reservoir Temp 150
o
F 135
o
F
Oil Gravity 20
o
API 16
o
API

Table 1. Reservoir properties

During pre execution phase of the project, the Kulin
Horizontal Well Execution Team did an assessment to identify
appropriate artificial lift methods for the horizontal well
project that would optimize pump operability and well
production. Horizontal wells located in the adjacent Duri field
were used to evaluate tubing pump performance. This analysis
was done to understand the critical factors that affected pump
performance. The Duri field has unconsolidated sand with
high reservoir temperature as result of steam flood process.
Statistically, tubing pump performance at 25 horizontal wells
in Duri is poor. The average of tubing pump efficiency is less
than 30% with 118 days average pump run life.
Table 2 provides the tubing pump efficiency of Duri
Horizontal wells.
Year # of Pump Installed Avg Pump Efficiency (%)
1999 6 20
2000 15 27
2001 19 43
2002 7 29

Table 2. Tubing pump efficiency in Duri Horizontal
wells (25 wells)
Some contributing factors that have caused low tubing pump

SPE 93594
Electrical Submersible Progressive Cavity Pump (ESPCP) Application in Kulin
Horizontal Wells
M. Taufan, SPE, R. Adriansyah, SPE, and D. Satriana, SPE, P.T. Caltex Pacific Indonesia
2 SPE 93594

ROTOR
STATOR
performance in Duri horizontal wells are: high friction losses
that prevent adequate pump travel and excessive sand
production that damages the tubing pump plunger. Although
some modifications had been made to reduce friction loss by
installing roller guides on the rod string, pump failure still
occurred frequently. The roller guides were damaged by
excessive production of sand due to poor sand control in
horizontal wells. Most of Duri Horizontal wells use pre-
perforated liner set in open hole as sand control and this has
failed to reduce sand production.
Realizing that Kulin has unconsolidated sand and the
horizontal wells were designed using a similar completion
with pre-perforated liner in open hole; the team took the
initiative to identify other artificial lift alternatives to tubing
pumps. The desired characteristics of the new system were a
rodless system with more resistance to sand production. The
team has considered both ESP and PCP separately but the ESP
is not designed to handle sand production, and the PCP is
using a rod system that is prone to failure in horizontal well.
The team then decided to utilize ESPCP as solution.

ESPCP Design
ESPCP is PCP (Progressive Cavity Pump) driving with an
ESP (Electric Submersible Pump) motor as a downhole drive
system. This configuration is a rodless system which
eliminates friction loss at tubing and rod. PCP is a single
helical (rotor) which rotates eccentric inside double helical
(stator). The PCP is a positive displacement pump. As the
rotor rotates inside the stator, fluid moves through the pump
from cavity to cavity.
As one cavity closes, its opposing cavity opens at exactly the
same rate. This results in a constant non-pulsating flow. The
PCP can handle viscous fluids and solids laden fluid. The
standard rotor is made from stainless steel, and hard chrome
plated for abrasion protection. The stator elastomer is made
from a mixture of compounds designed to handle variety of
produced fluids, solids and gases.
Figure 1 is Progressive Cavity Pump with 2 main component,
rotor and stator.



















Fig 1. Progressive Cavity Pump
Various types of stator elastomers are available from vendors.
The stator elastomer generally has a heat limitation associated
with bottom hole temperature. Some available products have
variety of temperature resistance to a maximum of 95
o
C (203
o

F), 105
o
C (221
o
F), 135
o
C (275
o
F) and 150
o
C (302
o
F).
Because the BHT of the producing sand was about 65.6
o
C
(150
o
F), we chose an elastomer with a temperature resistance
of 95
o
C (203
o
F).
Another consideration when designing a PCP installation is
determining whether the elastomer will be compatible with the
aromatics in the produced fluids. The ESPCP system
configuration is provided at figure 2.



Flex Shaft &
Cavity Pump
ESP Motor



Gear Reducer




Seal Section

Intake




Progressing

Fig 2. Electric Submersible Progressive Cavity Pump (ESPCP)

ESP Motor
ESP motor sizing is determined by the power required to start
and operate the PCP, the size of the casing and the downhole
temperature. Standard for the ESPCP system is two pole
motor with a 50Hz speed at 2,917 rpm and a 60Hz speed of
3,500 rpm.
Gear Reducer
The primary function of the gear reducer is to provide a speed
that is acceptable to PCP. The normal range of the PCP is 100
to 500 rpm.
The second function of gear reducer is to increase the torque
available to the PCP.
Gear ratio are varying depend on each product. Example of
gear ratio: 9:1 and 11:1
Seal Section
The main function is to prevent well fluids entering the gear
reducer and motor, isolating the specially formulated motor oil
from the well bore fluids. This isolation allows the motor oil
to expand or contract as downhole temperatures and pressure
vary.
Flex Shaft and Intake
The flex shaft assembly is designed to convert the concentric
rotation of the seal section shaft to the eccentric rotation
required by PCP. Design for high torque load. Utilize standard

SPE 93594 3
ESP intake base. Maximum intake flow is 9,000 bpd
(1,430m
3
/d).

To control the flow rates, head and pump efficiency, the
ESPCP was run using Variable Speed Drive (VSD), which is
operated at the surface. By adjusting the frequency, the VSD
system offers potential for controlling production and reduces
down time.

ESPCP Installation
ESPCP installation at horizontal wells KL082 and KL083 has
considered the maximum allowable inclination for the pump
placement. The ESPCP is capable to be operated in horizontal
wells with less than 15
o
/100 ft tangent section. ESPCP in
KL082 was installed at 64
o
inclination with 1.6
o
/100 ft build
rate inside 9-5/8 casing. Depth installation is 1,440 ft MD or
1,267 ft TVD. ESPCP in KL083 was installed at 58
o

inclination with 1.5
o
/100 ft build rate. The pump depth is
1,014 ft MD or 891 ft TVD.
The pumps were installed using 3-1/2 tubing and equipped
with 3-1/2 check valve and bleeder valve 90 ft above the
pump. To prevent motor cable friction with casing, a cable
guard was installed along the pump and tubing.
The ESP motor that was installed at both wells are two pole
motor with 60 Hz speed of 3,500 rpm, 562 series, 38 HP, 453
volts and 53 ampere. Actual setting is 40 Hz speed of 2,333
rpm. Motor Outside Diameter is 5.62 with 6.98 ft length.
The 562 motor series is suitable for minimum 7-32# casing
size.
Both Kulin Horizontal wells are using 9:1 gear ratio. At 40 Hz
speed of 2,333 rpm results in speed at the pump:
2,333/9 = 259 rpm
Motor Output torque = Motor HP * 5,252/ Motor Speed
= 38 (HP)*5,252/2,333 (rpm)
= 86 ft lbs
Gear reducer output torque = 86 ft lbs * 9
= 774 ft lbs
The PCP model is 054-12-045 with capacity of 340 BFPD/100
rpm.
Pump Rate = Pump Speed * Pump Capacity
= 259 (rpm) * 340 (BFPD/100 rpm)
= 881 BFPD
Pump dimension is 4.25 pump OD with 13.3 ft stator length.
Table 3 summarizes the ESPCP design which was installed at
KL082 and KL083 wells.

Motor Speed (RPM) @ 40 Hz 2,333
Gear Reducer 9:1
Pump Speed (RPM) 259
PCP Capacity (BFPD/100 RPM) 340
Pump Rate (BFPD) 881

Table 3. ESPCP design at KL082 & KL083

Field Result

KULIN 082
Well KL082 started production in April 2002. Initial
production was 708 BFPD, 531 BOPD and 25% water cut.
Average production of the wells is 445 BOPD with 20-30%
water cut range.
Fiq 3 showing production performance at KL082
200
300
400
500
600
700
800
900
A
p
r
-
0
2
M
a
y
-
0
2
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u
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u
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D
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p
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a
y
-
0
4
J
u
n
-
0
4
B
b
l
/
D
a
y
FLUID_RATE OIL_RATE


Fig 3. Production performance KL082

Since initial production the water cut is stable at level 20-25%
and slightly increase to 27% starting March 2004. Fig 4
showing water cut trend at well KL082.

10
15
20
25
30
35
A
p
r
-
0
2
M
a
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-
0
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J
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c
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a
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b
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a
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A
p
r
-
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3
M
a
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-
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J
u
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e
c
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3
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a
n
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4
F
e
b
-
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4
M
a
r
-
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4
A
p
r
-
0
4
M
a
y
-
0
4
J
u
n
-
0
4
W
C

(
%
)
Water Cut


Fiq 4. Water Cut trend at KL082

The ESPCP has better pump efficiency compared to tubing
pump efficiency in Duri horizontal wells. Average pump
efficiency at well KL082 since initial production is 66%. After
more than 800 days (2.2 years) producing time, there have
been no indications of pump failures. Fig 5 shows Pump
Efficiency at well KL082.

20%
40%
60%
80%
100%
A
p
r
-
0
2
M
a
y
-
0
2
J
u
n
-
0
2
J
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l
-
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D
e
c
-
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3
J
a
n
-
0
4
F
e
b
-
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4
M
a
r
-
0
4
A
p
r
-
0
4
M
a
y
-
0
4
J
u
n
-
0
4
Pump Eff


Fig 5. Pump Efficiency at KL082

Some operational problems were encountered early in the life
of the wells, when no fluids were produced while the pump
was running. A fluid level survey also indicated a high fluid
level above the pump. The team suspected that something was
plugging the pump intake. The team successfully used the
4 SPE 93594
technique of backflushing the pump by reversing the motor to
return the well to production without pulling the pump. By
reversed the motor rotation in couple minutes and then turn
back to normal motor rotation, the well was successfully
returned to production.

KULIN 083
Well KL083 starting producing in March 2003. Initial
production of the well was 518 BFPD, 394 BOPD and 24%
water cut. There were some problems early in the life of this
well. High oil viscosity with 16
o
API gravity and about 2
kilometers of 4 production line generated pressure build up in
production line. When starting the pump during the first 24
hours, the pressure at the well head reached 200 psi and was
continuing to increase. The Operations Team decided to shut-
in the pump while conducting a flushing job on the production
line. The flushing job indicated that there were no materials
plugging the production line. The team then decided to tie-in
KL083 surface production line with production line from
offset well KL073, which has high rate and high water cut,
with average 90% water cut and 900 BFPD. This commingled
production succeeded in reducing the well head pressure at
KL083 to 130 psi. The well was then successfully put on
production with close monitoring.
This well has demonstrated increasing water cut from an
average of 30% to 64% and resulted in lower oil production.
Average oil production in first 6 months was 400 BOPD and
decreased to average 150 BOPD. Fig 6 and 7 provides
production performance and water cut trend of KL083.
0
100
200
300
400
500
600
700
800
M
a
r
-
0
3
A
p
r
-
0
3
M
a
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-
0
3
J
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p
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t
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3
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D
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c
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0
3
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a
n
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4
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b
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4
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a
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4
A
p
r
-
0
4
M
a
y
-
0
4
J
u
n
-
0
4
B
b
l
/
D
a
y
FLUID_RATE OIL_RATE


Fig 6. Production Performance KL083

0
10
20
30
40
50
60
70
80
M
a
r
-
0
3
A
p
r
-
0
3
M
a
y
-
0
3
J
u
n
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3
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u
l
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3
A
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0
4
M
a
y
-
0
4
J
u
n
-
0
4
W
C

(
%
)
Water Cut


Fig 7. Water cut trend at KL083

As of June 2004, The ESPCP performance at KL083 exceeds
the expectation of the Kulin Horizontal Well Execution team
with running life of the pump is 450 days. There was no pump
recondition or pulling out job during this period. There were
pump down time recorded but not associated with pump
failure. The pump was down due to power outage and
unrelated facility issues with the pump performance. Average
pump efficiency since the well put on production is 56%. Fig
8 showing pump efficiency at KL083.

20%
30%
40%
50%
60%
70%
80%
M
a
r
-
0
3
A
p
r
-
0
3
M
a
y
-
0
3
J
u
n
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3
J
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0
3
A
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a
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4
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e
b
-
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4
M
a
r
-
0
4
A
p
r
-
0
4
M
a
y
-
0
4
J
u
n
-
0
4
Pump Eff


Fig 8. Pump Down & Pump Efficiency at KL083

Another advantage of the ESPCP system is that during the
put-on-production operations no oil was spilled at surface.
This was possible because the rodless system of the ESPCP,
eliminated the friction between the rod and stuffing box at the
well head that can contribute to small spills during start-up.

Production from these horizontal wells significantly
contributes to total Kulin field production. Incremental
production from horizontal wells is about 17% of total Kulin
production. Fig 9 illustrates the impact of the development of
horizontal wells on Kulin fields production. Since May 2004,
some wells in Kulin field were shut down due to an unrelated
facility safety issue, resulting in lower field-wide production.

2000
3000
4000
5000
6000
7000
8000
9000
J
a
n
-
0
1
M
a
r
-
0
1
M
a
y
-
0
1
J
u
l
-
0
1
S
e
p
-
0
1
N
o
v
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0
1
J
a
n
-
0
2
M
a
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2
M
a
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2
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M
a
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M
a
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J
a
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4
M
a
r
-
0
4
M
a
y
-
0
4
O
i
l

(
B
O
P
D
)
Without Hz Wells KL082 KL083


Fig 9. Illustrated the impact of the development of horizontal wells
in Kulin field.

Conclusion
1. ESPCP which is a combination between PCP and ESP
motor has some advantages to be implemented at
Horizontal well:
a. High production efficiency even for viscous fluid and
high solid content.
b. Rodless system will eliminate friction loss.
c. Without stuffing box, avoid oil spill at surface.
SPE 93594 5
d. High torque capabilities
e. Allows back flush capability by reversing motor.
2. ESPCP application at Kulin horizontal wells results in
higher pump efficiency with average 56 66 % compared
to tubing pump efficiency at Duri Horizontal wells which
has less than 30% efficiency.
3. ESPCP offers longer pump run life, proven at KL082 &
KL083 horizontal wells that never have pump problems
or pulling out job. As of June 2004, ESPCP KL082 has
been operating over than 800 days and ESPCP KL083
over 450 days.

References
1. Centrilift Product Catalog, Electric Submersible Pumps &
Equipment
2. Lee, Zabel., Electric Submersible Progressing Cavity Pump
(ESPCP): An Alternative Lift Method for Problem Applications
, Centrilift
3. Taufan, Mochamad., Horizontal Well KL082 Evaluation,
Internal Report, PT.CPI, 2002