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C-FER Printed September 2015
Technologies
Corporate Profile
For over 30 years, C-FER Technologies has created innovative technologies and developed
new solutions for oil and gas, pipeline and other industries that have reduced costs,
increased revenues, extended the life of systems and ensured regulatory compliance.
C-FER offers state-of-the-art expertise in the following areas: Real World Solutions
• Project Management • Production Engineering One of the keys
• Experimental Design • Limit States Design to successfully
• Investigative Engineering • Software Development bringing new
• Computer Modeling • Solid Mechanics technologies to
• Prototype Design and Manufacture • Field Services market lies in the
• Full-Scale/Structural Testing • Risk and Reliability Engineering ability to perform
tests at full scale,
C-FER holds patents and intellectual property rights to numerous energy simulated within
industry products and processes including revolutionary Downhole Oil/ a controlled
Water Separation technology, PC-PUMP® software, CalTranTM software, environment.
PIRAMID™ software and more.
C-FER’s world class laboratory services offer a
The C-FER Advantage powerful combination of testing and analysis
When there is a lot at risk, operators and suppliers alike rely on C-FER’s third tools designed to accommodate a vast range
party, independent verification methodology. Whether you are pushing of applied research to meet energy industry
the boundaries of technology, optimizing design, or quantifying reliability, requirements. C-FER has the know-how to
C-FER’s expertise and one-of-a-kind facility can meet your performance make solutions work in the real world.
qualification requirements.
For more information on our
For energy producers who use technology for strategic advantage, C-FER’s products and services visit
innovation expertise is a powerful resource for improving profitability
and safety. Our know-how extends beyond applied research to include www.cfertech.com
collaboration with manufacturers and service companies to ensure the
viable commercialization of new energy industry products and services.
C-FER
Technologies
Production Operations
...finding innovative solutions to production engineering problems.
Artificial Lift Assessment & Testing
• Progressing Cavity Pumps 0.07
Mode
9.4
Median
11.7
f(t) data
Weibull Distribution
0.05
0.04
60
0.03 y = -0.0361x + 10.348
R 2 = 0.0029
50 0.02
• Gas Lifts
0.01
40
T em p eratu r e Rise ( C)
0
o
1.5 4.5 7.5 10.5 13.5 16.5 19.5 22.5 25.5 28.5 31.5 34.5
Te mpe rature Rise, t (degC)
• Gear Pumps
30
20
• Dewatering Systems 10
0
-15 -10 -5 0 5 10 15 20 25 30 35
Ambient Temperature (oC)
C-FER www.cfertech.com
Technologies
Production Operations
Engineering Consulting
• Production Enhancement Studies
– Analysis of Field Data
– Technical and Economic Assessment of Novel and Alternative Practices
– Analysis of Thermal Recovery Alternatives
• Risk & Reliability Assessments
– Quantitative Risk Analysis (QRA) related to Production Operations,
Completions and Workovers
• Technical Training
– Gas Well Deliquification Options
– Downhole Oil/Water Separation
– Cold Heavy Oil Production Operations
Full–Scale Testing
• Artificial Lift System Performance
– High/Low Temperature
– Multiphase
– Heavy Oil
• Deliquification System Performance
– Novel Systems
– Controlled Gas Liquid Ratios (GLR),
Pressures
• Production Equipment
– Tubing Wear/Coatings
– Sucker Rod Performance
– CT Testing
• Hostile Environments
– Sour/Explosive Gases
– High/Low Temperature
C-FER www.cfertech.com
Technologies
Cyclic Steam Well Pad Flow Assurance
Heavy Oil
The future of oil production is heavy. The World’s heavy oil resources are unparalleled in
magnitude but they present unique challenges to ensure recovery is done in an environmentally
and economically efficient manner. C-FER is ideally positioned and experienced in the
following recovery methods to assist operators and equipment manufacturers in tackling these
challenges:
Thermal Recovery
Thermal extraction of heavy oil, using techniques such as cyclic steam, SAGD
and air injection require special approaches for the well casing and
artificial lift systems. Issues that have been investigated by C-FER include:
• Low intake-pressure pumping in SAGD wells
• Technical and life-cycle economic assessment of normal wellbore and
completion concepts
• Casing connection evaluation and qualification for thermal wells Managing Produced Sand
• Design and structural modeling of casing, slotted liners and various forms Managing Produced Sand
of sand screens
• Beam pump optimization in horizontal wells
• Steam injection and production inflow control in SAGD wells
• Drilling and completion best practices
Cold Production
Cold Heavy Oil Production with Sand (CHOPS) is a process developed in
Canada where sand production is encouraged to increase inflow in non-
thermal heavy oil operations. Issues that have been investigated by
C-FER include: SAGD Pump Testing System
• Technical and economic feasibility of CHOPS in other areas around the world
SAGD Pump Testing System
• Progressing cavity pumping system selection, optimization and run-life tracking
• Elastomer compatibility testing
• Gathering line operation with complex water-assisted flow regimes
• Handling and disposal of sand
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(PH,TH)
Heat Transfer
(PT,TT)
(PH,TH)
Heat Transfer
(PT,TT)
Heat
transfer from inner
Considerations (kPa,abs)
4800
The design process for selecting appropriate injection and 65% flow down ST
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LP–SAGD: Lab Testing of
Artificial Lift Systems JIP
In large regions of the Athabasca oil sands, where SAGD
recovery techniques are currently being used or considered,
the presence of a depleted or naturally low–pressured
formation directly above the reservoir makes it necessary to
operate the producing wells at relatively low pressures.
It is still uncertain if current artificial
lift systems can operate efficiently and reliably at these low pressures, especially
at low degrees of sub-cooling (i.e. close to steam saturation conditions). It is the
objective of this JIP to test a number of downhole and surface–driven pumping
systems at low intake pressures and low degrees of sub–cooling in a laboratory
environment to prioritize and select candidates for further field trials. Anticipated
downhole operating conditions will be replicated to the extent possible by installing
the pumping systems in a section of 244.5 mm (9 5/8”) casing at approximately 87°
inclination (close to horizontal).
For each pumping system, a baseline performance curve will be established, and then additional performance curves will be
determined for different temperatures and degrees of sub-cooling. The main goal of this study is to determine the minimum
intake pressure (or degree of sub-cooling) at which each downhole or surface–driven pumping system can operate without
suffering significant deterioration in performance, over a range of operating temperatures. The experimental flow loop consists
of a 244.5 mm, 60 kg/m (9 5/8”, 40 lb/ft) casing with 88.9 mm (3.5”) tubing that has the following capabilities:
Physical Setup
• Accommodates downhole and surface–driven pump systems up to Project Status
24.4 m (80 ft) in length, up to 12 m (40 ft) per section; Pump testing for the JIP began in June 2004. Five
• Allows for downhole gas (steam and air) separation at the pump systems have been tested to date. The flow loop
intake with a simulated submergence of approximately 2 m (6.6 ft); is now available for other pump or downhole
• Fully instrumented to allow real time pressure, temperature, flow equipment tests.
measurements and pump torque and speed.
• Fully automated to allow for continuous 24 hour long–term Participants
reliability testing
• The flow loop can be operated as either an open–loop or a • ChevronTexaco • NAOSC (Statoil)
modified–closed loop (i.e. inert atmosphere) system, meaning • ConocoPhillips • Paramount Resources
that a large range of field representative test fluids can be tested. • Devon Canada • Petro-Canada
Pressure and Temperature Limits • EnCana Oil and Gas • Suncor Energy
• Pump intake pressure from 0.1 MPag to 5.515 MPag (15-800 psig); • Esso-Imperial Oil • Total E&P Canada
• Pump discharge pressure to 12.410 MPag (1800 psig); • Husky Energy • Petrobras
• Pump intake temperature from 60°C to 260°C (140-500°F). • Innovation & Science (AERI)
Volumetric Capability • Nexen
• Liquid flow rate up to 1500 m3/d (9400 bpd)
– Water, oil or oil/water mixture
• Air injection up to 120 std-m3/h (70 scfm) at 4.137 MPag (600 psig)
at the downhole pump intake..
www.cfertech.com
SAGD Downhole Flow Control JIP
(SAGD Steam Injection Control JIP)
Operational experience in vertical and deviated thermal wellbores has shown that proper control of steam injection and
production inflow can have a significant impact on the steam-oil ratio (SOR), oil recovery , the rate of recovery and overall
economics of a thermal recovery project. Field evidence suggests that better downhole flow control methods are called for in
order to improve steam injection and production conformance, and to improve the uniformity of the steam chamber in order to
increase the oil rates, thermal efficiency and recovery in a number of SAGD projects currently in operation.
However, SAGD operators recognized that the industry must first address a number of technical and economic questions and
challenges in order to advance alternative steam injection and production inflow control methods to the point where it may be
considered a viable alternative. The common need to address these uncertainties became the motivation for the industry and
C-FER to initiate the SAGD Downhole Flow Control JIP, which for Phase I was named the SAGD Steam Injection Control JIP.
www.cfertech.com
Risk Analysis of Thermal Operations
Oil production using thermal stimulation, such as in SAGD, is becoming more prevalent. To aid in the identification and
quantification of the risks associated with the operation of a thermally-stimulated well, C-FER offers a quantified risk
assessment. In a Quantified Risk Assessment, the root causes of undesired events are identified, and the relative importance
of such events are determined. The risk associated with any design scenario is quantified with:
The risk can then be readily compared for the various scenarios, and key areas of concern can be highlighted.
Risk Scenario Comparisons:
Various scenarios are studied and compared according to the details of a specific project.
In a typical analysis, these could include:
Such a comparison provides a foundation for the development of a project, including a preferred completion, operational
practice, and safety response plan. It can also highlight areas of concern that may require special attention.
Our studies are customised and flexible, with a focus that is directed according to the customer’s needs.
combine to give the probability of the event at the top of the tree.
E2
External event
Flow tee causes flow tee
failure
Historical data is used where possible to define base event normal
failure
base event
B51
probabilities, and also to help fine-tune the fault tree so that higher- top of another tree
B20
level probabilities accurately reflect field knowledge. Testing and ‘OR’ gate
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Risk Analysis of Thermal Operations
Example of STARS™ output temperature
Reservoir Release Modeling contours in a SAGD reservoir (symmetric)
Fluid flow rates during a leak or blowout will vary for different reservoirs
and release scenarios, affecting the severity of the consequences. To
quantify these release rates, C-FER has made special use of the STARS™
reservoir simulator, combined with a wellbore simulator. This has allowed
for an estimate of release rates for conditions where wellhead pressures
are at, or near, atmospheric conditions. Independent critical flow checks
are also completed.
By modeling the flow through the wellbore in concert with the reservoir
response during a release, the rates and composition of the fluids can be
determined for each scenario. This information can then be used in the
consequence models to determine the severity of various hazards.
Consequence Modeling:
Several possible consequences are generally associated with an undesired
event during thermal production Schematic diagram of fire plume resulting Study Benefits:
operations. In a typical study, from a vertical jet of natural gas A Quantified Risk Assessment
models of consequences may
include: Thermal
offers strong value by
Radiation collecting often loosely-
• a gas jet or oil pool fire
Fire
defined hazards and risks, and
• oil spills
Plume Damage setting them in the context of
• a release of hazardous gas Receptor
• a steam jet a logical framework.
• lost production
Radius of
hazard area, Customers have noted that
Each relevant consequence is
modeled to assess the impact
vertical jet the assessment provides
on life safety, environmental boundaries in the design of
damage, and project economics. Contour plot of critical H2S concentrations major projects by identifying
along the ground near a release
areas of concern and
Consequences will differ
depending on the scenario.
Critical Threshold
30
H2S Concentration confirming when issues have
For example, a fire that occurs 20
10 ppm
50 ppm
100 ppm
been adequately resolved.
during a workover will likely 300 ppm
Bounds of Hazard Area (m)
10
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DHOWS–Downhole Oil/Water Separation
System Course
Registration
The course is open to all industry operators.
Course Description Participants inC-FER’s Downhole Oil/Water Separation
C-FER Technologies has spearheaded (DHOWS) Joint Industry Project included...
downhole oil/water separation system
(DHOWS) technology through its Joint Industry • Alberta Department of Energy
Project (JIP) since 1992. The knowledge • Amoco Exploration & Production Technology Group
• Anderson Exploration Ltd.
gained in the JIP has been compiled into a
• Aramco Services Company
comprehensive course on the implementation
• ARCO Exploration and Production Technology
of hydrocyclone separator-based DHOWS • BP Exploration Operating Company Limited
systems. • Baker Hughes Inc.
• Canadian Natural Resources
The course provides a complete overview of • Canadian Petroleum International Resources Ltd.
the technology, from field and candidate well • Chauvco Resources Ltd.
screening based on economic and technical • Chevron Petroleum Technology Company
criteria to basic design and operation of the • Conoco Inc.
systems. In addition to the systems based • CS Resources Ltd.
on hydrocyclone separators, systems based • Den norske stats oljeselskap a.s.
on gravity separation and reverse coning • ELAN Energy Inc.
• Gulf Canada Resources Ltd.
applications are also discussed in the course.
• Imperial Oil Resources
• Instituto Mexicano Del Petroleo
Who should Attend? • Marathon Oil Company
The course has been developed for personnel who deal with the • Maxus International Energy Company
• Morrison Petroleums Limited
design, implementation and operation of DHOWS systems. This
• Norcen Energy Resources Limited
includes field operators, completion and production technologists
• Norsk Hydro a.s
and engineers, and the staff of equipment manufacturers and • PanCanadian Petroleum Limited
vendors. Introductory material is included to accommodate • Penn West Petroleum Limited
participants with a limited knowledge of various pumping systems. • Petrobras
• Petro-Canada
Topics • Saga Petroleum a.s.
• Evaluating economics of DHOWS systems • Poco Petroleums Limited
• Guidelines for pool and well screening • REDA
• System design and implementation • Renaissance Energy Limited
• Review of the field experience from the initial prototypes • Phillips Petroleum Company Norway
and onwards • Schlumberger
• Shell International Exploration & Production B. V.
• Advanced topics such as Offshore Implementations,
• Talisman Energy Inc.
Dual Stage Separation and Desanding Systems
• Texaco Inc.
• Tri Link Resources Limited
• Wascana Energy Inc.
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Production Enhancement for Gas Wells
Background
• Water production in gas wells may result in liquid loading, which in turn...
– reduces gas production rates
– reduces recoverable reserves
– increases operating costs.
• Downhole gas/water separation technology (as well as established techniques such as velocity string or plunger lift) may
improve gas production rates.
• The applicability of each technique depends on specific field and well conditions.
• An engineering assessment of a number of wells in a field can determine the applicability of various commercially
available production systems.
Potential Benefits
• Increased gas flow rate (production acceleration)
• Reduced water handling (with downhole injection system) and other operating costs
• Increased recoverable reserves (capture)
• Reactivation of shut-in wells
Capabilities
• Multidisciplinary engineering team with state-of-the-art knowledge of production technology
• Extensive experience in petroleum applications and new technology deployment, including gas/water separation
• specialized in-house computer models for performance prediction
Engineering Services
C-FER’s approach to determining the suitability of different production systems consists of the following steps...
• Initial meeting with client to define ultimate objectives, based on client’s
development plans and current operating status of a property
• Pre-screening of candidate wells from field, based on overall reservoir and
well characteristics and on location-specific requirements or constraints
• Detailed review of top well candidates/systems including... Deliverables
– Well tests, logs, fluid analyses • In-house presentation of results
– Wellbore configuration of technical and economic analysis,
– Workover history including go-forward recommendations
– Production history • Formal report with format and level of
• Development of alternatives for enhancing production of candidate wells detail determined by client
• Detailed technical and economic analysis of selected alternatives... • Proposal for assistance in field
– Build/use proprietary nodal & economic models implementation and performance
– Determine impacts on production volumes monitoring (if warranted)
– Determine impacts on operating & capital costs
• Selection of top alternatives based on results of analysis
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Laboratory Facilities
LOAD FRAMES
C-FER operates a variety of large-scale servo-hydraulic load frames to simulate complex loading scenarios representative of field
conditions.
System Universal Testing System Tubular Testing Connection Testing Horizontal Testing System
System System
Maximum Length 6m Length 15 m Length 11.6 m Length 5.5 m
Specimen Base 2 x 18 m Diameter 1.5 m Base 2x2m Diameter 1.2 m
Dimensions
System can be reconfigured to
accept larger specimens
Maximum Compression 15 MN Compression 15 MN Compression 15 MN Tension 71 MN
Load Tension 15 MN Tension 15 MN Tension 15 MN
Dynamic 5 MN
Structurally capable of
22 MN with additional
actuators
Frame Vertical Vertical Vertical Horizontal
Orientation
Special Maximum stroke rate Bending capacity Bending capacity Energy dissipation system for
Features 100 mm/sec 27 MNm 8 MNm destructive testing
C-FER www.cfertech.com
Technologies
Laboratory Facilities
EXPERIMENTAL FLOW LOOP
The Experimental Flow Loop is used to test the performance of
downhole pumping systems over a range of operating temperatures,
pressures, flowrates and gas/liquid ratios.
Physical Setup
• Accommodates downhole- and surface-
driven pump systems up to 24.4 m (80 ft) in length,
up to 12 m (40 ft) per section;
• Allows for downhole gas (steam and air) separation at the pump
intake with a simulated submergence of approximately 2 m (6.6 ft);
• 11” 3000# API wellhead flange which allows for a variety of
standard wellheads to be installed.
• Fully instrumented to allow real time pressure, temperature, flow
measurements and pump torque and speed.
Volumetric Capacity
• Liquid flow rate up to 800 m3/d (5050 bpd)
– Water, oil or oil/water mixture
• Air injection up to 120 std-m3/h (70 scfm) at 4140 kPag (600 psig)
at the downhole pump intake.
C-FER www.cfertech.com
Technologies
Laboratory Facilities
DEEPWATER EXPERIMENTAL CHAMBER STRONG FLOOR AND WALLS
C-FER’s Deepwater • High capacity multi-use reaction floor
Experimental Chamber (DEC) (22 m x 12 m)
enables full-scale testing • Buttressed multi-directional reaction wall
of deepwater pipeline and (15 m long x 6 m high) for application of
production equipment. The multi-directional loading
vessel is unique because of the • Accommodates large-scale structural
size, pressure rating and ease assemblies and components with more than
of access. Equipped with quick 1,300 tie-down locations
release end caps, the vessel • Serviced by 15 tonne overhead travelling crane
ensures rapid installation
and removal of equipment, COMPONENT TESTING
reducing both testing time • 1000 kN capacity
and cost. servohydraulic
MTS machine for
Full-scale tests with comprehensive instrumentation, control and coupon testing
video monitoring minimizes the potential for costly equipment under a variety of
failures in deep water. load & temperature
conditions
• Working pressures to 55 MPa (8,000 psi) • 16,200 N-m
• 10.7 m (35 ft) long with a 1.22 m (4 ft) diameter torsion testing unit,
• Equipped with internal rams and reaction frames to apply with independently
tension, compression, torsion and bending loads to operated axial
specimens while under pressure tensile load
• Full–scale pipeline testing at working pressures, both capacity to 1,300 kN
internally and externally • Other self-contained computer-controlled load
• Rapid installation and removal of test specimens and and pressure systems for serviceability and proof
assemblies testing of hoisting equipment, couplings, valves,
• Internal video monitoring vessels, etc.
• Accommodates hydraulic, electrical, video and
instrumentation leads
C-FER www.cfertech.com
Technologies
Contacts
MANAGING DIRECTOR
Francisco Alhanati 780.450.8989 x253 f.alhanati@cfertech.com
C-FER FELLOW
Cam Matthews 780.450.8989 x252 c.matthews@cfertech.com
PRODUCTION OPERATIONS
Wayne Klaczek, Manager 780.450.8989 x306 w.klaczek@cfertech.com
ENGINEERING SERVICES
Paul Skoczylas, Manager 780.450.8989 x299 p.skoczylas@cfertech.com
C-FER www.cfertech.com
Technologies
C-FER Printed September 2015
Technologies
C-FER
Technologies
www.cfertech.com