Flow Control Devices (FCDs) have demonstrated significant potential for improving recovery in Steam Assisted Gravity Drainage (SAGD) production wells. One initial hypothesis was that steam breakthrough was delayed because the FCDs better homogenized injection and production by equalizing flow and compensating for pressure changes along the wellbore. However, in many cases, the field results were far greater than such an approach would have justified. The actual physics for this process are unclear, and not demonstrated in literature. Upon review of field data published by ConocoPhillips, the possibility of a steam blocking effect was proposed (Stalder, 2012), although the physical basis for this effect was not explored. This paper proposes an updated hypothesis to explain this effect, presents preliminary data to support the assumption, and introduces a new apparatus and methodology to characterize FCDs for SAGD applications. The traditional approach to steam control states that steam flashing at the producer should be avoided, as it will eventually lead to a completion failure. Alternatively, the proposed hypothesis contemplates using steam flashing at the producer to regulate flow in various segments of the completion, thus better enforcing conformance. The physics of this process will primarily be described analytically; however, this effect was also observed qualitatively in a small-scale experiment where water was flashed across an orifice. In order to design SAGD completions that leverage FCDs (and this effect), it was necessary to accurately characterize different FCDs under these challenging multiphase flow conditions. Since vendors use a variety of approaches when designing their FCDs, a protocol was developed to create a characterization procedure which was independent of the underlying FCD design and architecture, resulting in a direct comparison of the overall performance of each FCD. Part of this protocol required the construction of a new, high temperature multiphase flow loop capable of subjecting FCDs to representative SAGD operating conditions. Through fine control of the relevant test parameters, accurate performance measurements can be obtained for each FCD. This paper will present some information regarding the design and specifications of this new flow loop, as well as impart some of the lessons learned from its commissioning and initial operation.

ConocoPhillips has been on a quest to find a high volume artificial lift system that will operate reliably in a 250°C (482oF) downhole environment, which exists in certain SAGD applications. This presented two problems:there were no commercially available technologies for such a high temperature; andthere were no facilities capable of testing these systems. This paper describes the complexity of building and operating a high temperature flow loop rated for 250°C, and the lessons learned while upgrading an existing flow loop, from the initial design through the final commissioning phases. The paper also describes the issues encountered with the first artificial lift system tested at 250°C, which was a metallic stator progressing cavity pump system, rated for 1100 m3/d (6919 bpd) at 500 rpm. In the end, the test program not only served to validate and define the pump's performance, but also provided valuable lessons on the completion configuration and operational procedures. Introduction The ConocoPhillips technology group was tasked to find, select, and further develop artificial lift technology with the capability of handling fluid rates up to 1000 m3/d at 250°C (6290 bpd at 482oF) downhole conditions. The goal was not to just find and validate a single system, but to qualify several lift systems, in order to provide the production engineers with a "toolbox" of solutions. This challenge was divided and approached as two different projects:find, select and further develop potential lift systems with the needed volumetric capability; andvalidate these systems through high temperature testing. The latter was considered to be the bigger challenge of the two. ConocoPhillips did not operate any fields with downhole temperatures close to 250°C, so validation via field trial was not possible. A more controlled test facility (whether a well or flow loop) was also preferred, so that a comprehensive suite of performance curves could be collected to define the full operating envelope for each lift candidate. A test facility which was not associated with a specific pump vendor was also preferred, to avoid the legal and confidentiality issues with testing third party equipment. ConocoPhillips decided that an existing high temperature flow loop located at C-FER Technologies Ltd, in Edmonton, Alberta, Canada was the best option for the artificial lift validation testing. The loop had been built as part of a Joint Industry Project (JIP)1 in 2004, but needed to be upgraded to allow for testing at 250°C. This was a costly endeavor, and ConocoPhillips and C-FER contacted other Canadian SAGD operators to see if the upgrade could be completed as a JIP, thus sharing the capital cost among several interested parties. However, no other operators were interested in upgrading the loop at the time, so ConocoPhillips proceeded to fund the project entirely.

ConocoPhillips has been on a quest for a high-volume artificial lift system that will operate reliably in a 250°C (482°F) downhole environment. This paper will describe the testing and results of a high-temperature electric submersible pump (ESP) system in a flow loop built to validate downhole equipment for thermal applications, primarily for steam assisted gravity drainage (SAGD) developments. What makes this test program unique from previous tests is the longer duration (4+ weeks), the range of fluid temperatures (90°C to 245°C [194°F to 473°F]), and the type and volume of data collected. One of the key parameters monitored and documented was the internal motor winding temperature, which has been used to validate and calibrate a simulator for predicting motor performance in thermal environments. Background The group was tasked to find, select, and further support the development of artificial lift technology with the capability of handling fluid rates up to 1,000 m3/d at 250°C [6,290 B/D at 482°F] downhole conditions. The goal was not to just find and validate a single system, but to qualify several lift systems to provide the production engineers with a toolbox of solutions. This challenge was approached as two different projects: find, select, and further develop potential lift systems with the needed volumetric capability; and validate these systems through high-temperature testing. The latter was considered to be the bigger challenge. ConocoPhillips did not operate any fields with downhole temperatures close to 250°C [482°F], so validation via field trial was not possible. A more controlled test facility was preferred, so that a comprehensive suite of performance curves could be collected to define the full operating envelope for each lift candidate. A test facility that was not associated with a specific pump vendor was also preferred to avoid the legal and confidentiality issues with testing third-party equipment. It was decided that an existing high-temperature flow loop located at C-FER Technologies Ltd, in Edmonton, Alberta, Canada, was the best option for the artificial lift validation testing. The loop had been built as part of a joint industry project (JIP)1 in 2004, but needed to be upgraded for testing at 250°C [482°F]. ConocoPhillips contracted C-FER and funded the project entirely. Two lift systems have been tested to date in the flow loop after the high-temperature upgrade was completed in mid-2008. This paper focuses on the results of the second test program, which evaluated a Schlumberger high-temperature ESP system, developed for operation in thermal environments. Introduction In 2008, there were no commercially available ESP systems rated for 250°C [482°F] downhole environments. So, one of the existing systems was selected for testing to fully understand what would happen to the ESP components when the system was operated at or beyond the maximum temperature rating. The results would help determine how close the existing technology really is to reaching operation at the 250°C [482°F] target temperature, and, depending on the outcome, to help direct research funding into the appropriate places.

Metal-to-metal Progressing Cavity Pump (M PCP) technology has become an effective lifting method for challenging thermal conditions, such as for Steam Assisted Gravity Drainage (SAGD) production. This paper summarizes some of the technical challenges and key learnings following a unique high temperature test on an M PCP system developed by National Oilwell Varco (NOV), which was conducted in a high temperature flow loop at C-FER Technologies. This M PCP pumping system was evaluated by ConocoPhillips as part of their High Temperature Artificial Lift Validation program, the objective of which has been to test the performance of multiple forms of AL under SAGD-like conditions while at high fluid temperatures of 250°C (482°F). In addition to an evaluation of the M PCP system (i.e. including an assessment of the break-in period, levels of downhole vibration, rod torque, etc.) this program was unique in that it also assessed the performance of the same metallic PCP stator using two different PCP rotors, to mimic a rotor-swapping operation. Some of the challenges encountered during this test program including issues with the downhole completion, high levels of downhole vibration, and significant casing and tag-bar wear. This paper will summarize some of the technical challenges and lessons learned, in addition to sharing some of the key pump performance results for this unique M PCP test program.

The successful development and implementation of high temperature Electric Submersible Pump (ESP) technology for Steam Assisted Gravity Drainage (SAGD) applications has allowed operators to reduce their flowing bottom-hole pressures and achieve higher production rates. However, operating under these conditions brings the Pump Intake Pressure (PIP) closer to the saturation pressure of steam, which can result in live-steam production through the pump. The effect that live-steam has on pump performance is not particularly well understood, and has been a key challenge for operators when designing and optimizing ESP systems for SAGD applications.In early 2011, ConocoPhillips, Baker Hughes and C-FER Technologies embarked on an experimental test program to determine the consequences of producing live-steam through a centrifugal pump. This new program was meant to build on multi-phase work that had begun over a decade ago at the University of Tulsa (TU), where researchers had focused on experimentally measuring the two-phase flow performance of ESP stages with air and at moderate temperatures [Pessoa and Prado 2001]. The TU work ultimately resulted in a wave of new technology aimed at increasing ESP gas handling capabilities.Following a similar testing and ESP instrumentation philosophy, this new collaboration looked to build upon the TU experiments and expand the test fluids to include live-steam, water, and air at higher temperatures.This ultimately involved the design and construction of a unique high temperature Steam Flow Loop that allows for live-steam injection into a centrifugal pump, while monitoring both head and performance degradation. This paper will reveal some of the unique test results collected with the first pumping system, including snapshots of the stage-by-stage pressure contributions captured in real-time as air or air and steam migrates through the ESP being tested. These results also demonstrate the impact the presence of other gases can have on steam flashing and how it is important to consider both the gas and steam vapor effects in SAGD ESP designs. How Two-Phase Flow Affects a Multi-Stage Centrifugal PumpThe difficulties in pumping a two-phase liquid with a centrifugal pump (such as an ESP) generally arise from the large difference in density between the two phases. As the fluid enters the impeller eye, the buoyant force on the gas bubbles pushes them toward the low pressure area in the center of the pump; while the drag force on the bubbles acts in the same direction as the fluid flow through the stage, thereby having an effect of carrying the bubbles through the stage. If the buoyant force is very large or if the drag force is too small, retarded gas flow through the stage can result in an accumulation of gas near the center of the pump. The size of the bubble can then grow to a point where it reduces the capacity of the impeller, as a result of the gas phase interfering with the movement of the liquid through the fluid passages. For the purposes of this paper, this phenomenon will be