Improving downhole pump efficiency and well productivity in heavy oil reservoirs utilizing back pressure regulator

A highly unconsolidated undersaturated reservoir producing heavy oil with an API of 12.1° is located in Lindbergh Field of Elk Point area, Alberta, Canada. A specific well in this reservoir was initially designed to produce oil via a cold heavy oil production with sand (CHOPS) mechanism. However, a large amount of the sand production on a daily basis plugged the progressive cavity pump installed in the well. The cost of well services to unplug the pump on a monthly basis exceeded the revenue from produced oil, and thus, the well was considered uneconomic. Various techniques have been sought to control the sand production and to increase the cumulative oil production and the pump efficiency. Installing screens and meshes in the production interval of the wellbore was analyzed as a solution to the sand production. Installing screens increased the skin factor and resulted in a very low production rate of 0.15 m3/day. The cost of purchasing and installing screens was estimated to be approximately $87,650 with five shut-in days. In addition, the screens also needed further sand clean up, which is an expensive process. Hence, the screens were not recommended for this candidate well. A Back-pressure regulator (BPR) is currently installed on the casing of the well. The initial purpose of installing BPR on the casing was to control the wellbore pressure. The BPR restricts the flow of gas vented through the casing-tubing annulus. This study analyzes the effects of restricting flow of the vented gas such as solution gas reduction, which causes (i) higher settling velocity for the sand grain, (ii) lower Basic sediment and water (BS&W), and (iii) lower in situ oil density. The production data of candidate well obtained from AccuMap (v.18.12) shows that the production hours increased significantly after installing BPR. This is because the number of well services reduced by 90 %. This results in an approximately $34,000 per month increase in profit (assuming $30.00/barrel of oil) for each well. This shows one million dollars savings on a monthly basis when the application of the BPR installation is implemented on 30 similar wells. The cost of the BPR installed on well is $328.00, and there is no operating cost involved since the cost of additional, necessary maintenance and operation is nearly negligible. Moreover, this study provides the field examples of improper BPR operation, which resulted in economic loss. Possible solutions to fix the improper installation of BPR are proposed as well.