Case Study #06 - Improving Measurement Reliability in Heavy Oil Production
OVERVIEW
APPLICATION:
Measuring production in heavy oil systems to support operational optimization, cost control, and accurate, responsible reporting.
SERVICE CONDITIONS
Sur-Flo Paddle Meters are installed at multiple field locations across a major heavy oil operation in Western Canada. These units operate in challenging service conditions that include high-viscosity fluids, low ambient temperatures, and remote sites where rugged, low-maintenance instrumentation is essential. The meters were deployed as drop-in replacements with no piping modifications and are built to perform reliably in demanding upstream Class I, Div 2 environments.
OVERVIEW
A major heavy oil producer in Western Canada was experiencing frequent rebuilds, rising maintenance costs, and unreliable data from conventional PD meters. These issues were affecting both efficiency and reporting.
Sur-Flo provided a field-proven alternative with rugged Paddle Meters designed for cold heavy oil service. With drop-in installation and no piping changes, the meters delivered immediate improvements in accuracy, uptime, and long-term savings.
ABOUT THE CLIENT
A major Canadian energy producer with a strong presence in Western Canada, this operator is committed to responsible development and long-term operational efficiency. Their heavy oil program plays a key role in their broader production portfolio, with a focus on maximizing recovery, minimizing downtime, and maintaining high standards of performance and accountability.
THE CHALLENGE
The client had been relying on conventional PD meters in a key heavy oil region but began encountering ongoing issues, including:
Premature mechanical wear
Inconsistent measurements in high-viscosity oil
Frequent maintenance issues and costly rebuilds
Operational inefficiencies due to downtime
They required a more durable, accurate, and low-maintenance solution to support both their stewardship commitments and operational efficiency goals.
THE SUR-FLO SOLUTION
Sur-Flo provided a field-proven replacement with Paddle Meters designed specifically for heavy oil applications. These meters offered a seamless drop-in fit—no piping changes required—and quickly delivered measurable improvements in accuracy and reliability:
Improved measurement accuracy and reliability
Reduced maintenance and unplanned downtime
Lower total cost of ownership
Better data to support production optimization
Built with a robust design and minimal moving parts, Sur-Flo Paddle Meters are well-suited to heavy oil environments, making them a practical and reliable choice for operators working in demanding production conditions.
CONCLUSION
By transitioning to Sur-Flo Paddle Meters, the operator successfully addressed ongoing reliability and maintenance challenges in their heavy oil operations. The solution delivered immediate improvements in accuracy, reduced downtime, and simplified installation. The meters continue to perform reliably in demanding conditions, supporting the operator’s broader goals of efficient, cost-effective, and responsible resource development.
THE PATH MOVING FORWARD WITH SUR-FLO’S TECHNOLOGIES:
Sur-Flo remains committed to supporting the client’s measurement needs as their operations evolve. With proven performance in the field, our team continues to provide technical support, service parts, and additional flow measurement solutions as required. As the client explores further optimization opportunities across their heavy oil assets, Sur-Flo will be there to ensure their flow measurement remains accurate, dependable, and future-ready.