Exploring Innovation in Gas Flow Management for Enhanced Esp Efficiency and Reduced Downtime- A Comprehensive Review of Lessons Learned and Case Studies

Abstract This paper builds upon last year's presentation, which featured a case study showcasing the application of gas handling technology in the Midland Basin. With over 200 installations in the Permian Basin, this document expands on the insights gained from various applications, providing additional data that reinforces the operational principles and results presented in the previous year. In this paper, we delve into the intricate physical principles governing the gas handler's functionality in regulating free gas flow before reaching the ESP intake. Through the presentation of three case studies, we illustrate how these adjustments have significantly enhanced project profitability. The first case study examines a Delaware well completed in the Bone Spring, notorious for historical gas and sand challenges. The regulator was installed alongside the second ESP, with an expected liquid production of 1,200 BFPD and a GLR of 1,000 SCF/STB. The second case study focuses on a well completed in the Middle Spraberry producing 350 BFPD and a GLR of 1900 SCF/STB. Considering the production rates, a rod pump conversion was contemplated. The third case study explores a well in the Midland Basin that has slug flow on High GLR Formations, with an expected liquid production of 1,000 BFPD and a GLR of 2,000 SCF/STB. The fourth case study focuses on extending the life of second Electric Submersible Pumps (ESPs) before transitioning to a permanent lift method. The behavior of two wells, both before and after the installation of the fluid conditioning tool, is analyzed. The final case study focuses on gas slug mitigation in ESP systems affected by sand and scale. The study compares five runs of the well, examining the performance of different tools installed. In all case studies, we evaluate sensor parameters, presenting the before-and-after scenarios of production rates and drawdown. As unconventional reservoir development matures, the challenges related to well production increase. In recent years, there has been a significant uptick in the discussion surrounding gas slugging and gas-related issues. This paper compiles experiences from several installations with this technology and provides analysis of ESP performance. This groundbreaking technology represents a pioneering approach by regulating gas below the pump's sensor, distinguishing itself as the first of its kind in its class.