First Metal-PCP SAGD Field Test Shows Promise for Heavy-Oil Hot Production

Abstract

This article, written by Assistant Technology Editor Karen Bybee, contains highlights of paper SPE 110479," World's First Metal-PCP SAGD Field Test Shows Promising Artificial-Lift Technology for Heavy-Oil Hot Production: Joslyn Field Case" by Jean-Louis Beauquin, SPE, and Felix Ndinemenu, SPE, Total E&P; Gilles Chalier, Total E&P Canada; Lionel Lemay and Laurent Seince, PCM; and Alex Damnjanovic, KUDU Industries, originally prepared for the 2007 SPE Annual Technical Conference and Exhibition, Anaheim, California, 11–14 November. The paper has not been peer reviewed. Finding a reliable artificial-lift (AL) pumping system for heavy-oil thermal recovery has been a challenge, mainly because of the high operating temperatures (greater than 150ºC). Available options such as rod pumps and electrical submersible pumps (ESPs), which are well proved in the industry, are not well suited for thermal production. While rod pumps offer high-temperature service, they are limited in the flow rate they can deliver. ESPs can handle high volumes of low-viscosity fluids but are still limited in terms of maximum operating temperature. Metal progressing-cavity-pump (PCP) technology has been developed to meet the high-temperature requirement of steam-assisted gravity drainage (SAGD) and other thermal-recovery processes. Introduction Recovery of the world's large reserves of extraheavy oil (found mainly in the oil sands of Canada and Venezuela) by thermal processes has been increasing because of the high price of oil. Key to this recovery process is AL, which is required because of the very high density and viscosity of the crude and the relatively low reservoir pressures. Although gas lift remains an AL option when high pressure gas is available, pumping techniques are more popular because of their relatively higher efficiency and ability to generate more pressure at the surface for delivery to the treating plant. However, the main challenge with hot pumping is the high temperatures often required [as much as 260°C for SAGD and 350°C for cyclic steam stimulation (CSS)]. The dominant pumping technologies available are beam/jack pumps, ESPs, and elastomer PCPs. All these pumps have their peculiar limitations for hot production. While beam pumps offer high-temperature service, they are limited in the flow rate they can deliver. ESPs can handle high volumes of low-viscosity fluids, but they are still limited in terms of maximum operating temperature. For PCPs, the limitation is operating temperature of the elastomer (maximum 150°C).