Wellbore construction decisions—particularly for deviated or horizontal wells—often limit the installation of electrical submersible pumping (ESP) systems at the deepest possible setting depths. This reduces overall reserve recovery and cash flow.
The industry standard buildup or deviation rate is 6°per 100 ft for an ESP system to reliably pass through the curved section of the wellbore. Increasingly, operators require a tighter radius in horizontal or deviated wells to open the maximum amount of reservoir to the wellbore. However, in these tight-radius wellbores the bolted flanges connecting ESP system components are subjected to extra stress, resulting in potential equipment damage.
Baker Hughes has designed the CENesis Curve tight-radius system to maximize production by allowing the system to reliably pass through buildup rates up to 25°per 100 ft or more. The CENesis Curve tight-radius system uses patented boltless connections between the pump, motor, seal, and gas separator. These connections replace the traditional bolted flange design, allowing the system to be set deeper in the lateral section of the well, closer to the producing zones.
Placing the ESP at the lowest possible setting depth improves production by providing a larger fluid column above the pump and greater pressure drawdown. This allows for a higher-volume pump, which increases overall reserve recovery. Plus, deeper setting depths often have higher pump intake pressures, which improves ESP system reliability by limiting gas interference in the pump. By minimizing gas accumulation in the pump, shutdowns due to gas locking are prevented.
Traditionally，ESP system components are connected by a flange that uses bolts to secure the sections. This method increases rig time during installation. The typical connection also increases the risk of tools or bolts being dropped into the wellbore during installation. Tools or parts lost down hole require an expensive fishing job, and if left undetected, cause equipment damage when the ESP begins operation.
The new CENesis Curve system features a boltless design for each connection, reducing installation time and the danger of dropping bolts or tools down hole. Baker Hughes is the only service company offering this patented technology.
CENesis Curve Tight-Radius System Handled 21°Bend
Location: Oklahoma
An operator in Oklahoma drilled a new well and planned to use an electrical submersible pumping (ESP) system as the preferred artificial lift method. However, during drilling, the well path got off track, leaving the operator with a well with a 21° dog leg severity (DLS). The traditional ESP system, which the operator planned to install to maximize production from the well, was unable to pass through the severe buildup rates and the operator was unwilling to incur the cost related to re-drilling the well. The operator was faced with switching to a less effective method of artificial lift, but the team from Baker Hughes presented an alternative solution.
Baker Hughes account representatives suggested the CENesis Curve?tight-radius system. This innovative solution for deviated wells uses patented boltless connections between the ESP system components. Unlike traditional bolted flanges, the connection design allows the equipment string to reliably pass through buildup rates up to 25°per 100 ft. to be set deeper in the well, closer to the producing zone. Baker Hughes is the only oilfield service company offering this patented technology.
The CENesis Curve system was installed successfully and passed through a 21°deviation at 5,945 true vertical depth (TVD), allowing the operator to deploy an ESP system as originally planned without incurring any additional drilling costs. Daily production from the well was 400 barrels of oil per day—meeting the operator’s projected production target. The operator was pleased with the CENesis Curve system solution and has plans for future installations.
Location: Permian Basin
Challenges
- Operator in the Permian Basin:
-experienced 3 ESP failures;
- Operator drilled long horizontal:
-wells with a 12.5°deviation;
- Run times were reduced.
Baker Hughes solution
Baker Hughes installed the new CENesis Curve tight-radius system with FLEXPumpER pump, Electrospeed Advantage variable speed drive with MaxRate software, and AMBIT PLUS 24/7 production surveillance services;
ESP was able to set 445 ft deeper in the tangent section.
Results
- ESP passed through a 12.5° deviation;
- Set 455 ft deeper than competitor’s equipment;
- Daily oil production jumped by 80%;
- Gas handling solution ensured stable performance;
- Eliminated equipment shut downs.
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