Inefficient well operations result from a variety of poor production operations. An improperly designed rod string, improper size pump, incorrect stroke length, over-sized pumping unit, improperly sized motor, excessive casing pressure and many other parameters of a beam pumping system can result in inefficient operations. One of the most common causes of low efficiency is an efficient downhole gas separator. The low efficiency can result in excessive electrical power usage, a decrease in the amount of production from the well and additional maintenance requirements due to inefficient loadings of the pumping unit, rod string, motor and pump.1,6 & 7 Inefficient gas separators can be identified by obtaining an acoustic liquid level test which indicates a high gaseous liquid column above the pump and the analysis of dynamometer data which indicates incomplete pump fillage. Periodic acoustic liquid level tests and dynamometer measurements should be performed to verify that the downhole gas separator is operating efficiently. Tapping bottom with the pump, running the pumping unit at excessive speed, operating the pumping unit for excessive periods of time, increasing the tubing pressure or increasing the casing pressure is not the proper procedure for correcting inefficient downhole gas separation. Progressive cavity pumps operate much more efficiently with proper lubrication. A good gas separation that removes free gas from the liquid that enters the PC pump results in longer pump life, additional production and more efficient electricity usage and operation.
The first attempt to correct inefficient downhole gas separation should be to set the pump below the fluid entry zone if feasible. This is the most efficient method of downhole gas separation. However, if the pump is set above the fluid entry zone, a gas separator should be used that offers an efficient gas/liquid separation chamber with low dip tube friction loss which results in complete pump fillage if sufficient liquid inflow into the wellbore is available.
Downhole gas separators are divided into two types that are very different. If the gas separator is placed below the fluid entry zone, a single dip tube type of gas separator should be used below the pump seating nipple. If the gas separator is placed in or above the fluid entry zone, a gas separator assembly should be used that consists of an outer barrel having ports at the top of the barrel with a dip tube extending from the pump inlet down into the outer barrel and opening below the ports. An operator should be able to tell whether a gas separator is being used above or below the formation after viewing the gas separator. They should be built differently. In this paper, the outer barrel of the gas separator to be used above the formation is called outer barrel. It is sometimes called a mud anchor. The inner tube is called a dip tube and it is sometimes called a gas anchor. Clegg 2,3,4 discusses many types of gas separators and the principles of gas/liquid separation.
