ESP Rotary Gas Separator Configuration for Harsh Environments, High Contents of Free Gas, High Temperatures and Viscous Conditions

Abstract

Abstract The operation of Electric Submersible Pumps (ESP) in harsh reservoir conditions like high fluid viscosity, high bottom hole temperatures, and high free gas content is a constant challenge in an extra heavy oil Field located in Colombia. This is especially true in wells producing from the In-situ Combustion process that has been implemented in the Field to maximize ultimate oil recovery. Standard ESP configurations constantly faced gas-blocking events and had low system performance, reducing run life, and increasing operational project costs. This paper describes how a Rotary Gas Separator in addition to other gas handling technologies has successfully been implemented to overcome the described challenges in this Field. This paper presents the results of the successful implementation of the Rotary Gas Separator in a Colombian Field with high oil viscosity, high percentages of free gas, and high temperatures, including case studies where air injection is used as an enhanced oil recovery method. Additionally, comparative analyses are performed with the conventional used Vortex Gas Separator. ESP performance parameters achieved so far include better gas separation efficiency, handling up to 95% free gas at the pump intake; an increase of up to 19% in the drawdown; a reduction of up to 60% in downtime and shutdowns related to gas-blocking events; an average reduction of 30% in operating motor temperatures; and a significant increase in the run life compared with the previous runs that used Vortex Gas Separators. The implementation of the Rotary Gas Separator and other gas handling technologies are allowing the Operator to increase production and improve the performance and reliability of the ESP systems; thus, plans are being made to continue expanding this configuration to other wells in the Field.