Optimizing Horizontal Well Pumping and BHA Design to Reduce Bottomhole Flowing Pressure

Artificial lift optimization in marginal horizontal wells is often limited by gas interference and inefficient pump intake placement. Particularly in mature reservoirs producing below bubble point. As free gas evolves in the lateral, stratified flow conditions can reduce pump fillage and restrict drawdown in rod lift systems. This study presents a field case from a marginal horizontal well operated by A.C.T. Operating Company in Cochran County, Texas, evaluating the impact of the insert pump placement and intake gas separation on production performance. The well was converted from electric submersible pump to rod lift with the insert pump initially positioned in the vertical section to minimize mechanical risk. Field optimization later repositioned the pump deeper into the tangent section and incorporated intake gas separation, increasing total fluids production from approximately 358 to 560 BFPD while nearly doubling oil cut. Based on these results, a conceptual bottomhole assembly is proposed that integrates a lateral gas separation tool with a spring assisted standing valve to reduce liquid fallback and improve pump fillage. Inflow performance modeling indicates that reducing bottomhole flowing pressure to approximately 50 psi could increase oil production to nearly 20 BOPD, representing a potential incremental gain of approximately 6 BOPD. The proposed design will be evaluated through laboratory modeling and future field testing.