Abstract: A submersible pump system and method for producing oil from gassy wells is disclosed in which at least first- and second-stage gas separators protect a submersible pump from vapor lock. The pump communicates with the production tubing and is driven by a shaft extending from a motor, through the first- and second-stage gas separators. The first-stage gas separator has a first-stage inlet through the housing in communication with the production fluid from the producing formation. A primary means for separating gas components from the production fluid is in communication with the first-stage inlet and expels separated gas into the annulus through a first-stage gas outlet and advances the liquid component of the production fluid through the first-stage liquid outlet. The second-stage gas separator has a second-stage inlet communicating with the first-stage liquid outlet and leading to a secondary means for separating the gas from the production fluid.

Abstract: A method for constructing a multiple-stage gas separator assembly for downhole use upstream of a hydrocarbon producing submersible pump system is disclosed which has steps for forming a first-stage gas separator from a first conventional single-stage gas separator, connecting a coupling assembly to the first-stage gas separator at its downstream end, forming a second-stage gas separator from a second conventional single-stage gas separator by removing all lower flanges upstream of its fluid inlet, connecting the upstream end of the second-stage gas separator to the coupling assembly, and establishing a flow path from the first-stage liquid outlet to the second-stage inlet through the coupling assembly.