CHOPS, or Cold Heavy Oil Production with Sand, is an oilfield production technology applied in unconsolidated heavy oil reservoirs where cold heavy oil and formation sand are produced together under controlled conditions. This development approach has become increasingly important because thermal recovery places high demands on downhole tubulars and equipment, raises development cost, and is not always suitable for thinner heavy‑oil layers. In addition, strict sand‑control methods can reduce oil output and increase operating cost, which is why moderate sand production has become an important technical concept in selected heavy‑oil developments.

The engineering value of CHOPS lies in its effect on reservoir flow behavior. In suitable reservoirs, small sand particles that restrict permeability can be produced together with crude oil and enter the screen, improving near‑wellbore permeability and reducing flow resistance. The concept is also associated with multilateral flow guidance, in which more branches are created from the main wellbore to enlarge the contact area between the well and the oil‑bearing formation, helping improve productivity. Once a field adopts this type of cold heavy‑oil development route, the artificial lift system must be able to handle viscous crude, produced sand, and changing wellbore conditions over time.

In this environment, all‑metal HXBS PCP design becomes highly relevant. Instead of relying on elastomer sealing elements that can become weak points in abrasive heavy‑oil service, HXBS uses an all‑metal conical progressive cavity pump architecture designed for harsh lifting conditions. In heavy‑oil wells where sand production, wear, and run life are critical concerns, this design offers a stronger foundation for stable long‑term lifting.

CHOPS and the Need for a Different Lift Strategy

In heavy‑oil production, artificial lift is often judged first by whether it can move viscous fluid. In CHOPS‑based developments, that standard is not enough. The lift system must also remain reliable while the produced stream contains sand and while near‑wellbore flow behavior changes as production continues. A pump that performs acceptably in a conventional heavy‑oil well may still underperform in a development that combines cold production with moderate sand output.

Conventional PCPs remain widely used in heavy‑oil operations because they are well suited to viscous fluids. However, many conventional PCP systems rely on elastomer stators, and those components are vulnerable to abrasive wear, swelling, shrinkage, and performance decline in harsh service. In sanding heavy‑oil wells, these weaknesses can increase the risk of sticking, shorten run life, and drive up intervention frequency. That becomes especially important when project economics already depend on avoiding the higher equipment burden and cost profile associated with thermal recovery.

An all‑metal conical PCP changes that design logic. By replacing elastomer‑based sealing with metallic rotor‑stator components and pairing the pump with dynamic clearance control, HXBS creates a lift architecture better suited to abrasive, sand‑bearing, high‑viscosity production environments.

What Defines the HXBS All‑Metal Conical PCP Design

The core of the HXBS design is the FERROXIS® all‑metal conical progressive cavity pump, which sits at the center of the IntelliCPCP® artificial lift system. The pump uses a patented conical geometry and precision surface hardening to form a dynamic metal‑to‑metal seal, eliminating elastomer from the core pumping element. This design supports high and consistent volumetric efficiency while also improving structural resistance to wear, heat, and abrasive service.

The conical stator‑rotor geometry is one of the most important features in this design. It allows rotor‑stator clearance to be adjusted more precisely, helping the pump respond to changes in viscosity, wear, and solids loading during production. This geometry also supports efficient sand‑carrying production by providing operating flexibility that conventional PCP structures often lack.

The broader IntelliCPCP® system adds more than just the downhole pump. It combines the FERROXIS® pumping core with the DynaRL® drive system, THERMOLOCK® wellhead sealing, the Graspos balancing assembly, the RodSavior® rod‑tubing wear mitigation system, and the Synergix® intelligent VSD and monitoring platform. Together, these components are intended to improve lifting stability, reduce pump sticking, limit rod‑tubing wear, and maintain more consistent operating performance across demanding heavy‑oil conditions.

More details about this integrated configuration are available through the IntelliCPCP® all‑metal conical PCP system.

Why All‑Metal PCP Design Fits CHOPS Heavy Oil Wells

A CHOPS‑based heavy‑oil development creates a lifting environment defined by three main realities: produced sand, high crude viscosity, and long‑term economic pressure to reduce interventions. The HXBS all‑metal conical PCP design addresses all three.

The first reality is solids handling. In reservoirs where moderate sand production is part of the production approach, pump reliability depends on whether the internal geometry can tolerate and move solids rather than fail because of them. The conical pump structure used by HXBS is designed for dynamic clearance adjustment and efficient sand‑carrying production, which directly improves suitability for sanding heavy‑oil service. The system also includes a dynamic clearance sand‑handling function that enlarges running clearance when needed to keep solids in suspension, flush them through the pump, and reduce the risk of sand bridging and sticking.

The second reality is high viscosity under cold production. Heavy oil produced without relying primarily on thermal stimulation remains difficult to lift, and fluid mobility can deteriorate as conditions change in the wellbore. HXBS specifies lifting capability for ultra‑heavy crude with viscosities up to 20,000 mPa·s at 50°C, which gives the all‑metal conical PCP a strong technical position in difficult viscous service.

The third reality is lifecycle performance. A heavy‑oil project loses value quickly when production is interrupted by repeated pump failures, high maintenance frequency, or costly workovers. IntelliCPCP® is designed to extend run life through dynamic clearance adjustment, automated wear compensation, reduced startup torque, and integrated monitoring and control. The system has also achieved field‑proven maximum run life exceeding 50 months in demanding heavy‑oil applications, showing that the design philosophy is built around sustained operating stability rather than only initial production performance.

For a broader heavy‑oil perspective, see the HXBS article on advanced artificial lift system solutions for heavy oil fields.

Main Design Advantages in Sand‑Producing Heavy Oil Service

The HXBS all‑metal conical PCP design offers several advantages that are particularly relevant to heavy‑oil developments built around CHOPS principles.

Stronger resistance to abrasive service

Because the core pumping element is all‑metal and surface‑hardened, it is better suited to abrasive solids than conventional elastomer‑based PCP structures. This improves durability in sanding heavy‑oil wells and reduces the risk that solids will rapidly damage the sealing interface.

Better control of operating clearance

The conical geometry allows more precise control of rotor‑stator running clearance. Clearance directly affects lifting efficiency, wear behavior, and the pump's ability to continue operating when viscosity and solids conditions change. Being able to tune that clearance during the life of the well helps maintain stable performance.

Lower risk of pump sticking

Dynamic clearance sand‑handling helps keep abrasive solids moving through the pump and reduces the buildup conditions that can cause bridging or sticking. Startup torque can also be reduced to 51% of rated value, which lowers hard‑start risk when solids or high‑viscosity fluids are present.

Better long‑term operating stability

DAGS‑01 and DAGS‑02 are designed to optimize volumetric efficiency and compensate for wear‑induced clearance enlargement over time. This helps preserve performance as production conditions evolve and supports a longer effective service life, which is critical in heavy‑oil assets where workovers are costly.

More complete system support

The artificial lift architecture extends beyond the pump itself. DynaRL®, THERMOLOCK®, Graspos, RodSavior®, and Synergix® support drive control, sealing, balancing, wear mitigation, and intelligent monitoring, creating a more stable overall operating system for heavy‑oil production. In CHOPS‑type environments where well conditions evolve, this system view is often more effective than focusing on a single piece of hardware.

Where This Design Can Deliver the Most Value

This design approach is especially valuable in heavy‑oil projects where unconsolidated formations produce sand, where cold production remains economically attractive, and where repeated interventions quickly erode project returns. It is also applicable in developments that need a pump architecture capable of working across a wide operating envelope, including high viscosity, gas‑liquid mixtures, corrosive service, and complex well profiles.

IntelliCPCP® is applied in conventional wells, ultra‑heavy‑oil wells, high‑sand‑producing wells, corrosive and sour wells, marginal and low‑rate wells, and high‑angle or horizontal wells. This breadth matters because many heavy‑oil projects do not remain static over time. Fluid properties, wellbore conditions, and production priorities change, so operators often need an artificial lift system with more flexibility than a narrow single‑condition design can provide.

Additional heavy‑oil lift guidance is available in HXBS's article on how to choose the right oil well artificial lift system for heavy oil wells.

FAQs

Why is all‑metal PCP design important in CHOPS‑related heavy‑oil production?

These projects can combine heavy crude, produced sand, abrasive wear, and pressure to minimize intervention cost. An all‑metal conical PCP is relevant because it is designed for sand‑carrying production, high‑viscosity lifting, and longer run life in harsh heavy‑oil service.

What makes HXBS different from conventional PCP designs?

HXBS uses an elastomer‑free conical rotor‑stator structure with metal‑to‑metal sealing, dynamic clearance adjustment, wear compensation, and integrated drive and monitoring technologies through the IntelliCPCP® system.

Can this type of PCP only be used in thermal wells?

No. Although the design is highly capable in thermal heavy‑oil service, the same features—sand handling, wear resistance, viscosity capability, and lifecycle reliability—also matter in non‑thermal heavy‑oil developments where cold production is used.

What is one of the main economic benefits of this design?

One of the biggest economic benefits is lower intervention frequency. By reducing sticking risk, compensating for wear, and extending run life, the system can help lower maintenance burden and improve heavy‑oil project economics over time.

Conclusion

CHOPS is a heavy‑oil reservoir development and production technology that uses cold production and controlled sand output to improve near‑wellbore flow capacity and well productivity in suitable unconsolidated reservoirs. HXBS all‑metal conical PCP design does not change that production concept; it provides an artificial lift solution that can operate effectively under the demanding conditions such developments create.

With FERROXIS® as the all‑metal pumping core and IntelliCPCP® as the integrated artificial lift platform, HXBS focuses on durability, sand‑carrying capability, dynamic clearance control, and long‑term operating stability in heavy‑oil service. For operators evaluating lift options in sand‑producing heavy‑oil reservoirs, a practical next step is to look in detail at the IntelliCPCP® all‑metal conical PCP system together with HXBS's heavy‑oil artificial lift solutions.