Electric Submersible Screw Pump (ESSP) is a hybrid system combining the features of a screw pump (PCP) and an electric submersible pump (ESP), making it ideal for horizontal well applications. As a rodless pumping system, it eliminates friction between rods and tubing, enhancing efficiency. The screw pump's ability to handle sand makes it particularly suitable for formations prone to sand production. The Kulin horizontal well project began in early 2002 and was completed by December 2003. The first well, Kulin082 (KL082), and the second, Kulin083 (KL083), were designed to address challenges from unconsolidated sand in the adjacent Duri field, where traditional rod pumps struggled due to sand production. In such cases, conventional screen pipe production methods are ineffective, prompting the need for a sand-tolerant, rodless artificial lift solution. Initially, KL082 produced 708 barrels of liquid per day with 531 barrels of oil and a 25% water cut, while KL083 had a daily output of 518 barrels of liquid, 394 barrels of oil, and a 24% water cut. Due to the limitations of both screw pumps in horizontal wells and ESPs in handling sand, the ESSP was selected as the optimal solution. ESSPs were installed in 9 5/8-inch production intervals with straight sections having a well slope of less than 2 degrees per 100 feet. The stator rubber operates within a temperature range of 135–150°F, which is below the rubber’s maximum limit. Ground-based variable speed drives (VSDs) control flow and pump efficiency. These two horizontal wells achieved 2.5 to 3.5 times higher output than vertical wells in the same area. The ESSP design uses an ESP as the downhole drive system, with the rotor rotating inside the stator to move fluid. The rotor is made of stainless steel with a chrome-plated surface for corrosion resistance. Manufacturers offer different stator rubber temperature ratings, such as 95°C (203°F), 105°C (221°F), 135°C (275°F), and 150°C (302°F). Based on the bottom-hole temperature of approximately 65.6°C, the 95°C-rated product was chosen. Compatibility with aromatic hydrocarbons in the fluid was also considered. The motor size depends on factors like power requirements, casing size, and bottom-hole temperature. A gear reducer provides the necessary speed and torque for the screw pump, while seals prevent fluid ingress into the motor and gear unit. A flexible shaft transfers rotation from the seal shaft to the pump rotor. During installation, the ESSP in KL082 was placed at 1,440 feet depth with a true vertical depth of 1,267 feet and an inclination of 64°, with a well slope of 1.6° per 100 feet. KL083 was installed at 1,014 feet depth with a true vertical depth of 891 feet and an inclination of 58°, using 3½-inch tubing. A 3½-inch control valve and mixing valve were installed 90 feet above the pump, and a cable protector was added to prevent cable wear. The ESSP motor operated at 2,333 rpm with a gear ratio of 9:1, resulting in a pump speed of 259 rpm and a flow rate of 881 barrels per day. Field performance showed that KL082 operated for 800 days with an average pump efficiency of 66%, while KL083 ran for 450 days with an average efficiency of 56%. Both systems experienced no major failures, though initial issues in KL082 were attributed to possible inlet blockage, which was resolved after reversing the motor. Key conclusions include the ESSP’s suitability for horizontal wells due to high efficiency, rodless operation, no packing boxes, high torque, and reverse flushing capabilities. Its efficiency (56–66%) far exceeds that of rod pumps in similar conditions, which typically fall below 30%. The long operational life of the ESSP is evident in KL082 and KL083, with KL082 operating continuously for over 800 days as of June 2004.

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