(33) New Gas Bypass System for Unconventional Wells on ESP

In the Permian Basin, new unconventional wells on ESP systems experience production challenges due to high gas to liquid ratio. Unconventional wells having high initial rates with steep declines requires wells to be pumped aggressively early on. ESP’s by nature are designed to pump only liquids. Gas entering the ESP not only decreases volumetric efficiencies, but also causes high temperature issues and erratic run behavior. This decreases production and degrades the mechanical integrity of the ESP, leading to higher maintenance costs and ESP failure. Since ESP failures are one of the major expenses incurred by the operator, the most effective method to reduce OPEX is to increase runtime and decrease ESP failures by reducing the amount of free gas that enters the pump. Operating conditions can be significantly improved by utilizing the innovative technology of the ESP Gas Bypass when paired with proper ESP design and operational practices. The ESP Gas Bypass utilizes a packer to isolate all flow before reaching the pump intake and creates an isolation chamber below the ESP. Pressure is then created so as fluid moves upward, gas is released naturally. The primary focus of the tool is to utilize the casing to create a natural downhole gas separator, which allows trapped gas to be discharged well above the pump intake of the ESP. This paper presents the technology behind the ESP Gas Bypass and offers case study results that proves the positive impact of this tool on overall operating expense.