Integrated system for viscosity reduction in heavy oil wells with artificial lift through controlled heating using variable frequency drives

An integrated system for reducing viscosity of a heavy crude oil in a well with an artificial lift system (ALS), the system comprising:

• a heating apparatus comprising:
• a housing resistant to corrosion, high temperatures, and high pressures;
• a coaxial pipe-in-pipe electric heater tube comprising:
• a casing comprising an outer pipe of the coaxial pipe-in-pipe electric heater tube;
• an internal tubing equipped with an encapsulated linear electric resistor disposed inside the casing,
• wherein the internal tubing and the casing define an annular space therebetween for heating fluid;
• at least one heating element based on the encapsulated linear electrical resistor arranged along the heating apparatus or the coaxial pipe-in-pipe electric heater tube;
• and
• a plurality of physical and logical sensors for measuring temperature and viscosity data of the heavy crude oil at an inlet and an outlet of the heating apparatus;
• an electronic control unit equipped with an adaptive algorithm configured to analyze temperature data and viscosity data in real time and adjust power of the at least one heating element through a first variable frequency drive (VFD1);
• a permanent magnet motor (PMM) or an induction motor (IM) directly coupled at a wellhead of the well configured to drive a pump of the ALS via a string of rods;
• and
• a second variable frequency drive (VFD2) electrically connected to the ALS configured to control a speed of the pump,
• wherein the electronic control unit is configured to coordinate operation of the heating apparatus and the pump, such that heating reduces viscosity and mobility of the heavy crude oil to facilitate extraction.