Saudi Aramco and Baker Hughes announced the installation of the TransCoil rigless-deployed electrical submersible pumping (ESP) system, which is designed to help operators bring wells on production faster and lower the costs associated with installing and replacing ESPs.

Because they can eliminate the need for a rig in fields where rig availability is a concern or where high intervention costs can limit artificial lift options, Baker Hughes says that operators can minimize deferred production and lower their overall lifting costs to extend the economic life of their assets.

The TransCoil system features an inverted ESP system with the motor connected directly to a new, proprietary power cable configuration, eliminating the traditional ESP power cable-to-motor connection, which improves overall system reliability. Unlike wireline-deployed ESPs, the fully retrievable TransCoil system does not have an in-well “wet connection,” which requires a rig to pull and replace if the wet connection fails, the company says.

The power cable design enhances the reliability of the deployment string compared to coiled tubing-deployed ESPs that simply pull the power cable through the coiled tubing. Fatigue testing and thermal growth analysis were conducted at the Baker Hughes Coiled Tubing Research and Engineering Center to enhance materials selection and system design. The TransCoil system cable design also extends the operating range to 12,000 ft compared to traditional coiled tubing-deployed ESP systems, which are limited to approximately 7,000 ft because, at greater depths, the weight of the power cable will cause it to collapse inside the coiled tubing, creating an electrical failure.

Baker Hughes says the TransCoil system can be installed in 4½-in. to 9-in. casing in wells with flow rates up to 18,000 BPD. In mature offshore fields, where high intervention costs can limit the application of ESPs, the system can be deployed through the existing 4½-in. tubing, saving the time and money required to pull the existing completion. Another advantage of the TransCoil technology compared to wireline-deployed ESPs is that it can be installed through a deviation in the wellbore. This capability allows operators to land the ESP closer to the producing zone for greater reservoir pressure draw down and reserve recovery.

A TransCoil system was recently installed and commissioned in Saudi Aramco’s Khurais field. Rig-based work to replace the completion and install a vertical electrical penetrator system was completed ahead of the rigless operations. A Baker Hughes coiled tubing team helped plan the operation, delivered a surface unit to the wellsite, and worked with artificial lift engineers to install the TransCoil system at 4,900 ft in 7-in. tubing. The rigless operation improved efficiency by reducing installation time nearly 50 percent over a rig-based installation and further deployment efficiency improvements are expected in the future.