American Oil and Gas Reporter - June 2014 - 116

not doubt we can save operators at least
10 percent of their normal rod failure
costs and downtime," he concludes. "Saving 10 percent of a total failure cost that
can be in the millions each year is pretty
hefty."
Progressive Cavity Pumps

The self-contained mobile unit from Hickman Sales and Service uses advanced automation technology to confirm that every sucker rod connection adheres to American Petroleum Institute recommended circumferential displacement method specifications.
According to the company, the Stable Data System is designed to reduce rod failure
rates by applying the exact amount of required torque when making a connection.

quantity of wells and how the operator
leverages the data from the host software,
Dean says payback on the capital cost
typically is a matter of months. "An automated system can pay for itself easily in
three-six months," he assesses. "Without
hesitation, I can say every operator can
pay off a system in 12 months or sooner."
Automated Rod Connections
Hickman Sales and Service Inc. in
Odessa, Tx., is applying advanced automation technology to the sucker rod
coupling and makeup process for rodpumped wells. Automated torque and circumferential displacement reduces downtime and production losses related to
sucker rod string failures, and eliminates
uncontrolled variables that can lead to
high failure rates, says founder Don Hickman.
The company describes its new Stable
Data System as a self-contained, mobile
unit with automated components and
electronic modules to ensure that every
sucker rod connection meets API recommended circumferential displacement
method specifications.
"Properly cleaning and visually inspecting the thread connection area before
assembly is essential, and then the data
system automatically controls the power
tongs, makes up the rods in the proper
range, and logs the data for each connection," Hickman details.
He goes on to point out that a multitude
of variables can impact the sucker rod
makeup process, including rod materials,

surface finish of the pin shoulder and
coupling face, and lubricants. The rig's
hydraulic system produces the most uncontrolled variables, such as engine rpm,
hydraulic flow rates, and system pressure,
along with the power tongs' mechanical
integrity, and human error. Sucker rod
failures can originate in any of these factors, Hickman notes.
"The system is designed to eliminate
uncontrolled variables and reduce rod
failure rates through an effective, consistent
and precise automated process," he says.
"It applies the exact required torque necessary to make up each connection to
API recommended practice, and has a
simple green, yellow or red light system
to let the operator know if a connection
was made up properly."
The operator must accept the connection before the system will proceed to
the next connection, he describes. If the
system detects a problem, he notes, the
operator can stop to ascertain its nature
and correct it before the connection disappears down the well.
"If the operator gets a yellow or red
indicator, he has to stop to correct the
issue identified on the display screen
before he can go to the next connection,"
Hickman says. "If he gets a green indictor,
the connection was made up properly
and he can move to the next one."
Hickman says the mobile system has
been thoroughly field tested in the Permian
Basin and has launched commercially.
"We have not yet had the opportunity to
collect data on cost savings, but we do

116 THE AMERICAN OIL & GAS REPORTER

Permanent magnet motors are also an
important part of advances in progressive
cavity pump applications, says Iain
Maclean, CEO of Zilift Ltd. The company's TorqueDrive™ system couples a
compact permanent magnet motor with
the company's patented torque converter
technology to deliver power to the PCP.
"TorqueDrive consists of a permanent
magnet motor, contactless magnetic torque
converter, and an equalizer section aimed
at PCP applications," he states. "Among
other benefits, this technology significantly
reduces lifetime lifting costs and extends
economic production life."
The technology has successfully completed its first operational field trials in a
heavy oil artificial lift application in a
series of wells in California's San Joaquin
Valley, Maclean reports. "TorqueDrive
surpassed initial field trial targets, having
exceeded 150 days running and counting,"
he notes. "This is the first known practical
demonstration of a magnetic torque converter in a downhole environment, and
TorqueDrive is powered by the smallest
downhole artificial lift motor successfully
installed in an oil well worldwide."
He indicates the technology eliminates
the rod string, reducing production rod
and tubing failure downtime. TorqueDrive
also eliminates the stuffing box and associated leak issues with a static seal
arrangement, Maclean reports, adding
that PCPs that are equipped with the
TorqueDrive system can be used on- or
offshore, and in vertical, directional or
horizontal wells.
"While this system was designed for
heavy oil operations, we also see its application in lower-rate light oil wells and
in gas well deliquefaction," he remarks.
According to Maclean, a slim-line
profile allows the system to be deployed
and operated through severe doglegs and
into a full horizontal position. Furthermore,
he says, removing the rod string shortens
workover or maintenance activities and
the system's design allows installation
through coiled tubing and cable-deployed
systems, further reducing artificial lift
maintenance.
The San Joaquin Valley field trial
wells included an integrated monitoring
system for real-time data feedback on
reservoir conditions, he details. Automated
routines constantly monitored pump per-

American Oil and Gas Reporter - June 2014

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