Introduction

A mid-deep conventional heavy oil cold production well in the Gudong Oil Production Plant of Shengli Oilfield, with a pump setting depth of approximately 1,202 meters, was prone to sand locking during operation under its original artificial lift equipment, resulting in increased operating loads. Despite the addition of drag-reducing agents, stable production could still not be achieved.

1.How to achieve cost reduction and efficiency enhancement in heavy oil cold production?

To address the well's production issues of high sand content and frequent pump sticking, we deployed the IntelliCPCP® All-Metal Conical PCP artificial lift system. Through the all-metal conical pump body, dynamic clearance adjustment, and remote operational control, it provides a novel solution for sand evacuation downhole and the restoration of production.

Clearance Management and Sand Evacuation System

Conventional stator-rotor fit clearance is relatively fixed. Once sand particles enter the pump, they tend to accumulate between the stator and rotor, resulting in increased operating resistance and higher loads.

When IntelliCPCP® detects sand locking, the DynaRL® rotary lifting mechanism controls the upward movement of the conical rotor. Utilizing the FERROXIS® all-metal conical PCP—where both the rotor and stator feature a conical structure—the upward axial movement of the rotor instantly increases the radial fit clearance between the stator and rotor. Once the clearance is enlarged, the fluid medium can carry the sand particles away under gravity and fluid dynamics to complete flushing, downward discharge, or expulsion. After sand evacuation is complete, the system lowers the rotor to resume production.

Dynamic Stator-Rotor Clearance Adjustment

Due to the high viscosity of the crude oil in this well, fluid inflow into the pump is difficult. If the stator-rotor fit clearance remains constant, a trade-off easily occurs between pump efficiency and operating torque. IntelliCPCP® controls the axial position of the conical rotor within the stator via the downhole lifting system assembly and edge algorithms, matching the optimal lifting clearance according to current operating conditions. This reduces the resistance of high-viscosity fluid passing through, decreases equipment operating torque, and lowers operational loads.

Intelligent Oilfield O&M

IntelliCPCP® monitors torque, temperature, rotational speed, pressure, displacement, and other parameters in real-time. After wireless transmission, the real-time operating status can be viewed remotely. Field personnel can remotely monitor operating parameters and make adjustments, thereby reducing the costs of labor and operation and maintenance equipment.

From downhole pump bodies and surface drives to intelligent control, the IntelliCPCP® All-Metal Conical PCP artificial lift system achieves collaborative operation through dynamic clearance adjustment, sand expulsion and anti-locking, operational monitoring, and remote regulation.

2.Actual Operating Economic Benefits

After deploying IntelliCPCP®, the well achieved the following performance improvements during its operating cycle:

• MTBF extended by 1,202 days

• Annual crude oil production increased by 394.35 tons per well

• Comprehensive power consumption decreased by 45.45%

Comprehensive Economic Benefit: Achieved a comprehensive annual cost reduction and efficiency gain of 599,800 RMB per well.

3.Conclusion

IntelliCPCP® continuously monitors equipment operating status and provides early warning for sand-locking risks. Once sand locking occurs, the downhole channel can be opened in a timely manner on-site to restore production after sand evacuation, and the system operating status can be remotely adjusted based on operational parameters.