Predicting Gas Separation Efficiency of a Downhole Separator Using Machine Learning

Artificial lift systems, such as electrical submersible pumps and sucker rod pumps, frequently encounter operational challenges due to high gas–oil ratios, leading to premature tool failure and increased downtime. Effective upstream gas separation is critical to maintain continuous operation. This study aims to predict the efficiency of downhole gas separator using machine learning models trained on data from a centrifugal separator and tested on data from a gravity separator (blind test). A comprehensive experimental setup included a multiphase flow system with horizontal (31 ft. (9.4 m)) and vertical (27 ft. (8.2 m)) sections to facilitate the tests. Seven regression models—multilinear regression, random forest, support vector machine, ridge, lasso, k-nearest neighbor, and XGBoost—were evaluated using performance metrics like RMSE, MAPE, and R-squared. In-depth exploratory data analysis and data preprocessing identified inlet liquid and gas volume flows as key predictors for gas volume flow per minute at the outlet (GVFO). Among the models, random forest was most effective, exhibiting an R-squared of 96% and an RMSE of 112. This model, followed by KNN, showed great promise in accurately predicting gas separation efficiency, aided by rigorous hyperparameter tuning and cross-validation to prevent overfitting. This research offers a robust machine learning workflow for predicting gas separation efficiency across different types of downhole gas separators, providing valuable insights for optimizing the performance of artificial lift systems.