This study examines current trends in downhole oil production, with particular emphasis on the growing
prevalence of complex wells resulting from the widespread application of advanced stimulation
technologies. Special attention is given to the operation of electric submersible pump units (ESPUs) in
Russia and the Eurasian region, as well as to the operational challenges associated with their use. High
gas content and the presence of solid particles in produced fluids are identified as the primary factors
contributing to ESP failures. To mitigate these effects, the implementation of abrasion-resistant gas
separators is proposed. Field statistics indicate that approximately 100 gas separators are installed
monthly on Russian oil wells. The paper presents experimental results for several separator designs,
together with a methodology for accelerated resource testing under laboratory conditions. The findings
demonstrate that separator wear is highly localized but can lead to severe damage under harsh operating
conditions. A technique for preventing housing cutting and structural degradation of gas separators is
also proposed, significantly reducing the probability of equipment failure. Implementation of the
proposed engineering solutions is expected to improve separator reliability, reduce material and time
expenditures associated with failure remediation, and enable refurbishment and reuse of equipment.
These improvements contribute to enhanced economic efficiency of oil production operations. The
scientific and practical significance of the work lies in the development of new technological approaches
that increase equipment reliability while reducing operational risks in complex wells.
doi: 10.5829/ije.2027.40.01a.07