Integrated Control Systems

Case Histories

Rotoflex 2" bore well pump
set at 8900 feet
with a 306" stroke length

Our first case history is a well with a Rotoflex 1100 pumping unit with a 306” stroke length.

The 2’ bore pump is set at 8900 feet. The Cardbuild^®System was installed In January of 2009. Prior to that time the well was running approximately 3.5 SPM with a conventional VFD system and was producing 380 BGPD. Prior history indicated about 3 failures per year that required a rig. These included tubing leaks, rod parts and pump changes. Some of these issues continued to be worked through after the Cardbuild^® System was installed. As existing problems were eliminated the rig frequency decreased significantly. The last rig job was 3/29/2010. When the well was put back into operation after that date, it ran approximately 5 SPM with a production test rate of 540 BGPD. It ran this way until January 2014 when it was replaced with a pumping unit with a 366” stroke length. In the four years after the pre-existing problems were cleared up, it required only routine maintenance work. It never experienced a mechanical failure that required a rig or an extensive shut down period. During this period, there were over 9,000,000 pump strokes and total fluid lifted was approximately 700,000 barrels.

Conclusion:

After installation of the Cardbuild^® System this well has consistently operated at higher stroke speed which has increased well displacement by approximately 40%. At the same time, equipment failures, both surface and down hole, have dropped substantially.

Net results"

Conventional System

CardBuild System

Increased SPM from 3.5 to 5 and BPD from 380 to 540
At least 2 years running without a down hole failure and only routine maintenance

Mark 1824-427-216 well pump
with a 216" stroke

Our second case history well has a Mark 1824-427-216 pumping unit.

The 1.5” bore pump is set at about 10,000 feet. This unit, with a 216” stroke, was previously driven by an AC motor running across the line at 6.7 SPM. The Cardbuild^® System was installed in April of 2010 and the stroke rate was increased to 9.1 SPM. The displacement increased 100 BPD, resulting in an additional 20 BPD of oil. This is a highly deviated well with a prior history of frequent failures and expensive repairs. After reviewing failure data, company personnel stated failure frequency was down over 50%.

Conclusion: Since the Cardbuild^® System was installed on this well, SPM was increased by 35% resulting in a significant increase in displacement and decreased failure frequency over 50%.

Net results:

Increased SPM from 6.7 to 9.1 and BPD from 80 to 100
Reduced failure frequency over 50%

The well has a 3.25" bore pump
at a depth of 1200 feet.

Our third case history is a 912 conventional unit pumping heavy oil in a steam flood field.

Prior performance:

This unit has a 3.25” bore pump at a depth of 1200 feet. Prior to the installation of the CardBuild® System, it was displacing approximately 940 barrels gross per day at 6.6 SPM and did not pump off. To accomplish a cold start, an operator would manually start and stop the well for approximately two hours to get the unit to a point where the amount of float would allow it to run. The operator would then stay at the site to monitor operation until he thought it was safe to leave. The total time was usually three to four hours. Rod float severe enough to cause the polish rod to bend was not unusual for this well.

Performance after installing the ICS Control:

The Cardbuild® system with Rod Float Optimization (RFO) was installed in January 2013, The unit now runs at 9.1 SPM, yielding a test rate of 1600 barrels gross per day and runs at approximately 70% fillage. It is subject to recurring rod float incidents which are managed by the control system with no detrimental effect. Since January 2013, there have been no bent polish rods. A cold start still takes several hours, but it is completely automatic. No operator presence is required once it is set in motion. When an operator shuts the well down and restarts it soon enough to make a cold start procedure unnecessary, the operator can bypass the cold start and go immediately to normal RFO mode.

Net results:

Increase SPM from 6.6 to 9.1 and BPD from 940 to 1600.
Automatic (un-attended) cold start control sequence.
No reoccurrence of bent polish rods.