Looking for ChampionX upstream chemical solutions? Click Here

Gas Control

Gas in a production stream can drive down the efficiency of some artificial lift systems, or cause them to stop working altogether.

Designing the right artificial-lift system to operate with a steady state flow of gas is challenging enough. But the challenges only multiply during intermittent gas production, or slugging. If your lift system is not properly selected and designed to handle gas, you can expect an expensive well intervention to replace the system with another type of lift.

ChampionX’s Gas Control Solutions

Our lift experts approach gas control with a three-phase strategy aimed at minimizing pump damage and optimizing performance.

Phase 1 – Separate and Divert

Our primary control solution focuses on separating the bulk of gas from the production stream and diverting it to the annulus before it can enter the pump. We achieve this two ways:

  • Passive devices. SPIRIT Gas Separators contain an internal baffling system that separates the gas from liquids. ChampionX ESP  Gas Anchors are perforated tubulars attached to an ESP that control the entrance of gas. Both systems provide simple, effective gas separation without any moving parts.
  • Active devices. Our WHIRLAWAY® Rotary and Vortex Gas Separators effectively isolate and expel free gas to the annulus, reducing free gas volumes from entering the downhole pumps in an ESP system. The pumps work more effectively and for longer periods with a lower risk of gas locking.

Phase 2 – Robust Pump Designs

Apergy Artificial Lift's division designs pumping solutions that effectively handle certain volumes of gas, without significant losses of operational efficiency.

  • With no moving parts, ChampionX jet pumps process fluids with GLRs as high as 2,000:1, with no risk of gas locking.
  • For intermittent gas production, our Harbison-Fischer Variable Slippage® Pump (VSP), a sucker-rod-drawn, positive-displacement pump, enhances production by eliminating gas lock. The pump’s tapered barrel allows some separation of gas from the production stream, creating a pressure equalization that boosts production while extending sucker-rod life.

None of our products are simply off-the-shelf, one-size-fits-all solutions. Our product specialists work with you to first understand your well’s unique gas challenges, and then carefully design the right gas control solution to extend the productive life of the asset.

Phase 3 – Control

ChampionX Artificial Lift's division provides industry-leading control systems that sense changes to gas content in the production stream and then make real-time changes to the lift system’s operation. For example, our Theta Oilfield Services XSPOC diagnostic software suggests changes to rod pump speed as free gas volumes change, and gives the user the opportunity to change stroke speed remotely. For ESPs, our LOOKOUT Monitoring system uses real-time production data to give an early warning of gas locking, allowing you to quickly change parameters such as ESP rotational speed to accommodate.