Addressing High Gas Challenges in ESP Systems through the Application of MGH
Authors: Al Kalbani Mahmood , AlSalmi Abdullah , AlSaadi Faisal , Soliman Ahmed , Seifeldin Mohammed 
Published: November 2024

Presents an investigation conducted on a series of Electric Submersible Pump (ESP) wells, with a high free gas content reaching up to 75% gas volume fraction. The study quantitatively analyzes the impact on various ESP performance indicators, thereby evaluating the overall ESP operational efficiency consequent to the Multi-Phase Gas Handler (MGH). The primary purpose of the MGH implementation revolves around addressing the operational challenges posed by gas-laden production, which inherently poses difficulties for ESPs (ELECTRICAL SUBMERSIBLE PUMP)

The methodology employed for this investigation comprehends the systematic monitoring of ESP performance variations, pre and post MGH installation, followed by a precise comparative analysis of pertinent performance parameters. The parameters subjected to the comparison are ESP run life, ESP uptime, number of operational interventions (trips), and the extent of current fluctuations. Records monitored and compared for those key indicators before and after installing the MGH to measure the variation in the performance. Those performance indicators are linked with the volume of production and the production deferments.

Practical evidence derived from the study demonstrates the pronounced impact of the MGH on the study's parameters. Notably, a significant reduction in current fluctuations from an average of 17% to only 3% average has been recorded. These lower levels of fluctuation shall reduce the stresses on the ESP electrical system which will contribute to a longer run life in addition to helping to stabilize the power supply system. The ESP trips due to gas issues which mostly need an operational intervention are observed and showed a considerable decrease of 26% fewer trips. The effect of the lower number of trips would be reflected in continuous production, and hence less deferment. Concurrently, there is a noteworthy enhancement in uptime from 63% to 91%. The ESP run life showed a significant increase as well of 16% higher run days till the time this document is prepared. It is expected to have a much higher run life than what has achieved so far, considering the stable performance of the ESPs.

Free gas is always a challenge to produce wells with ESP. The gas degrades the pump efficiency in terms of reducing the pump generated head and the pump produced flow rate. Higher free gas than what the pump can handle could result in gas lock and prevent the pump from production. This paper illustrates the impact of one of the innovative technologies and to what extent this technical solution can help increase production and decrease the associated costs. It is a showcase of the impact of the MGH as a new solution for high free gas wells which could not be produced efficiently with previous ESP technology.

The presence of gas in wells equipped with Electric Submersible Pumps (ESP) poses significant challenges, including reduced run life, increased downtime, frequent interventions, and diminished production rates. This study evaluates the impact of integrating Multiphase Gas Handlers (MGH) with ESP systems in wells experiencing severe gas interference. The implementation of MGH technology led to substantial improvements in operational performance and production efficiency. Key findings include extended ESP run life, increased uptime, and a marked reduction in trips and maintenance interventions. Furthermore, the enhanced gas handling capability of the MGH-ESP combination resulted in a significant boost in oil production rates. These results underscore the potential of MGH technology to mitigate gas-related issues, providing a reliable and cost-effective solution for optimizing artificial lift operations. The success of this implementation highlights the need for broader deployment and continuous monitoring to fully realize the benefits of advanced gas handling techniques in similar well conditions.