Innovative Solutions for Enhancing ESP Performance: Addressing Gas Lock Issues Through Flowback Loop Technology and Packer Removal

Abstract This paper aims to address and mitigate the exacerbated ESP gas lock issues in packer completion operations, in Microporous reservoirs in North West Oman, that hinder fluid lifting, reduce production rates, and cause frequent ESP trips. By introducing an innovative solution for packer removal, it seeks to enhance ESP performance, prolong run life, and significantly reduce deferment, particularly in microporous/tight reservoirs with limited water injection support. Packer removal is considered justified under the company's well integrity management practices if a well cannot flow naturally within three days. To evaluate this, flowback tests were conducted in the field to assess natural well flowing capability within this timeframe. Multiple campaigns successfully demonstrated free-flow capability under ambient conditions. Additionally, Dynamic Transient Simulation analysis was used to predict natural flow following ESP shut-ins under atmospheric backpressure conditions. Model validation and sensitivity analyses were performed to evaluate ESP shut-ins and restarts without activating the ESP. The correlation between simulation results and flowback test findings reinforced the reliability of the conclusions. The implementation of flowback loop technology has shown substantial practical benefits. Based on flowback loop and dynamic transient modeling, the inaugural campaign of packer removal from four wells significantly reduced ESP trips, improved operational efficiency, and decreased oil deferment. In 2023, packer removal where feasible led to a net oil deferment reduction of approximately 22,000 barrels. By 2024, extending packer removal to 18 wells further reduced deferment by around 750 bbl/d. This technology not only improves production by allowing gas to escape, preventing gas lock conditions, but also ensures well integrity compliance without the adverse effects of traditional packer use. This dual benefit showcases a forward-thinking approach to managing ESP gas lock issues. The adoption of flowback loop technology combined with dynamic modeling represents a significant strategic advancement. This solution enables real-time evaluation of a well's natural flow capacity within the critical initial 72-hour period post-installation. This approach aligns with well integrity management standards, providing a proactive solution to prevent future gas lock issues and enhancing overall operational efficiency.