Rigless Advancements: Enhancing Electric Submersible Pump Reliability Through Cable Deployment

Majid M. Rafie (), Tariq A. Almubarak, Khaled M. Mutairi and Mulad B. Winarno
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Majid M. Rafie: Saudi Aramco EXPEC ARC, Dhahran 31311, Saudi Arabia
Tariq A. Almubarak: Saudi Aramco EXPEC ARC, Dhahran 31311, Saudi Arabia
Khaled M. Mutairi: Saudi Aramco, Dhahran 31311, Saudi Arabia
Mulad B. Winarno: Saudi Aramco, Dhahran 31311, Saudi Arabia

Energies, 2025, vol. 18, issue 22, 1-15

Abstract: Electric Submersible Pumps (ESPs) are widely deployed in high-flowrate wells but are constrained by frequent failures and the need for rig-based interventions. This study presents the development and field validation of a rigless cable-deployed ESP (CDESP) system designed to enhance operational uptime and reduce intervention costs. The system features a corrosion-resistant metal-jacketed power cable, an inverted ESP configuration that eliminates the motor lead extension (MLE), and a vertical cable hanger spool (VCHS) for surface integration without removing the production tree. A field trial in a high-H 2 S well demonstrated successful rigless deployment using coiled tubing (CT), achieving over two years of continuous runtime. Post-retrieval inspection revealed minimal wear, validating the system’s mechanical durability and reusability. Operational performance demonstrated reduced non-productive time (NPT), enhanced safety, and cost savings, with deployment completed in under 24 h, compared to the typical 10–14 days for rig-based methods. The CDESP system’s compatibility with digital monitoring and its potential for redeployment across wells positions it as a transformative solution for offshore and mature field operations. These findings support the broader adoption of CDESP as a scalable, efficient, and safer alternative to conventional ESP systems.

Keywords: cable-deployed ESP; rigless intervention; electric submersible pump; artificial lift; coiled tubing deployment; high-H 2 S wells; ESP reliability; digital oilfield; well intervention; downhole monitoring (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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