When reservoir fluid has high free gas content at pump intake, such key parameters of the pump as flow rate and developed pressure are deteriorated significantly.
In this case a Gas separator is usually installed before the pump to recover its efficiency and allow higher initial gas content in fluid.
Gas separator decreases GVF (Gas Volume Factor) down to figures acceptable for the pump. Free gas in rotary gas separators is centrifugally accumulated near to center line and then channeled back to the casing annulus.
Another complicating factor which affects the successful ESP operation is abrasive wear due to high solids presence. As a result, protective liner and housing of the gas separator were worn dramatically and sometimes they were even cut off by solids, so part of ESP system got lost in hole.
Novomet designers developed brand new abrasion resistant gas separator of 362 and 406 series. The main idea was to minimize vortex formation and recirculation flow structures. This approach was successfully proved during testing and such design led to several times higher abrasion resistance than it was before.
Separating ability of different designs was simulated by CFD methods and then proved by full-scale tests.
Abrasion resistant gas separators (ARGS) are available in two series:
- 362 series: N362GS1500 AR2 – for pumps with rated capacity up to 1500 bpd;
- 406 series: N406GS3800 AR2 and N406GS2600 AR2 – for pumps with rated capacity up to 3800 and 2600 bpd, respectively.
Coming soon abrasion resistant gas separators:
- of 449 and 535 series
- high capacity ARGS N362GS4500 AR2 and N406GS6800 AR2.
- protective liner from corrosion resistant Cr-Ni stainless steel
- axial thrust bearing in protector
- application of a shaft with involute splines increases its max brake horsepower
- bearing bushings are from hard alloy
- corrosion resistant modification is available
1. Application for complicating factors:
• high TSS (solid content) – up to 350 ptb
• high GVF at intake – up to 85%
• wells after hydraulic fracturing
2. Separation process was optimized by CFD methods and extensive empirical study done at separation and abrasion test benches.
3. Design features of pressure and separating modules are unique and patented.