Gas Release System Bypass (GRSB): An Advanced Gas-Handling Technology to Enhance ESP Performance in High-GLR Wells

Abstract

The objective of this paper is to present the Gas Release System Bypass (GRSB), an advanced gas-handling and separation technology designed to optimize the performance of Electric Submersible Pump (ESP) systems in high Gas-Liquid Ratio (GLR) and slug-flow environments. The scope includes the system's operating principles, design components, and field validation in wells approaching the limits of ESP operability. The system comprises four key components: a Triple Seal Packer, a Pressurization Chamber, a Centrifugal Regulator, and a Gas Release Bypass section. These components operate in sequence to enhance Gas-Liquid interaction. Initially, large gas slugs are mechanically dispersed into smaller bubbles. Subsequently, an increase in pressure within an enlarged chamber promotes gas reabsorption into the liquid phase. Centrifugal forces further reduce bubble size, enhancing phase homogenization. Finally, residual free gas that cannot be reabsorbed is vented through a controlled one-way bypass system located above the ESP discharge. Field applications conducted in five wells in the Midland Basin demonstrate the effectiveness of the GRSB in improving ESP performance under high-GLR conditions. Comparative analysis of pre- and post-installation data focuses on key operational parameters, including Pump Intake Pressure (PIP), motor current, operating frequency, and motor temperature. Results indicate a production rate increase in all cases, significant stabilization of PIP, reduction in current fluctuations, improved thermal behavior of the motor, and optimization of operating frequency within recommended ranges. Most notably, the implementation of the GRSB enabled wells previously operating outside optimal ESP conditions to return to more stable operating envelopes. This was caused by reduced gas interference effects, improved pump efficiency, enhanced drawdown capability, and fewer unplanned shutdown events related to gas locking and severe slugging conditions. Furthermore, field results demonstrated extended ESP runtime and delayed transition requirements to alternative artificial lift methods. By effectively regulating and removing free gas before it reaches the pump intake, the GRSB provided improved ESP performance under challenging gas-prone operating conditions (Guanacas et al. 2024; Vazhappilly et al. 2025). Overall, the Gas Release System Bypass represents an effective approach for artificial lift optimization, enabling operators to sustain production in wells approaching ESP operational limits while significantly improving system stability, reliability, and efficiency.