Flowrise Oil Tools → Case Studies
PROVEN
IN THE FIELD.
Real operations. Real engineers. Real results. Every case study showcases a real challenge solved with Flowrise’s precision PCP engineering — tracked, validated, and documented from selection to deployment.
OIL & GAS · CANADA
Project Overview
Location: Canada
Application: Heavy crude oil extraction
Conditions: High viscosity +
high solids content
Summary
Operation under extreme conditions with highly viscous crude oil and a significant presence of sand, resulting in recurring failures in conventional PCP systems.
The Challenge
High-viscosity crude with 35% sand content. Standard competitor pumps failing every 60 days due to elastomer abrasion, causing production losses exceeding $40K/intervention and unacceptable downtime for the operator.
The Flowrise Solution
Custom-engineered Grade HY rod string with German-formulated NBR elastomer stator optimized for sand abrasion and heavy crude viscosity profile at downhole temperature.
Run-Life Extension
4x
60 days → 240 days between interventions
Production Rate
+40%
From 280 to 392 BOPD continuous
OPEX Reduction
−65%
Workover cost savings vs prior 12 monthsous
ROI Recovery
18mo
Full investment recovered in under 18 months
Summary
Recurrent polished rod failures at the stuffing box level caused unacceptable loss of containment.
Through advanced simulation and stress mapping, Flowrise assessment uncovered the hidden fatigue triggers.
Flowrise then engineered a smarter path forward—optimizing polished rod speeds as a short‑term measure and upgrading the rod alloy to eliminate the risk entirely.
The Challenge
Problem identified:
-
At certain running speeds the PCP system operates out of the natural resonant frequencies. Operating at this sustained condition led the polished rod into induced fatigue failure.
-
Loss of containment at the stuffing box level.
-
Unacceptable downtime with subsequent production deferment.
The Flowrise Solution
-
Advanced simulation-based engineering, Identification of stress concentration zones along the polished rod.
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Recommended a range of operating speeds out of the resonant zone as a short term management solution.
-
Change the material alloy of Polished in order to withstand the axial and torsional loads.
360 days
Run-Life Extension
Thread removed from the system; failures occurred due to unrelated causes
Production Deferment
+100%
Downtime reduced from 9 days to zero by eliminating this failure mode
OPEX Reduction
−12%
Workover cost savings vs prior 12 months
ROI Recovery
05 days
Full investment recovered in under 5 days (per well avg)
Summary
Declining brownfield performance was aggravated by excessive operating expenses and power shortages in an environmentally sensitive area. Through a strategic conversion to energy-efficient PCP systems, the operation achieved a step-change in uptime, delivering increased production rates and restoring power grid stability.
The Challenge
Inefficient rod pump performance restricted production and drove excessive downtime costs due to insufficient power generation 200 km offshore Karratha in Western Australia. Frequent well shut-ins caused by grid instability made the legacy lift systems unsustainable for long-term viability.
The Flowrise Solution
A technical upgrade to high-performance PCP systems transformed the operation. Engineered for hot and high water cut application, the new configuration delivered consistent lift, and optimized power consumption to stabilize the local grid.
-33% KWH
Less Power
48 KWh → 32 kWh
Production Rate
+28%
From 280 to 392 BPD
18mo
ROI Recovery
Full investment recovered in under 18 months
How We Engineer Each Solution
Our Proven Engineering Process
01
Well Profiling
Fluid analysis, depth, temperature, GOR, sand content, H₂S levels and production targets — complete operational data collected before any design begins
02
System Design
Engineers model the pump, rod string, drive head and VSD as a complete integrated system using our proprietary selection software.
03
Material Selection
Elastomers, alloys and coatings selected for chemical and thermal compatibility. German elastomer formulations tested at downhole conditions.
04
04
Manufacturing & QC
CNC machining with ±0.01mm tolerance. 100% dimensional inspection. Pressure test and rotor-stator fit verification before shipment.
05
Field Support
Engineers on-site for installation and startup. VSD tuning. Performance monitoring at 30, 90 and 180 days post-installation.
Your Operation Could Be Next
YOUR WELL.
OUR ENGINEERING.
Tell us about your operation and our engineers will design a PCP solution with the precision that turned these case studies into results.