Marcelino Mota - Baker Hughes
OBJECTIVES/SCOPE
Unconventional wells with moderate-to-high gas-liquid ratios can experience gas interference that limits electrical submersible pump (ESP) drawdown and creates unstable operating conditions. This paper presents a Permian Basin field case where an alternative gas-handling configuration was implemented to improve gas separation, stabilize ESP operation, and increase production under GLR conditions of approximately 1,400-1,800 scf/bbl.
METHODS, PROCEDURES, PROCESS
The previous ESP configuration exhibited unstable drawdown, motor-current fluctuations, and frequent short cycling associated with gas interference and variable fluid inflow. The system was redesigned using a booster configuration in which a gas handler was installed below the gas separator and main pump string. This arrangement was intended to condition the multiphase flow before separation, improve gas-handling capability, and provide more stable fluid delivery to the main pump stages. Performance was evaluated by comparing production and ESP operating trends before and after the intervention.
RESULTS, OBSERVATIONS, CONCLUSIONS
Following installation of the booster gas-handling configuration, oil production increased by approximately 56%, from 119 BOPD to peak rates of 188-207 BOPD. Total liquid production increased by approximately 80%, reaching up to 570 BPD, while average liquid production was approximately 400 BPD. The motor load profile became smoother and more consistent, with fewer current fluctuations than observed with the previous ESP system. Despite increasing GLR during operation, the ESP continued to exhibit stable performance, indicating improved tolerance to changing gas conditions and effective gas management upstream of the main pump stages. The system maintained operational stability for more than 210 days. The field results indicate that appropriately positioning a gas-handling device ahead of the primary gas separation and pumping stages can improve drawdown, production, and ESP stability in unconventional wells affected by high free-gas fractions.
NOVEL/ADDITIVE INFORMATION
This case demonstrates a practical gas-management strategy for ESP applications in high-GLR unconventional wells. Rather than relying solely on gas separation at the pump intake, the booster configuration combines upstream multiphase flow conditioning with subsequent gas separation, providing field evidence that the arrangement can expand the stable ESP operating envelope while improving drawdown and oil production.