Successful Application of Innovative Technology to Enhance Gas Handling Efficiency and Extend Run Time in Permian ESP Wells: A Case Study

Abstract With over 6 million barrels of oil produced per day, the Permian is the largest unconventional basin in the United States. The horizontal wells in this region typically have lateral lengths averaging 10,000 feet. These extended laterals frequently feature numerous undulations, which directly result in gas interference when combined with high water cut and a rapid decline in bottomhole pressure. This flow instability can severely impact the performance of Electric Submersible Pumps (ESPs), resulting in issues such as gas locking, gas blocking, head reduction, and motor overheating. In severe cases, these problems can lead to ESP failure, thereby limiting the well's production potential. To address these challenges, leading oil and gas companies have rigorously investigated effective methods to mitigate severe gas interference in high Gas Liquid Ratio (GLR) wells. This paper presents the results of a successful application of a gas booster design utilizing new gas handler pump (GH) just before the separator, which significantly improved gas separation and gas handling, extended the run life of the ESP, and reduced operating costs. Several case studies were selected to evaluate the efficiency of the newly developed boosted gas separator design. In some cases, a single well had two consecutive ESP installations—the first using a standard configuration and the second upgraded with a booster configuration. In other cases, two wells from the same pad were selected, one equipped with a conventional ESP and the other with the booster design. Operating parameters from both configurations were monitored and compared throughout their respective run lives. Teardown and root cause analyses were performed to identify failure mechanisms. Additionally, well models were developed and history-matched for validation, followed by sensitivity analyses to assess gas separation efficiency. Based on the root cause analysis, the cyclic nature of the well's operating parameters, due to the high gas interference – high GLR, caused a significant electrical stress on the electrical components of the ESP system. In contrast, the results of the second installation indicated that the boosted gas separator increased the gas separation efficiency by 26% compared to the standard design. The gas booster system stabilized production flow. This is shown by the improved operational parameter trends. The result was greater drawdown at the pump intake and improved up-time for an increase of 10,000 Barrels of liquid production from the initial 60 days of operation. The successful implementation of the new gas booster design in the Permian has allowed the operating companies to address the challenge of gas interference effectively, improving the performance and reliability of ESP systems. The gas handler pump is expected to be an essential component for ESPs designed for high GLR wells.