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Phillips W.,Hydraulic Rod Pumps | Mehegan L.,Hydraulic Rod Pumps | Hernandez J.,KUDU Industries
Society of Petroleum Engineers - 2013 SPE Artificial Lift Conference - Americas: Artificial Lift: Where Do We Go From Here | Year: 2013

Hydraulically actuated sucker rod pumps have been around since the 1940's but have not received a widespread adoption or acceptance on the order of beam pumps, ESP's or PCP's. This is in no small part, due to a reputation of high maintenance costs and frequent failures. Innovations in hydraulically actuated sucker rod pumps, with a keen insight for the oilfield environment, have helped improve reliability and reduce maintenance costs. Among these improvements are the elimination of persistent external hydraulic leaks, a long-stroke capability, and a simplified control system. The instrumentation and control of the hydro-mechanical system is accomplished with an innovative method for determining both polished rod position and load based solely on the hydraulic fluid dynamics. This eliminates any sensors, or points of failure, at the wellhead. Vast improvements in control and data acquisition have greatly reduced the failure rates of hydraulic sucker rod pumping systems by automatically responding to adverse conditions. By allowing operators to remotely interact and troubleshoot the system, a finer grained level of optimization can be achieved by closely matching the wells inflow to the production rate. In some down-hole failure cases, such as a stuck pump, a unique advantage of a hydraulic system allows the operator to attempt unsticking the pump by overloading the polished rod. Although this procedure is not always successful, it does provide a last resort that may save the cost of pulling the well. This procedure is unique to a hydraulic system because there are no structural or reducer load limitations beyond that of the rod-string capacity. The long-stroke improves down-hole equipment runtimes by distributing the wear over a larger surface and by reducing the cyclic fatigue on the rod-string. While the hydraulically actuated sucker rod pump is not appropriate for every well, it does offer significant advantages in those wells where it is suitable. These advantages include long-stroke capability, remote optimization, and safe operation in terms of no external moving parts. The complete system is simple, cost effective, and portable, making it ideal for both permanent and trial installations. Copyright 2013, Society of Petroleum Engineers.


Yakemchuk L.,Penn West Exploration | Tryhuba T.,Kudu Industries | Woolsey K.,Kudu Industries
World Oil | Year: 2011

The combination of technologies addresses the sand and inflow issues in a horizontal oil well producing from the Bakken zone in Saskatchewan' Court heavy oil field. A technology, the Left-Helix pump, was developed in conjunction with Kudu Industries aimed at keeping produced sand from building up in the sump and eventually blocking the inlet of the pump. The relatively small pump is designed with a reverse geometry intended to produce fluid in a downward direction, and is run below a higher-powered, upward- producing pump that lifts those downward-directed fluids to surface. Kudu's PCP Well Manager pump-off controller was also installed at the well. The pump-off controller combines wedge flowmeter technology and microprocessor control of electric and hydraulic motors to prevent pump-off by controlling the production rate, resulting in extended run life and increased cumulative production. The system sustains optimum fluid inflow by maintaining the lowest possible bottomhole pressure.


Rae M.,Royal Dutch Shell | Seince L.,PCM Inc | Mitskopoulos M.,Kudu Industries
World Oil | Year: 2011

A recent run of an all-metal progressing cavity pump (PCP) in Shell's Orion field in Cold Lake, Alberta, Canada, that produces oil sands demonstrated the pump's wide operating range in terms of production volume, pressure, temperature, and viscosity. The pump remained downhole during various steam and chemical stimulations designed to reduce differential pressure between the injector and producer. This innovative process showed that production can be optimized by combining steam and chemical stimulation. The well has now produced for 14 mo with total gross flowrates varying from 440 bpd to 1570 bpd at pump speeds ranging 125-170 rpm. The pump load has varied from 150 to 1000 ft-lb. Bottomhole temperatures have ranged from 125°C to 260°C. The high-temperature package handled the wide range of operating temperatures and associated viscosities, intakes, and differential pressures. Speed adjustment enabled the pump to fit production and well capability as downhole conditions varied. Due to low rotating speed, no emulsion issues arose and run life performed by the equipment surpassed the original expectation of one year. To date, Shell has installed 12 all-metal PCP at Orion field with no failures to date. One pump was pro-actively pulled for a liner re-completion.


Jahn S.,Kudu Industries | Baldwin B.,Kudu Industries
Society of Petroleum Engineers - 2013 SPE Artificial Lift Conference - Americas: Artificial Lift: Where Do We Go From Here | Year: 2013

The Progressing Cavity Pump (PCP) applications continue to expand from heavy and medium into light oil applications. The benefits include lower capital cost, less visual impact, smaller footprint and decreased operational costs primarily as a result of the high mechanical efficiency of a PCP. The difference between premature failure and long-term success can be minimized by following best practices and lessons learnt from 20 years of experience evaluating thousands of wells. Light oil usually has a high percentage of Mono-Aromatics of which the most common are Benzene, Toluene, and Xylene (BTX). The molecular structure of BTX enable it to attack or attach onto the elastomer, causing aggressive swelling and softening. Light oil is usually found at deeper, warmer reservoirs causing the BTX to be more active and aggressive while also reducing the mechanical strength of the elastomer. H2S and CO2 can also be associated with light oil and have adverse effects on the elastomer. This paper will discuss how to gather important data, sort information, select equipment and provide operational guidelines to improve the overall success of PCP's in light oil. Copyright 2013, Society of Petroleum Engineers.


Woolsey K.A.,Kudu Industries
Journal of Canadian Petroleum Technology | Year: 2012

To extend the run life of the pump while producing all available fluid is the goal of all progressing-cavity-pump (PCP) operators. The primary challenge is to do so without starving the pump and causing damage to the stator. The petroleum industry has been searching for years to find a reliable way to control PCPs for pumpoff. Several methods have been used, from monitoring torque to manual fluid levels. To date, none of these have been commercially successful. A method for controlling these wells has been developed combining wedge flowmeter technology and microprocessor control of both electric motors using variable-frequency drives and hydraulic motors using proportional control valves. This method has proved to be accurate and reliable, extending the run life while producing all available fluids. Combining this automated technology at the well with a Webbased system that feeds back real-time data to a dedicated surfacecontrol- and-data-acquisition (SCADA) host allows PCP technical experts to diagnose problems and operators to respond quickly to changing well conditions. This presentation discusses the advances in automation and optimization of PCPs. The method will be explained, and fieldstudy results showing actual well tests will be presented. Copyright © 2012 Society of Petroleum Engineers.

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