New High Performance ESP Gas Separator

Abstract

Abstract This paper presents a new research method, design, and field testing of a new type of mechanical gas separator for electrical submersible pump systems (ESPs) that increases the operating flow range and separation efficiency while decreasing erosion problems and improving reliability. A state-of-the-art test system was developed to view the internal workings and measure two-phase flow through mechanical separation devices to understand flow paths, recirculation, and separation efficiency, along with the collective and individual performance of various components of a gas separator. The result, a new "helical" design with optimized throughput, has a significant increase in total flow capacity, enhanced erosion protection, and improved gas locking prevention mechanisms. Field tests of the new gas separators were conducted in conventional, unconventional, and CO2 flooded oil wells in the Permian Basin. Performance was evaluated by monitoring motor cooling, motor current fluctuations, intake pressure (drawdown), and wellhead pressure in wells with a high gas/liquid ratio (GLR) or gas volume fraction (GVF) and gas slugging. Cycling and continuous operations were compared for both conventional gas separators and the new gas separator to demonstrate the improved performance of the ESP in these well conditions. The hydro-helical separator system is a new generation of downhole gas separator with a higher flow range, better gas separation efficiency, and reduced erosion, and has been proven to work in different types of wells.