CASE STUDY No.

1022012 - TOP TAG

Improved Progressing Cavity Pump technology extends pump run life and increases production in heavy
oil wells.

ABSTRACT
A heavy oil slant well producing from the Upper GP Reservoir just north of Bonnyville, Alberta, Canada
had experienced extreme production difficulties since its start up in January 2008. Continual loading and
flushing of the well contributed to high operating costs and less than optimum production. In April 2009,
the operator installed an innovative Progressing Cavity Pump bottomhole component called a Top Tag™.
The Top Tag improves fluid agitation by eliminating restrictions and plugging potential. After installing the
Top Tag, average monthly operating costs decreased from $30.69 Barrel of Oil Equivalent (BOE) to $9.94
BOE and production increased from 24bbl/day to 32bbl/day.

GEOLOGY & WELL HISTORY

The Upper GP reservoir is a cold heavy oil production (CHOPS) area slightly north of Bonnyville, Alberta,
Canada. The operator perforated the well in the Upper GP at 501.0 – 507.0 mKB. This formation has a
water cut of 35% and a 40% sand cut. The oil gravity is 11° API with a viscosity of 28,660 cp@20oC, oil
density o 991.8kg/m3 and minimum depth of 494.5 mKB.

TECHNOLOGY SELECTION
A Progressing Cavity Pump (PCP), a type of artificial lift, was used to produce this heavy oil slant well. A
PCP is a positive displacement pump engineered to deliver a consistent head capacity along with
superior sand lifting capability compared to other forms of artificial lift such as a Pump Jack or ESP.
Compared to other artificial lift methods; PCP’s are simple to install, require less power and typically have
lower operating and capital costs. PCP’s are also capable of handling producing solids and high viscosity
fluids along with a proven track record for heavy, medium and light oil production.

Initially the well used a PCP with a tag bar; a bottomhole accessory placed below the rotor and stator,
Fig. 1. The tag bar is the landing spot for a rotor space out and prevents components from falling
downhole in the event of a failure. There are several different designs for a tag bar but generally they
consist of a slotted steel rod that is fastened width wise across the middle of a short tubing pup joint, Fig.
2. Intake issues due to restrictions and plugging potential result from fluid entering the pump through the
small slots in the tag bar. These intake issues were the cause for the continual loading and flushing
required to produce this well. In April 2009, the operator changed the pump to a Kudu 13K 1300 with a
Top Tag.
The Kudu Top Tag enabled the operator to locate the rotor inside the stator without using a tag bar. A tag
bar has limited fluid agitation capability but the Top Tag utilizes a paddled rotor to directly mix the fluid
within the casing. As the stator intake is continuously cleared, Top Tag reduces burnt pumps due to
plugged pump intake, Fig. 3. Fluid is able to enter the pump freely as there is no jewellery or restrictions
dowhhole. Further adding to Top Tag’s diversity, it is capable of being reused, repairable and rebuilt. It
makes it easy to coil into the annulus and clean out the sump.

APPLICATION
After installing the Top Tag in April 2009, production greatly improved and operating costs decreased
significantly. The Top Tag reduced the frequency of flushing and loading as the rotor was able to
continuously clear the pump intake. This improved wellbore agitation prolonged pump run life and
simplified trouble shooting. The Top Tag improved average monthly operating costs from $30.69 Barrel of
Oil Equivalent (BOE) to $9.94 BOE and production increased from 24bbl/day to 32bbl/day, Fig. 3. As
Figure 3 illustrates oil production greatly improved and continues to stay at high production levels.

Fig. 1. Typical tag bar installation

 Fig. 2. Tag Bar Examples

Fig. 3. Top Tag installation

Fig. 3. Historical production from a heavy oil field in Upper GP reservoir.