Enhancing the Reliability of Electric Submersible Pumps in Challenging Operating Environments Using Advanced Engineering Solutions

This study examines current trends in downhole oil production, with particular emphasis on the growing prevalence of complex wells resulting from the widespread application of advanced stimulation technologies. Special attention is given to the operation of electric submersible pump units (ESPUs) in Russia and the Eurasian region, as well as to the operational challenges associated with their use. High gas content and the presence of solid particles in produced fluids are identified as the primary factors contributing to ESP failures. To mitigate these effects, the implementation of abrasion-resistant gas separators is proposed. Field statistics indicate that approximately ۱۰۰ gas separators are installed monthly on Russian oil wells. The paper presents experimental results for several separator designs, together with a methodology for accelerated resource testing under laboratory conditions. The findings demonstrate that separator wear is highly localized but can lead to severe damage under harsh operating conditions. A technique for preventing housing cutting and structural degradation of gas separators is also proposed, significantly reducing the probability of equipment failure. Implementation of the proposed engineering solutions is expected to improve separator reliability, reduce material and time expenditures associated with failure remediation, and enable refurbishment and reuse of equipment. These improvements contribute to enhanced economic efficiency of oil production operations. The scientific and practical significance of the work lies in the development of new technological approaches that increase equipment reliability while reducing operational risks in complex wells.

کلیدواژه ها:

oil production ، gas separators ، Downhole ، Electric Submersible Pumps ، Accelerated Life Testing ، Abrasion resistance