ESP: Gas handling device

Gas  handling  devices  may  be  a  better  alternative  for  wells  prone  to  high  free  gas, slugging, foams and emulsions. These are essentially centrifugal pumps with large stages, mixed  (or  axial)  impellers,  large  vane  openings,  steep  vane  exit  angles  and  sometimes include multiple  vanes. 

Instead of separating, their purpose is to break large gas bubble into smaller ones thereby reducing the risk of gas locking and making it easier for gas to be re-absorbed into solution, and to homogenize the gas with liquid phases, prior to entering the pump intake.

An additional benefit of gas handlers is, because more gas is retained in the flow stream, this gas is then available to help lift fluids in the tubing above the ESP discharge head thereby reducing hydraulic horsepower requirements.

Applications: A Gas Handler is generally considered if the Free Gas Percentage at the intake of the pump is from 30% to 60% by volume.

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ESP: Pump Intake

As the name suggests “ Pump Intake ” is where the well fluid enters the Submersible Pumping System. Care should be taken when designing a submersible pump intake because it is such a vital point in the system that when not designed properly may create all kinds of problems.

There are three types of intake Sections:

  • Standard Intakes or BOI (bolt on intake),
  • Integral (manufactured as part of the pump),
  • Gas Separators (static and rotary gas separators).

Standard and Integral Intakes:

Standard intakes (BOI and integral) do not separate gas.  Some gas separation might occur, but it will only be natural separation due to some of the gas not turning and going into the intake when the rest of the fluid does. Therefore, the standard intake is for wells that produce with a very low free gas to liquid ratio. The amount of free gas by volume at pump intake conditions should be no more than 10% to 15% by volume (depends if it is a radial or mixed flow stage)
                           

Usually, the pump intake is a separate component that bolts onto the bottom of the pump section. Occasionally, the pump is built in either a lower tandem or single configuration. In these cases, the pump intake as an integral part of the pump assembly.

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ESP: Pump Stage

A “ Pump Stage ” consists of an impeller, diffuser and thrust washers. As shown by the following figure, the impellers rotate with the shaft and spin at the RPM of the motor. The stationary diffusers turn the fluid into the next impeller and do not rotate. Pumps are assembled by stacking stages on a shaft and compressing the stack in a housing. A stage will produce a given amount of flow and lift (head) at the motor RPM.

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Updated list of API and ISO Standards for Gas Lift

In this article, the last updated list of API and ISO standards for Gas Lift is presented. These standards can be considered as reference documents as well as a basis for training classes in the subject of Gas Lift.

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Gas lifted well: Operations & unloading process

Gas lift operations and unloading procedure are described in the following demonstration video:

In order to further explain all these aspects and more simplify the process, gas lift operations have been described in the next paragraphs:

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