Producing oil at full potential with an electrical submersible pump (ESP) in slim wells has always been a challenge for the petroleum industry. Operators often face risks of motor lead extension (MLE) damage, limited cable protection, and higher installation costs. A recent project in Abu Dhabi’s Upper Zakum Oilfield highlighted this challenge and demonstrated how KOALA ESP Cable Protector offered a reliable, cost-saving solution.

The Challenge

In the Upper Zakum Oilfield, engineers were tasked with deploying a high-rate slim ESP system in a narrow wellbore. Several issues quickly emerged:

• Limited clearance in slim wells made it difficult to protect ESP cables properly.
• High cable damage risk occurred during running-in-hole due to friction and tight well conditions.
• Excessive operational cost was expected if the ESP system failed, requiring slot recovery or costly replacements.

The operator needed a robust solution that would protect ESP cables, ensure long-term production, and avoid unnecessary downtime.

KOALA’s Tailored Solution

KOALA’s engineering team worked closely with the oilfield operator to design a custom ESP Cable Protector specifically for the slim well conditions. Importantly, KOALA provided this design service free of charge, ensuring the customer could test and validate the solution without upfront risk.

Key features of the KOALA ESP Cable Protector included:

• Precise fit for slim wells – a custom protector designed to match the wellbore dimensions, ensuring proper clearance.
• High-strength materials – corrosion-resistant alloy capable of withstanding harsh downhole environments.
• Simple installation – modular design allowed quick integration with the ESP system, saving rig time.
• MLE safety – effective protection against friction, crushing, and twisting during deployment.

Field Results

After a two-week trial in the Upper Zakum Oilfield, the results were clear:

• No cable or MLE damage occurred during deployment.
• The slim ESP system achieved stable production for more than 365 days without failure.
• Oil production increased by approximately 15% compared to previous completions.
• The operator saved an estimated USD 2 million by avoiding slot recovery and unnecessary ESP replacements.

The customer praised KOALA’s fast response and professional support, and they have since expanded the use of KOALA ESP Cable Protectors across multiple slim wells in the region.

KOALA’s Commitment

KOALA is more than just a manufacturer. We are a trusted partner for oilfield operators worldwide, offering:

• Free design service for every project, tailored to well-specific conditions.
• Custom samples developed together with customers to ensure satisfaction.
• Reliable long-term solutions that reduce ESP system risks and extend equipment lifespan.

Conclusion

For operators facing slim well challenges, cable protection is critical to ESP system success. The case of Abu Dhabi’s Upper Zakum Oilfield proves that the KOALA ESP Cable Protector not only ensures cable integrity but also delivers cost savings, production efficiency, and peace of mind.

If your oilfield project is struggling with ESP cable protection or sensor installation issues, KOALA is ready to provide a free design and customized sample—helping you achieve safe and efficient production.