Electrical Submersible Progressing Cavity Pump for Oil & Gas Industry

The NEMO® Electric Submersible Progressing Cavity Pump (ESPCP) Systems by NETZSCH are an advanced solution that combines the benefits of electric submersible permanent magnet motors (PMM) and progressing cavity pumps (PCP). These systems are designed to improve oil production efficiency, especially in wells with challenging conditions like high viscosity fluids, multiphase mixtures, and wells requiring deep installation.

This system utilizes an electric submersible motor to directly power the downhole progressing cavity pump. This design eliminates the need for surface mechanical drives and sucker rods, reducing mechanical wear and increasing the efficiency of power transmission. This also avoids the typical problems of disconnected sucker rods and pipe failures. They are installed within the tubing downhole, unlike traditional PCP systems where the motor is on the surface. This design reduces surface equipment, minimizes footprint, and is suitable for wells with high deviations or horizontal sections.

Energy-saving and highest reliability

The electric submersible progressing cavity pump system is an energy-saving solution with excellent reliability in all applications. It is equipped with numerous downhole sensors. They provide information on the pump’s pressure, temperature, vibration, and motor temperature.

Hence, you can continuously monitor the fluid level and react to possible changes as quickly as possible. It also enables high flow rates in complex (deviated and horizontal) wells and fluid conditions. In addition, the electric submersible progressive cavity pump system reduces your operating costs thanks to its low failure rate.

Advantages of the ESPCP Systems

Efficiency in Deep and Deviated Wells

Unlike traditional PCP systems that rely on sucker rods, ESPCP systems eliminate mechanical transmission losses and wear caused by well deviations.

Reduced Mechanical Wear

The primary advantage of ESPCPs is the elimination of sucker rods, which are prone to wear and tear in deviated wells. This reduces mechanical friction, wear on the tubing, and the need for frequent maintenance, extending the system's lifespan.

Compact Surface Footprint

By eliminating surface mechanical equipment such as sucker rods, drive heads, and pump jacks,ESPCP systemssignificantly reduce the surface footprint. The compact setup also reduces noise and visual impact, contributing to a less intrusive operation. No backspin unlike conventional PCP because there are no sucker rods

Electric Submersible Progressing Cavity Pump Construction

ESPCP Pump System, NETZSCH, Pumps, Systems

The NEMO® Electric Submersible Progressing Cavity Pump (ESPCP) system's construction integrates advanced components to optimize performance in challenging oilfield environments.

The heart of the ESPCP system is the downhole electric submersible motor that powers the pump by providing rotational energy. It is designed to operate in harsh well conditions, capable of withstanding high temperatures and pressures while driving the rotor within the stator. The motor is installed inside downhole tubing, reducing surface equipment requirements and ensuring efficient energy transmission. An electrical cable runs from the surface to the downhole motor, supplying the necessary power. The cable is designed to resist the high temperatures, pressures, and corrosive fluids typically found in oil wells. Cable protectors are often used to ensure the cable remains intact during the system's operation and installation. On the surface, the ESPCP system includes a control panel that manages the operation of the downhole motor. This control system can include frequency inverters to adjust the motor speed, enabling precise control over the pump's output.

Automation features may include real-time monitoring and remote operation capabilities, allowing the system to be adjusted based on well conditions. A torque anchor is provided to prevent the pump from rotating within the tubing. This prevents tubing from unscrewing and ensures that the energy generated by the motor is efficiently transferred to the rotor, maximizing fluid production. The pump housing is compact and rugged, allowing it to be deployed in deep or deviated wells without being damaged during installation or operation. The ESPCP system includes mechanical seals to protect the motor and pump internals from well fluids and contamination. These seals are designed to withstand the harsh chemicals and abrasives found in oilfield fluids. Bearings support the shaft and rotor, ensuring smooth and efficient rotation under high loads and minimizing wear.

Handling of Multiphase Fluids: Can handle multiphase fluids (oil, water, and gas mixtures) without the need for separation equipment. This capability is essential in wells where high gas fractions, water cuts, or sand content are present.
High Efficiency for Viscous Fluids: These systems excel in pumping high-viscosity fluids like heavy oil, bitumen, or sludges, which other pump types struggle with. The progressing cavity technology ensures efficient handling of these challenging fluids with minimal pulsation and shear. The system is particularly well-suited for thermal recovery operations where viscous fluids need to be pumped at high temperatures.
Lower Energy Consumption: ESPCP systems consume less energy compared to traditional electric submersible pumps (ESPs) due to their high efficiency in moving viscous and abrasive fluids. They can be equipped with variable speed drives (VSDs) to optimize energy usage and control the pump's output based on real-time well conditions, ensuring that only the necessary power is used.
Minimized Downtime and Maintenance:ESPCP systems are designed for easy servicing without needing to remove the tubing, which reduces workover costs and downtime during pump maintenance or replacement. The ability to replace pumps without a rig and the lower number of wear parts significantly reduce the operational expenses over time.
Adaptability to changing Well Conditions: Thesesystems offer high flexibility in adapting to various well conditions. They can be customized to handle a wide range of flow rates, pressures, and fluid compositions, making them suitable for both low and high-flow wells. The downhole sensors and monitoring systems allow operators to adjust the pump’s operation based on real-time data, ensuring optimal performance.
Improved Performance in High Gas Content Wells:ESPCP systems perform efficiently in wells with high gas-to-liquid ratios and gas slugs. The progressing cavity pump can handle gas volumes without gas locking, which is a common issue with traditional electric submersible pumps (ESPs).
Automated Control and Monitoring:ESPCP systems can be integrated with advanced downhole sensors to provide real-time data on temperature, pressure, and fluid levels. This allows for automated control, improving operational efficiency and reducing the need for manual adjustments. The ability to monitor the system in real-time enhances predictive maintenance, reducing the chances of unexpected downtime.
Environmentally Friendly: Due to their energy efficiency and the ability to handle multiple fluid types without separation equipment, ESPCP systems reduce the need for additional processing equipment and minimize environmental impact. Their compact surface footprint also makes them ideal for environmentally sensitive areas.

Name	Stator size (inch)	Pressure max. (bar)	Capacity max. (m³/d at 100 rpm)	Speed (rpm)
NETZSCH ESPCP 166	1,66	240	1,1	500
NETZSCH ESPCP 238	2,3/8	240	3,2	500
NETZSCH ESPCP 278	2,7/8	300	32	500
NETZSCH ESPCP 350	3,1/2	300	80	500
NETZSCH ESPCP 400	4	240	120	500

Further sizes and technical data on request.

Worldwide Service and Support for Your NETZSCH Pumps & Systems

Comprehensive Aftermarket Services for Your NEMO® Electric Submersible Progressing Cavity Pump Systems

At NETZSCH, our commitment to your success extends well beyond the initial purchase of your NEMO® FSIP® Progressing Cavity Pump. We offer a complete range of aftermarket services to ensure your pump operates at peak efficiency and reliability throughout its lifecycle.

Consultation: Our experts provide tailored advice to help you select the right pump configuration and optimize your processes.
Spare Parts: We maintain a full inventory of genuine spare parts to minimize downtime and ensure optimal pump performance.
Maintenance: Our routine and preventative services keep your pump running smoothly and prevent unexpected breakdowns.
Repair: Swift and Efficient: Our prompt repair services ensure minimal disruption and a quick return to operation.
Modernization: We offer modernization services to keep your pump system up-to-date with the latest technology and performance standards.

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Discover the efficiency and reliability of our ESPCP Pump Systems. Contact our technical team to discuss your fluid handling needs and learn how our customizable pump solutions can optimize your operations. We offer consultation, technical support, and help in selecting the right pump for your application.

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Electrical Submersible Progressing Cavity Pump (ESPCP) System

Energy-saving and highest reliability

Advantages of the ESPCP Systems

Efficiency in Deep and Deviated Wells

Reduced Mechanical Wear

Compact Surface Footprint

Electric Submersible Progressing Cavity Pump Construction

FAQs

How does an ESPCP system differ from a traditional PCP system?

What types of fluids can ESPCP systems handle?

Are ESPCP systems suitable for offshore applications?

What are the main applications of ESPCP systems?

Literature

Get in Touch for Expert Pump Advice

Your contacts and companies at NETZSCH

News from NETZSCH Pumps & Systems

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