INTAKES
As the name suggests “Intakes” are where the well
fluid enters the Submersible Pumping System.
INTAKES
There are three types of intake Sections:
Standard Intakes or BOI (bolt on intake)
Integral
Manufactured as part of the pump
Gas Separators
Pump Intakes
Standard, BOI and
integral intakes do not
separate gas.
Some gas separation
might occur, but it will
only be natural
separation due to a
percentage of the gas
not turning and going
into the intake when
the rest of the fluid
does. Bolt-on Intake
Integral Intake
Standard Intakes
Intakes can be either ARZ, which
is the preferred configuration, or
standard.
The ARZ intake uses Zirconia
bearings and sleeves to better
protect against abrasive wear
and lateral vibration. This is
important so near a protector
seal.
ARZ Intakes
REDA Engineering recommends that only ARZ type
intakes be used, because the reliability of the unit
(especially the protector) will be greatly enhanced by
the durability of the compliant Zirconia bearings.
ARZ Intakes are available in 338, 387, 400, 540, 562, and
675 series
INTAKES
Intakes are available in various combinations of
Carbon Steel and Redalloy, Monel and Inconel shafts,
ARZ, ARZ-SS and ARZ-ZS bearing pairs for all pump
series
Static Gas Separators
Original gas separator designs were based on increasing
gas separation by forcing the fluid flow to reverse in
the well-bore. This is where the name of this type of
gas separator, REVERSE FLOW, comes from.
Since this type of gas separator does no real "work" on
the fluid, it is also called a "static" gas separator.
Static (Reverse Flow) Gas Separator
As well fluid enters the gas
separator it is forced to
change direction.
Some of the gas bubbles
continue to rise instead of
turn - or rise inside the gas
separator and exit the
housing back to the annulus.
INTAKE / GAS SEPARATOR
STATIC GAS SEPARATOR/
REVERSE FLOW GAS SEPARATOR
• Fluid comes in the screen with
approximately 60° of angle
• Fluid will be reversed and sent
up to the pump by pick up impeller
• Effective to separate up to 20% of
gas volume content in the
producing fluid
REDA 65 GS
Gas Separator
Reverse Flow Type Gas Separator
Angle drilled holes
Angle drilled holes
65 Type RF Type
Static Gas Separator Static Gas Separator
REDA Gas Avoider Intake
For Deviated Wells
REDA Gas Avoider Intake
For Deviated Wells
REDA GAS AVOIDER
Dynamic Gas Separators
Dynamic is defined in the dictionary as
“Force Producing Motion”
Which implies that this type of gas separator uses
force.
Dynamic Gas Separators
Dynamic gas separators actually impart energy to the fluid in
order to get the vapor to separate from the liquid.
The original gas separator was called a KGS (short for either
Kinetic Gas Separator or Kobylinski Gas Separator).
This design uses an inducer to increase the pressure of the
fluid and a centrifuge to separate the vapor and liquid.
This design could likewise be called a CENTRIFUGAL, or
ROTARY gas separator.
In high GOR wells the REDA rotary gas separator removes the free gas from the produced
fluid. By venting this gas to the annulus, the separator prevents cycling, gas lock and
cavitation resulting in a stable motor load and increased run life.
The rotary separator uses centrifugal force to separate the free gas. The gas/fluid mixture
enters the intake ports and moves to the screw type inducer.
Here, the pressure of the fluid is increased and moved to the centrifuge where the
separation occurs. The fluid is forced to the outside of the separator and on to the first pump
stage. The lighter gas rises through the flow divider and is vented to the annulus.
For lower GOR applications, a reverse flow separator or standard ported intake are
available.
Inducer
Dynamic Gas Separators
Dynamic gas separators have gone through an evolution at
REDA; and as with other products have been improved upon as
newer models have been introduced.
The first REDA dynamic gas separator the KGS was introduced
in 1982 and has been through several upgrades.
Dynamic Gas Separators
The rotary gas separator design works in a
similar fashion to a centrifuge.
The first model had centrifuge "paddles"
spinning at 3500 rpm - and was believed to
cause the heavier fluids to be forced to the
outside, through the crossover and up into the
pump, while the lighter fluid (vapor) stays
toward the center, and exits through the
crossover and discharge ports back into the
well.
INTAKE / GAS SEPARATOR
ROTARY GAS
SEPARATOR
Fluid come in through the
screen, up to the Inducer
Inducer centrifuges the fluid
Centrifugal effect separates
vapor from the liquid
Heavier fluid moves to the
housing, gas stays around the
shaft
Liquid is directed to the pump,
gas directed back to annulus
Effective to separate gas up
to 60% of total gas content
Dynamic Gas Separators
The KGS and RS technology of dynamic gas separation was
a large step forward in gas separator efficiencies, but they
had limitations.
Because of the large mass on a long unsupported shaft,
these gas separators tended to experience bearing failures
more often than other types of equipment.
Dynamic Gas Separators
Some of the bearing failures were due simply to the fact that
gas (vapor) does not lubricant well. The addition of Zirconia
bearings provided a benefit here.
Some failures could be attributed directly to abrasives. The
addition of Zirconia bearings also extended the life of the
earlier gas separators.
Dynamic Gas Separators
Engineering determined the design was still not as reliable as it
should be and more work was required.
The problem was the extended length of unsupported shaft in an
area with a rotating mass of very high inertia.
This may be radially unbalanced either in manufacture, or in
operation; because it is filled with a non-homogeneous (non-
uniform) fluid of variable specific gravity. It may also be eroded
unevenly by abrasives with time - or even a combination of all three.
Dynamic Gas Separators *RS-ES
The next step in the evolution of the dynamic separator
significantly reduced the mass of the rotating element and
decreased the radial bearing spacing. Result: the *RS-ES
separator.
Mass
ARZ Bearing
Eliminated
L1
Mass L2
Eliminated
ARZ Bearing
ARZ Bearing
Dynamic Gas Separators *RS-ES
Increasing the residence chamber section improves the
overall performance but increases the bearing spacing
potentially reducing reliability.
Gas
Liquid
Dynamic Gas Separators *RS-ES
The larger vertical blades in the old models of gas separators
KGS/*RS actually remixed the already separated fluid. This
took additional power and reduced the effectiveness of the
separation.
From a technical perspective, the *RS-ES made the existing
*RS separators redundant.
Dynamic Gas Separators *RS-ES
The Enhanced Stability Rotary Separator *RS-ES is
currently available in Redalloy construction, in 387, 400 and
540 series and is the recognised standard for most
applications where the vortex type gas separators are not
available.
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Inducer
Dynamic Vortex
Gas Separator
Discharge Crossover
Multiple vortex generators
Multiple flow-through ARZ
bearings
Axial flow inducers
Dynamic Vortex Gas Separator
Vortex Gas Separators
The vortex gas separator is currently available
in 400 and 538 Series, VGSA D20-60 in 400 and
VGSA S20-90 and S70-150 models in 538.
The VGSA includes the following features in its
standard construction:
Redalloy
High strength shaft
ARZ
monel trim.
Gas Separators Efficiency
Testing conducted at Tulsa University actually showed that
natural separation could be as much as 60 %; and that with a
REDA rotary gas separator, total separation efficiencies
could be as high as 99 %.
The testing also indicated that gas separators (all types) do
have definite flow ranges where they are effective and other
flow ranges where they are not. The TU tests agreed well
with REDA's assessment.
Dynamic Gas Separators
The total fluid volume (O+W+G) must be within the
permissible operating range of the Gas Separator
selected for the application.
Gas Separators Efficiency
When we talk about gas separator performance we are
normally interested first in separation efficiency.
Free gas separated
Separation Efficiency =
Free gas available
Gas Separators Efficiency
We might also talk about gas separator performance in
terms of "gas ingestion percentage"
This GIP is simply 1 - Separation Efficiency.
GIP quantifies how much of the free gas present at the
intake would go into the pump. Normally this will include
natural separation also.
Gas Separators Efficiency
Separation efficiency is not an easy number to predict
due to the number of variables involved.
Natural separation alone might vary from as low as 5 %
to as high as 70 % depending on the fluid makeup,
velocities, flow patterns, equipment dimensions, etc.
Some Factors Impacting the Natural and
Mechanical Separation
Hydrocarbon Components Bubble Point, etc.
Casing and Equipment Size Flowrate
% Free Gas by Volume at Construction of Mechanical
Intake Separator
Pump Intake Pressure and Equipment Obstruction (Y-
Temperature Tool)
GLR Frequency
Casing Pressure
Wellbore Orientation
Gas Separators Efficiency
Normally we would use rule-of-thumb estimates like the
following based on experience:
Separator Type Separation Gas Ingestion
Efficiency Percentage
Standard Intake 0 - 20 % 80 - 100 %
Static (Reverse Flow) 25 - 50 % 50 - 75 %
Dynamic (Rotary) G.S. 80 - 95 % 5 - 20 %
538 Series VGSA S20-90 Gas Separator Efficiency
VGSA S20-90 Performance Curves for % Free Gas by
Volume After Total Separation
100
% Free Gas by Volume Before
80
Any Separation
5%
60
10%
40 15%
20%
20
0
0 2000 4000 6000 8000 10000
Liquid Flow Rate (BPD)
538 Series VGSA S70-150 Gas Separator Efficiency
VGSA S70-150 Performance Curve for % Free Gas by
Volume After Total Separation
100
Before Any Separation
% Free Gas by Volume
80
5%
60 10%
15%
40
20%
20
0
0 5000 10000 15000
Liquid Flow Rate (BPD)
Comparision at 15 % Free Gas by Volume After
Total Separation
% Free Gas by Volume Before Any
100
80
Separation
60 VGSA S70-150
VGSA S20-90
40 OLD TECH
20
0
0 3000 6000 9000 12000 15000
Liquid FLow Rate (BPD)
400 Series VGSA D20-60 Gas Separator Efficiency% Free Gas by Volume
Through the Pump After Total Separation
100
90
80
5% in to pump
% FREE GAS BY VOLUME BEFORE *
10% in to pump
70
15% in to pump
ANY SEPARATION
60 20% in to pump
50
40
20%
30
15%
20
5% 10%
10
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
LIQUID FLOW RATE AT INTAKE (BPD)
Application of Dynamic Gas Separators
From a technical perspective, the CRS-ES and DRS-ES made
the CRS and DRS redundant.
The VGSA D20-60 can be an advantage over 1000 bpd. As the
graph indicates efficiency above 5500 bpd, is not good.
In 7" and higher applications, the VGSA S20-90 or VGSA S70-150
should be utilized to replace the 540 Series GRS-ES and the
obsolete models KGS and GRS, especially in abrasive
applications.
Laboratory test of the VGSA S20-90 suggest near 100%
effectiveness in the lower range.
Application of Dynamic Gas Separators
The vortex gas separator is currently available in 538 Series
VGSA S20-90 and VGSA 70-150 models and in 400 Series VGSA
D20-60 only.
Standard construction includes:
Redalloy
1.187" High strength shaft for the 538 Series and .875”
Inconel shaft for the 400 Series
ARZ
monel trim.
Application of Dynamic Gas Separators
The total fluid volume (Oil, Water and Gas) must be
within the permissible operating range of the Gas
Separator selected for the application.
Permissible Flow Ranges(in bpd total fluids at 60 Hz)
TYPE MAX. RATE MAX. RATE MINIMUM
(EFFECTIVE) (PERMISSIBLE) RATE
338 Series
ARS (338 Series) 2440 BPD 250 BPD
400 Series
65GS 1750 BPD 4300 BPD NA
RF 2500 BPD 6000 BPD NA
DRS, DRS-ES 4000 BPD 500 BPD
VGSA D20-60 5500 BPD NA
513 / 538 Series
74GS 3600 BPD 9000 BPD NA
RF 4800 BPD 12000 BPD NA
GRS, GRS-ES 7000 BPD 1000 BPD
VGSA S20-90 9000 BPD NA
VGSA S70-150 15000 BPD NA
Application of Dynamic Gas Separators
Rarely do we get something for nothing.
This holds true for gas separators too.
Rotary gas separators require power, though they do
some work as well.
The horsepower requirement for operation of the gas
Separator have to be added and considered when
selecting the ESP motor.
Application of Dynamic Gas Separators
Rotary separator HP required @ 60 Hz
Series 338, ARS 1.75 HP
Series 400, DRS 1.25 HP
Series 400, VGSA D20-60 3.0 HP
Series 540, GRS 7.00 HP
Series 538
VGSA S20-90 6.0 HP
VGSA S70-150 14.0 HP
When to Add Gas Separator OR REDA AGH
% Free
Gas
By 20-25
Volume
Into 15
Bottom
Pump 10
VAPOR X 100
VAPOR+LIQUID 400 540 LARGER
BOTTOM PUMP SERIES