Recently, our all‑metal IntelliCPCP® intelligent conical progressive cavity pump (PCP) artificial lift system was successfully installed and commissioned in Well Ji 2‑15H operated by Sinopec Zhongyuan Oilfield Company, Inner Mongolia Production Plant, marking another major breakthrough for this innovative lifting technology in complex well environments and heavy‑oil operations. This deployment not only validates the adaptability of IntelliCPCP® in high‑viscosity, horizontal wells, but also opens a new chapter of energy‑efficient, technology‑enabled oil production for marginal and difficult‑to‑produce assets.

Tackling Extreme Challenges with Innovative Technology

Well Ji 2‑15H is a horizontal well with a pump setting depth of 884.18 m, characterized by highly complex downhole conditions and demanding production parameters. The reservoir falls squarely into the heavy oil category, with fluid viscosity reaching approximately 2,500 mPa·s at 50°C and further increasing to around 5,000 mPa·s under operating conditions, which significantly complicates artificial lift design and long‑term production stability.

Historically, this well relied on a combination of carbon dioxide injection, chemical viscosity reducers, and an electrically heated beam‑pumping system to maintain production. Even with these measures, daily liquid rates fluctuated between only 1–8 m³, and the overall economics were challenged by high energy consumption, frequent interventions, and limited productivity gains.

Against this backdrop, our IntelliCPCP® intelligent conical PCP artificial lift system demonstrated outstanding technical adaptability to high viscosity, high deviation, and thermally stressed environments. By replacing the legacy beam‑pumping and electric heating approach, IntelliCPCP® is engineered to:

• Improve lifting efficiency in ultra‑viscous fluids while reducing dependence on energy‑intensive electric heating.

• Maintain stable production in horizontal sections where rod‑tubing interaction and wear commonly lead to failures.

• Support integrated injection‑production workflows in thermal heavy oil recovery, minimizing workover frequency and field operating costs.

During on‑site installation, HXBS (Wuxi Hengxin Beishi Technology Co., Ltd.) dispatched two senior field engineers to provide end‑to‑end technical support, including system check‑out, parameter optimization, and start‑up supervision, ensuring a smooth transition to the new artificial lift configuration. Their involvement helped shorten commissioning time and establish a robust baseline for subsequent production optimization.

Technology Leadership: Unlocking the Full Potential of Progressive Cavity Pumps

The IntelliCPCP® intelligent conical PCP artificial lift system adopts a revolutionary conical rotor‑stator geometry combined with an intelligent surface adjustment mechanism, enabling precise control of the running clearance and its impact on pump performance. This design fundamentally addresses the core pain points of conventional PCPs—namely frequent pump sticking, sensitivity to temperature cycling, and short run life in heavy‑oil, high‑temperature applications.

All‑Metal Conical PCP Design

At the heart of IntelliCPCP® is the FERROXIS all‑metal conical progressive cavity pump, built entirely without elastomers and optimized for extreme thermal environments typical of heavy oil thermal recovery operations. Key capabilities include:

• Completely elastomer‑free, all‑metal construction, leveraging patented conical geometry and precision surface hardening to form a dynamic metal‑to‑metal sealing interface.

• Reliable operation at bottomhole temperatures up to 380°C, with stable performance in surface ambient temperatures from −35°C to 45°C.

• Ability to lift ultra‑heavy crude with viscosities up to 20,000 mPa·s at 50°C, significantly extending the workable envelope beyond conventional PCP solutions.

These attributes make IntelliCPCP® particularly suitable for CSS (cyclic steam stimulation), SAGD (steam‑assisted gravity drainage), and hybrid EOR projects where severe thermal cycling, sand, and multiphase flow routinely cause premature failures in traditional lift equipment.

Intelligent Dynamic Clearance Control

The IntelliCPCP® system integrates proprietary DAGS™ (Dynamic Clearance Adjustment System) technology, allowing operators to dynamically tune rotor‑stator clearance from the surface based on real‑time well conditions. Through coordinated control of rotational speed (RPM) and running clearance, the system:

• Optimizes volumetric efficiency across changing fluid viscosities and gas fractions.

• Minimizes energy loss due to clearance mismatch, improving overall system energy efficiency.

• Automatically compensates for wear‑induced clearance growth, extending pump run life and maintaining stable production.

DAGS‑01 focuses on volumetric efficiency optimization, while DAGS‑02 provides adaptive axial wear compensation and sand‑handling clearance management to prevent pump sticking in high‑sand environments. Together, these capabilities allow IntelliCPCP® to maintain an optimal operating window in wells where viscosity, pressure, and temperature change significantly over time.

Horizontal Well Optimization and Rod‑Tubing Wear Mitigation

Horizontal wells such as Ji 2‑15H pose unique mechanical challenges, especially in rod‑driven PCP systems, where rod‑tubing contact can cause severe wear, torque spikes, and string failures. IntelliCPCP® addresses these challenges through:

• A Graspos™ balancing assembly that isolates the rotor‑stator clearance from dynamic axial loads and maintains the optimal operating clearance under fluctuating thermal and pressure conditions.

• The RodSavior™ rod‑tubing wear mitigation system, which dynamically distributes rod string forces, reduces helical buckling, and minimizes contact forces along the horizontal section, thereby extending rod and tubing service life.

By reducing rod‑tubing friction and stabilizing the rotor assembly, the system sustains high efficiency in horizontal wells while significantly lowering the risk of mechanical failures and unscheduled workovers.

Integrated Surface Intelligence and Digital Control

The IntelliCPCP® artificial lift system is complemented by Synergix™ intelligent VSDs and HXBS Monitor digital platforms, forming a full‑stack PCP solution. These components provide:

• Real‑time data acquisition of torque, pressure, temperature, and RPM, with local and remote HMI interfaces for multi‑well monitoring and control.

• AI‑driven optimization algorithms that automatically adjust pump speed and running clearance to maintain optimal efficiency and respond to events such as steam breakthrough, gas surges, and sand influx.

• Automated wellhead sealing mechanisms (THERMOLOCK™) that enhance wellhead integrity during high‑pressure steam injection and production without repeated tubing removal.

For heavy oil assets, this level of integration translates into higher uptime, fewer interventions, and more predictable production performance.

Project Impact: From Marginal Asset to Scalable Benchmark

IntelliCPCP® is a highly innovative artificial lift technology with substantial application potential in heavy‑oil, horizontal, and thermal recovery wells where conventional PCPs and beam‑pumping systems struggle to deliver sustainable economics. Its design directly addresses the key limitations of traditional PCP technology in scenarios such as thick, viscous oil, long horizontal laterals, high GOR, and harsh thermal cycling.

For wells like Ji 2‑15H—which historically were considered marginal due to poor economic performance under legacy processes—the deployment of IntelliCPCP® offers a practical pathway to transform asset value. When the system achieves:

• Stable production uplift under high‑viscosity, horizontal well conditions, and

• Reduced operating and maintenance costs via extended MTBF, fewer workovers, and lower energy consumption,

It becomes a compelling candidate for broader field‑wide replication. Across multiple Sinopec‑operated oilfields, IntelliCPCP® deployments have already delivered an average 45.63% increase in MTBF and cumulative cost savings exceeding USD 600,000, underscoring the system’s tangible economic benefits.

As global operators push deeper into heavy oil and unconventional resources, technology‑driven artificial lift solutions such as IntelliCPCP® will play an increasingly central role in achieving efficient, economical, and low‑intervention production. HXBS remains committed to continuous innovation in high‑temperature PCP design, digital optimization, and lifecycle services, helping clients unlock complex reservoirs with lower risk and higher returns.

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