High-flow heavy oil production requires more than a larger pump or higher speed. It requires an artificial-lift system that can manage viscosity, torque, thermal expansion, sand, rod-string loads, and pump clearance as one coordinated system.

HXBS provides an integrated solution built around the IntelliCPCP(®) intelligent conical progressive cavity pump system. It combines an all-metal conical screw pump, a rotating and lifting surface drive, wellhead protection, downhole balancing components, intelligent controls, and remote monitoring.

Heavy-Oil Production Challenges

Heavy and ultra-heavy oil wells often need high liquid rates, but higher flow can also increase resistance, torque demand, sand-related restrictions, and restart risk.

Common challenges include:

• High viscosity and poor fluid mobility

• Sand, scale, gas, and corrosive fluids

• High torque and difficult restarts

• Thermal expansion during CSS or steam-injection operations

• Rod-tubing wear in deviated and horizontal wells

• Pump sticking, unstable torque, and frequent workovers

In these wells, increasing pump speed without controlling clearance, torque, rod load, and wellhead stability can create more operational risk instead of stable production.

HXBS Integrated Solution

The IntelliCPCP(®) intelligent conical PCP system is designed as one coordinated artificial-lift system.

It integrates:

• FERROXIS™ all-metal conical screw pump

• DynaRL™ rotating and lifting surface-drive system

• THERMOLOCK™ wellhead sealing protection

• Graspos™ downhole balancing component

• Synergix™ intelligent controls and operator interface

• HXBS Monitor digital monitoring platform

IntelliCPCP(®) can be configured for tubing sizes of 5.5 inches and above, well depths up to 1,500 m, deviations up to 80°, bottomhole temperatures up to 380°C, and ultra-heavy oil viscosity up to 20,000 mPa·s at 50°C.

Adjustable Clearance for High Viscosity

Conventional PCPs generally operate with a fixed rotor-stator clearance. The FERROXIS™ conical pump uses controlled axial rotor movement to adjust radial clearance according to changing well conditions.

A tighter gap can support volumetric efficiency. A larger flow path can help reduce resistance when handling highly viscous fluids, sand, or changing thermal conditions.

This capability gives operators a more practical way to balance flow capacity, pump efficiency, and operational stability without relying only on higher rotational speed.

DynaRL™ Rotation and Lifting Control

The DynaRL™ Drive System supports both rod-string rotation and controlled axial movement. This enables operators to manage rotor position, pump-clearance adjustment, sand handling, anti-sticking actions, and production restart after thermal operations.

For a high flow conical screw pump installation, this means higher production does not need to depend only on increasing speed. Controlled clearance management can help maintain a more stable torque and load profile as well conditions change.

Correct surface-drive alignment is also essential. The drive, polished rod, wellhead, rod string, and downhole pump must operate along a stable centerline to reduce unnecessary side loading, seal wear, vibration, and unstable torque transfer.

Thermal Recovery and Wellhead Protection

IntelliCPCP(®) supports injection-production integration, allowing operators to inject steam and produce oil through the production string without pulling tubing. This capability is relevant to CSS and other thermal heavy-oil recovery operations.

Before steam injection, the DynaRL™ system can help establish the required rotor-stator position. After injection and cooling, the system can support a controlled return to the production position.

THERMOLOCK™ provides controlled wellhead sealing during pumping, steam injection, and production restart. This helps maintain safer and more reliable transitions during high-temperature operations.

Downhole Load and Wear Management

Temperature, pressure, and operating loads can cause rod-string expansion and contraction. In deviated and horizontal wells, side loading can further increase rod-tubing contact and mechanical wear.

The Graspos™ downhole balancing component helps maintain the intended rotor-stator position as axial loads change. Its RodSavior™ design is intended to reduce rod-tubing wear and support more stable operation in challenging well trajectories.

Intelligent Monitoring and Startup

Synergix™ controls and HXBS Monitor provide local and remote visibility into operating data such as torque, speed, pressure, temperature, and pump status.

Operators can use this data to establish baseline conditions and identify abnormal torque, sand-related restrictions, clearance issues, or thermal-cycle effects before they develop into larger production problems.

A reliable installation should include:

• Matching pump configuration to viscosity, depth, temperature, deviation, sand conditions, and production target

• Aligning the surface drive, polished rod, and wellhead centerline

• Confirming smooth polished-rod movement and stable wellhead sealing

• Setting conservative startup speed, torque limits, and protection logic

• Establishing baseline operating data before gradually increasing production

Build High Flow with Greater Control

High-flow heavy-oil production should not require operators to accept frequent pump sticking, unstable torque, excessive wear, or repeated workovers.

The HXBS IntelliCPCP(®) system combines adjustable conical-pump clearance, rotating and lifting drive control, thermal wellhead sealing, downhole load management, and real-time monitoring. This integrated approach helps heavy-oil operators pursue higher flow with greater operating control and long-term reliability.