HydraPakTM Downhole Hydraulic PCP Update & Presentation - April 2012
April 1, 2012
During Q1 2011 CJS installed two prototypes of the company’s hydraulically powered downhole rotary driver connected to industry standard progressive cavity pumps “PCP” into Lloydminster Alberta wells. The driver and PCP are conveyed on and powered via CJS's FlatPak umbilical. The system can optionally include a capillary to inject chemical along with data cables and downhole sensors to monitor pump intake and discharge pressures and temperatures for fluid level control.
Trademarked as the CJS “HydraPak System” a triple FlatPak umbilical conveys and actuates the downhole rotary motor and pump. Two coiled tubing conduits are used to complete the closed loop hydraulic circuit powering the downhole motor and the third conduit is used to receive production fluids and solids to surface.
Initial field-testing was successful and the wells quickly stabilized at oil production rates ranging from 4.0 M3/d to 7 M3/d with PC pumps running at 70 and 160 rpm respectively. The wells mainly yielded heavy oil during the initial testing of the HydraPak system.
Since initial testing, CJS redesigned the HydraPak system configuration to produce a “slim-hole” solution. The pump is connected immediately below the FlatPak umbilical with the driver stationed at the bottom of the downhole assembly. Included with version two of CJS’s system is a multiple seal assembly that permits the operator to hydraulically shift into or replace driver seals without rig intervention. Since re-running version two of the HydraPak system, the wells have produced on an un-interrupted basis for approximately 5 months. Multiple tubing and annular cleanouts have taken place to deal with produced sand from the wells. “It’s all working as designed” said Scott Kiser, CJS Director of Business Development.
“We have now installed four systems in Lloydminster CHOPS wells and we will soon be running our fifth system. We are actively working with a hydraulic motor manufacturer to increase the horsepower output of our rotary driver that we expect to expand the versatility of our system substantially” said Kiser. “The seal assembly is a big success extending the run life of the system without rig or coiled tubing unit intervention”.
“Now that we have proven our system a success in the field” said Kiser “we intend to continue to expand its application. We see a big market for this technology permitting optimized production from deviated and horizontal wells without associated wear and tear of conventional rod driven PCP systems. Additional inherent benefits of HydraPak compared with ESPCP technology include:
- Capital Efficiency
- Live installation without spooling and banding equipment
- Simplifies inclusion of injection lines and data conductors in the umbilical
- Elimination of the problematic gearbox
- Eliminates loading and unloading wear on the motor
- Eliminates cooling issues inherent to electric motors
- Reduces rig intervention with side entry cleanout options
Kiser continued, “Since the development of the first HydraPak Driver, we have now reduced the overall size of the system so HydraPak will fit into 5.5 inch cased wells. We expect our new motor design will be available later this year offering more horsepower in a “smaller package” that would permit 4.5 inch cased applications” said Kiser.
CJS Coiled Tubing Supply Ltd. is a privately owned company with offices in Lloydminster and Calgary Alberta. For more information please email scott@cjsflatpak.ca.