Performance Improvements of ESPs using 500 and 700 series PMM in High Demand (High Flow & High HP) applications.

This paper presents the Gas Release System Bypass, the latest advancement in gas regulation and separation technologies for Electric Submersible Pump systems operating in high-GLR and gas-slugging environments. The GRSB enhances conventional gas-handling methods by integrating the principles of gas regulation, pressurization, centrifugal dispersion, and controlled gas venting through a dedicated bypass system. This design ensures that fluids delivered to the pump intake are properly conditioned, enabling stable ESP performance, improved drawdown, and reduced motor temperature, while mitigating shutdowns associated with gas interference. The system serves as a high-efficiency solution for wells nearing the limits of ESP operability and as an intermediate step before transitioning to alternative artificial lift systems.

The GRSB integrates four major components a Triple Seal Packer, Pressurization Chamber, Centrifugal Regulator, and Gas Release Bypass section, working sequentially to homogenize fluid and efficiently vent free gas. Large gas slugs are first dispersed into smaller bubbles, then reabsorbed through pressure increases generated within an oversized chamber. Centrifugal forces further break remaining bubbles, and any unrecombined gas is vented through a one-way valve above the ESP discharge. The result is a stable, homogenized liquid stream that promotes efficient motor cooling and consistent pump operation

Three field applications in the Midland Basin demonstrate the system's impact. In Case Study 1, installing a downsized pump with a GRSB reduced PIP from historical levels to 390 PSI at only 52 Hz performance previously unattainable. Case Study 2 achieved a drawdown to 420 PSI at 63 Hz, improving on prior limits of 630 PSI at similar frequencies. In Case Study 3, GRSB deployment increased total fluid production by 55% and boosted oil output from 85.7 to 118 BOPD, highlighting improved flow stability and gas-handling capacity. Across all cases, sensor data indicated lower motor temperatures, fewer shutdowns, enhanced pump efficiency, and reduced NPT.