Historical Review of Artificial Historical Review of Artificial Lift in EgyptLift in Egypt

ByByM. Ghareeb M. Ghareeb

(Lufkin Middle East)(Lufkin Middle East)

I. F. ZahranI. F. Zahran(Egyptian Petroleum corporation)(Egyptian Petroleum corporation)

outlineoutline The history and the future application of the artificial lift The history and the future application of the artificial lift

system in the Egyptian oil fields. system in the Egyptian oil fields. The main operating problems.The main operating problems. The actions taken to overcome or improve these The actions taken to overcome or improve these

problems. problems. Special emphasis is given to the artificial lift systems in Special emphasis is given to the artificial lift systems in

the marginal fields.the marginal fields.

OIL FIELDSOIL FIELDSGAS FIELDSGAS FIELDS

EGYPT EGYPT Oil / CondensateOil / Condensate & & GasGas PRODUCTION PRODUCTION

SETTIHAPY

EL TEMSAHWAKAR&KERSH

PORT FOUAD

TAO

THEKAHKAMOSE

MANGO

SETH

QANTARRA

E. DELTA

KHILALA

SIMIANSAFFRON

SCARABROSETTA N. BALTIM

BALTIM

ABU MADIEL WASTANI

NW. QARA

W. ABU MADI

DISUQ

N. ABU QIR

W. ABU QIRABU QIR

KANAYES

RAS KANAYES

TAREK

HOURS

N. ALAMEINALAMEIN

E. RAZZAKAGHAR

RAZZAK

YADMA

OBAYIEDEMRY

FALAK

TUTW. TUTUM BARKA

Salam

S. UMBARKA KHALDA

HAYAT

DORRAMAN

M. NEMELEIHA

LOUTSM. SE

KARNABARDYZAHRA

YASSERSAFIR

S. DABAA

SITRA – 1&3

SITRA – 5

BED-2

BED-3

BED-15 NE. ABU GHARADIG

ABU GHARADIG

N. ABU GHARADIG

WD-33

WD-33/1

GPCABU SENNAN

BED-1

BED-4 WD-19

QARUN

W. QARUN

BENI SUEF

DARAG

SUDRMATARMA

ASLWARDA

RAHMI

AMER

BAKR

W. GHARIB

RAS GHARIB

EL AYUNUM EL YUSR

KAREEMKHEIR

SHUKHEIRGS 365-373

AMALSIDKIE. ZEIT

GAZWARINAZEIT BAY

RAS EL ESHRAS EL BAHAR

GEMSA

GEMSA-SEGEISUM

E. MALLAHA

RABEHWADI SAHL

HURGHADA

FELEFEL

HAREED

TAWILA

ASHRAFI

BAHAR-NEHILAL

SHOAB ALIGH 376

GARA M.WALI YOUNS

NESSIEMMORGANBADRI

RAMADANJULY

GS-300

BELAYIM L.BELAYIM M.

FEIRANSIDRI

ABU RUDEISOCTOBER

RAS BADRAN

N. OCTOBER

CAIROCAIRO

ISMAILIATANTATANTA

ALEXALEX..

MATRUH..

EL HAMRA..

Oil and Gas WellsOil and Gas Wells

OIL WELLS89%

GAS WELLS11%

NATURALFLOWING

ARTIFCIAL LIFT

89 %

11 %

Artificial Lift SystemsArtificial Lift Systems

GL20%

ESP40%

SR34%

J ET4%

PCP2%

PCP % 0.1 1.0 1.9 1.7

J ET % 4.2 3.9 3.3 2.9

SR % 24.7 26.1 28.5 30.5

ESP % 34.3 35.8 36.6 36.2

GL % 22.1 20.3 17.8 17.8

FLOWING % 14.6 12.8 11.9 10.9

1999 2001 2003 2005

History of The Artificial Lift System

Selection of Artificial LiftSelection of Artificial Lift

Production rate

Experience

Capital Cost

Availability

Well Completion

Common Artificial Lift Completion

Single Zone completion

Commingle completions

Selective completion

•Pumped off

•Gas Interference

•Solids (sand, debris)

•Corrosion

•Scale

Pump Problems Resulted from:

Low production wellsLow production wells Shallow wellsShallow wells Low gas oil ratio wellsLow gas oil ratio wells

Beam Pumping System Beam Pumping System

Medium production wells from medium depth

•Western desert •1000 BFPD from depth 6500 ft ( N-nada field)

•700 BFPD from 7000 ft (Sheiba field)

•1600 BFPD from 3500 ft ( Faras field)

Sucker Rod Completion

Average Static Reservoir Pressure

0

500

1000

1500

2000

2500

1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006

Date

Pre

ssu

re,P

SIA

Failure History of Sucker Rod Pumping Failure History of Sucker Rod Pumping ComponentsComponents

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

% F

ailu

re

Beam Unit 2 2 3 2 3 4

Tubing 9 8 9 7 5 5

DHP 50 51 50 54 52 52

Sucker Rod 39 39 38 37 40 39

2000 2001 2002 2003 2004 2005

Average Run Life for a Sucker Rod Average Run Life for a Sucker Rod Pumping System (W.D)Pumping System (W.D)

0

100

200

300

400

500

600

700

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005

Year

Ru

nn

ing

Lif

e, d

ay

s

Pump

Rod

Electrical Submersible Pumping System Electrical Submersible Pumping System (ESP)(ESP)

OffshoreOffshore High volume wellsHigh volume wells Water production wellsWater production wells

Medium to Low volume wellsMedium to Low volume wells(1000 -200 BFPD)(1000 -200 BFPD)

Average Run Life for an ESP in a High Average Run Life for an ESP in a High Water cut field (Active Water Drive Water cut field (Active Water Drive

Reservoir) Reservoir)

0

20

40

60

80

100

120

2000 2001 2002 2003 2004

Year

Ru

nn

ing

lif

e, m

on

th

Average Running Life For ESP “W.D”Average Running Life For ESP “W.D”

Ras Fanar Field Location MapRas Fanar Field Location MapESP component failures

Ras Fanar ESP Failure FrequencyRas Fanar ESP Failure Frequency

0 5 10 15 20

Penetrator failure

ESP parted at D/Hsensor

Cable

Protector

Gas Separator ShaftBroken

Broken Pump Shaft

Motor failure

Number Failure

Average Total System Efficiency for the Different Artificial Lift Systems for WD Area

(end of 2000)(end of 2000)

67

39.534.4

17.6813.84

0

10

20

30

40

50

60

70

80

PCP SR ESP Jet HPP

Artificial l ift system

Average Total System Efficiency for the Different Artificial Lift Systems for WD Area

(end of 2004)(end of 2004)

67

47

31

21

0

10

20

30

40

50

60

70

80

PCP SR ESP Jet

Artificial lift system

69

48

35

17

0

10

20

30

40

50

60

70

80

PCP SR ESP Jet

Artifcial Lift Sysytm

To

tal

sy

ste

m E

ffe

nc

y %

Average Total System Efficiency for the Different Artificial Lift Systems for ED Area

(end of 2000)(end of 2000)

MARGINAL FIELDSMARGINAL FIELDS

LESS THAN

5 MILLION BBLS

OIL RESERVE

CASE HISTORIESCASE HISTORIES

1- ZARIF FIELD

2- RAS EL HEKMA FIELD

MEDITERRANEAN SEA

RED SEA

WESTERN DESERT

ZARIF FIELDZARIF FIELD

55 Km From Meleiha Field

6 Oil Producing Wells

1 Water Source Well

1 Water Injector Well

2500 Bopd

30 % Water Cut

0

200

400

600

800

1000

1200

1400

1600

1800

Mar-94 Jun-94 Sep-94 Jan-95 Apr-95 Jul-95 Oct-95 Feb-96 May-96 Aug-96

Time

Pre

ssu

re ,

PS

I

Cumulative production @ June 1996 1.7 MMSTB

Zarif Field: Reservoir Pressure Zarif Field: Reservoir Pressure PerformancePerformance

power fluid to wellsMain manifold

Ves

sel

Tri

ple

x u

nit

Tri

ple

x u

nit

Tri

ple

x u

nit

Tri

ple

x u

nit

Zarif Field: Jet Pumping SystemZarif Field: Jet Pumping System

Zarif Field: Water Injection SystemZarif Field: Water Injection System

GENERATOR

TRANSFORMER

SWITCH BOARD

CHEMICAL INJ. UNIT

WELL Z-9 (ESP) WELL Z-6

SOURCE INJECTOR

0

0.5

1

1.5

2

2.5

3

3.5

1994 1995 1996 1997 1998 1999 2000 2001 2002

Lif

tin

g C

ost

$/B

BL

Zarif Field: History of the Lifting CostZarif Field: History of the Lifting Cost

Jet pumping

Beam pumping

MEDITERRANEAN SEA

RED SEA

WESTERN DESERT

RAS EL- HEKMA FIELDRAS EL- HEKMA FIELD

70 Km From Meleiha Field

1 Oil Producing Well

250 Bopd

16 % Water Cut

WELL COMPLETIONWELL COMPLETION WELL COMPLETIONWELL COMPLETION

S.S.DS.S.D

PackerPackerLanding nippleLanding nippleLanding nippleLanding nipple Perforated jointPerforated joint

Setting nippleSetting nipple

7" Casing7" Casing

3 1/

2" T

ub

ing

3 1/

2" T

ub

ing

Surface unit type Mark-IISurface unit size 912 D-365-144PPRL, Ibs 29681MPRL, Ibs 9320Motor HP 72Rod size 87Max. rod stress, PSI 31425Min. rod stress, PSI 4227Rod loading % 61.5Tubing size , in 3 1/2down hole pump size 2.0Down hole pump type RHWCPumping depth , ft 7500Dynamic fluid level 6500production rate ,BOPD 200Bs&w , % 16

SR SPECIFICATIONSR SPECIFICATION

TO MELEIHA - EL HAMRA PIPE LINE

DEMULSIFIER INJ.

500 BBLS

TANK

500 BBLS

TANK

Ras El Hekma: Production System

One of the real challenges facing the oil industry in Egypt is to keep up production and maximize reserves in mature oil fields.

The application of proper artificial lift systems is key to improving productivity of the mature and marginal fields .

Conclusion and Recommendations

Artificial lift system for marginal fields must be operationally flexible

Profitability in development of marginal oil fields can be improved by the sharing and / or renting of facilities .

Conclusion and Recommendations

For solution drive and low productivity reservoirs , the Sucker rod system proved to be the most suitable lifting system.

The original field development plan should address all known constraints and consider future changes to the lift method .

Conclusion and Recommendations

Managing the artificial lift requires continuous production performance monitoring , technology transfer and training for company personnel .

For active water drive reservoirs , all the artificial lift systems work efficiently .

The choice of a suitable type of AL depends on the required production rate and field location.

Conclusion and Recommendations

Historical Review of Artificial Historical Review of Artificial Lift in EgyptLift in Egypt

ByByM. Ghareeb M. Ghareeb

(Lufkin Middle East)(Lufkin Middle East)

I. F. ZahranI. F. Zahran(Egyptian Petroleum corporation)(Egyptian Petroleum corporation)