Development and Field Testing of New High-Performance Downhole Gas Separator for Electric Submersible Pumping Systems

Abstract

Abstract This paper presents new research methods, designs, and field testing of a new type of mechanical gas separator for electric submersible pumping (ESP) systems that increases the operating flow range and separation efficiency performance, while decreasing erosion problems and improving reliability. A state-of-the-art test system for measuring and understanding the internal workings of two-phase flow conditions and throughput of mechanical separation devices was used. This testing enabled visual understanding of internal fluid flow, recirculation, separation efficiency, and collective and individual performance of various components of the gas separator. The result is an innovative hydro-helical separator system with optimized components. The intake is designed with smooth intake flow paths to maximize flow capability and minimize erosion. Also in the design is a new fluid-mover stage with significantly higher capabilities of handling two-phase flow and gas lock protection. A stationary helical component replaces the dynamic vortex inducer, allowing for more efficient gas separation and increased throughput of the fluids within the separation chamber. The helical component precisely directs the separated fluids with its increased velocity into the crossover pathways. The crossover is designed for maximum throughput, low resistance flow passages, and erosion protection. Field testing results show a significant improvement in production and drawdown of the well. The Hydro-Helical™ gas separator is the industry's new generation of downhole gas separators with the highest flow range, higher efficiency, and reduced erosion.