Introduction of Dynamic Gas Separation to SAGD

Summary Gas production in steam assisted gravity drainage (SAGD) operations presents significant challenges, including reduced production rates, shortened ESP run-life, and unstable production. This paper demonstrates the effectiveness of integrating dynamic gas separation with existing gas avoidance methods within the same ESP string to address these issues. A series of diagnostic analyses were conducted on electrical submersible pumps (ESPs) experiencing frequent No-Flow Events (NFEs) due to gas-locking, revealing that gas-oil ratio (GOR) values had been underestimated by approximately 500%. To mitigate these challenges, the Upper Tandem Gas Separator (UT- GS) was introduced and installed above the Bottom Feeder Intake (BFI) in SAGD ESP applications. UT-GS employs vortex action to dynamically separate free gas, venting it to the annulus while maintaining compatibility with existing gas avoidance strategies. Field deployment of the UT-GS in over 50 wells since March 2024 has yielded an average production increase of 25% and a reduction in motor amperage fluctuation. The system has proven effective in wells with ESPs installed near-horizontal, eliminating NFEs and stabilizing motor performance. The UT-GS adds less than 1 meter to the ESP string and does not affect maximum allowable frequency (MAF), as it separates gas without contributing significant head. Unlike conventional gas-handling ESP designs that require over-staging and higher power input, the UT-GS operates with only ~5 hp of additional power. This configuration enables comparable or improved production rates with up to 50% lower power consumption. The results indicate that UT-GS provides a reliable and efficient solution for gas management in SAGD ESP applications.