Can Shrouds Be the Fix for Gas-Prone Wells?

Field trials in 35 Surmont wells show shrouded ESPs can cut gas interference and boost production reliability

22 Aug 2025

Canadian oil sands producers are reporting field evidence that shrouded electric submersible pumps (ESPs) can stabilise output in steam-assisted gravity drainage (SAGD) wells prone to gas interference.

At the SPE Gulf Coast Section ESP Symposium in August 2025, researchers presented results from more than 35 wells at Surmont in northeastern Alberta. Specially designed canned ESPs and inverted shrouds were deployed to counter the effects of non-condensable gas entering the pump intake. In most cases, the modifications restored lifting efficiency and increased liquid production, reducing the erratic performance caused by gas slugging and vapour lock.

Non-condensable gas co-injection is widely used in late-life SAGD to manage chamber pressure and lower steam-to-oil ratios. However, the return of this gas to producer wells can disrupt pumping systems. The Surmont trials suggest that shrouds, which guide fluid flow and divert gas away from the intake, can improve stability under these conditions.

The findings are significant for Canada, where ESPs are the dominant artificial lift method in SAGD wells and equipment reliability is central to both cost control and emissions performance. Improved gas handling at the pump intake reduces unplanned interventions, allowing wells to remain on stream for longer and supporting steadier production in one of the world's most challenging heavy oil environments.

Researchers said the results highlight the potential of relatively simple design modifications to address long-standing issues in SAGD operations, offering operators a path to greater efficiency and reliability without major system overhauls.