Neil Johnson Vazhappilly, Odessa Separator, Inc.
Lance Vasicek, DG Petro
This paper presents a novel technology designed to address the challenges posed by 100-mesh frac sand (149 microns) in rod pumps, particularly in the Permian Basin. This sand often causes premature pump failures by clogging and damaging key components like the plunger and barrel. The solution extends pump run life and prevents pump sticking.
The multilayer filtering system leverages the concept of completion screens, a long-established technology in the industry, but with a redesigned approach to be integrated in the production cycle where it is compatible for rod pumps and is made to filter sand sizes ranging from 60 to 300 microns, effectively removing particles traditional vortex separators miss. Its innovative design includes eccentric layers with dimples, maximizing open area to nearly 40% across its 288-inch length. The modular setup allows multiple units to be combined in tandem, enhancing filtration capacity while minimizing pressure drop.
Field installations in the Permian Basin have demonstrated significant operational benefits. In one case study, pump run time tripled following the system's implementation, reducing well interventions and equipment replacement. This improvement also lowers the carbon footprint of operations.
Uniquely, using patented Dual-Flow technology, this system integrates with vortex and gas separators for added protection against solids and gas. Constructed with premium materials and a robust assembly process, it offers durability and long-lasting performance for rod pump applications.