Luis Guanacas, Norman Grimes, Luke Bell - Odessa Separator Inc.
Sand production remains a challenge in ESP applications because uncontrolled solids can cause erosion, abrasion, vibration, plugging, premature equipment failure, and increased lifting costs. Conventional sand-control solutions rely on filtration; however, screens with smaller slot sizes may experience plugging under variable sand production and high-viscosity fluid conditions. This paper presents a field application of the homogenization principle, which focuses not on separating sand but on controlling and distributing solid inflow to prevent sand slugs from reaching the ESP.
The method was applied in a directional well with a history of short ESP run life and high sand production. Sand sieve analysis showed that 81.2% of the particles were smaller than 70 Mesh, while sand production fluctuated between 0.760 and 21.360 kg/day. Based on the sand distribution and production conditions, six 3-1/2-in. × 4-ft × 75-slot V-Mesh Tubing Screens were selected. The configuration provided 1,079.7 in² of open area and a pressure loss of 0.03 psi.
Following installation, sand production decreased and stabilized at an average of 0.317 kg/day for more than three months. Stable vibration, current, and voltage indicated improved ESP operating conditions, allowing motor frequency to increase and liquid production to rise from 1,600 to 1,800 BFPD. The results demonstrate that homogenization can provide reliable sand management, reduce plugging risk, protect ESP integrity, and enable increased production in sandy wells.