Optimizing Electrical Submersible Pump (ESP) Design and Operation for Low-Productivity Gassy Wells

Abstract Electrical submersible pumps (ESPs), though widely adopted for artificial lift, are susceptible to performance degradation in high-gas-volume wells. Gas can cause motor overheating, reduced hydraulic efficiency, and mechanical damage to the motor and cable, leading to intermittent shutdowns and premature ESP failure. This case study highlights the challenges of deploying ESP systems in low-production wells with high-gas challenges. ESP system installed in such a well experienced immediate performance degradation due to severe gas interference, leading to costly well interventions. Dismantle inspection and failure analysis (DIFA) is provided. A collaborative effort with a technology provider and a comprehensive ESP design resulted in the successful optimization of ESP performance and the recovery of previously inaccessible hydrocarbons from these low-production, high-GOR wells. The integrated approach incorporates a permanent magnet motor (PMM), tandem gas separators, compression mixed-flow pump stages, axial-flow gas handler (AGH), and Monel armored leaded power cable. ESP system successfully handled GORs exceeding 3,000 SCF/STB, WC below 10%, and a productivity index of 0.2 BPD/psi, significantly improving well production by reducing downtime, extending equipment life, and maximizing reservoir recovery. This paper provides a comprehensive overview of the system's components and their contributions to enhanced performance. The successful application of the integrated solution to other low-productivity, high-gas-volume wells in the field, has expanded the boundaries of ESP technology. Long-term monitoring has confirmed the stability and reliability of the ESP system in mitigating gas interference and maximizing production. This breakthrough enables the application of ESP technology to a wider range of challenging well conditions, unlocking significant production potential, previously thought to be unsuitable.