historical review of artificial lift in egypt by m. ghareeb (lufkin middle east) i. f. zahran...
TRANSCRIPT
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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)
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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.
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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..
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Oil and Gas WellsOil and Gas Wells
OIL WELLS89%
GAS WELLS11%
NATURALFLOWING
ARTIFCIAL LIFT
89 %
11 %
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Artificial Lift SystemsArtificial Lift Systems
GL20%
ESP40%
SR34%
J ET4%
PCP2%
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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
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Selection of Artificial LiftSelection of Artificial Lift
Production rate
Experience
Capital Cost
Availability
Well Completion
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Common Artificial Lift Completion
Single Zone completion
Commingle completions
Selective completion
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•Pumped off
•Gas Interference
•Solids (sand, debris)
•Corrosion
•Scale
Pump Problems Resulted from:
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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)
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Sucker Rod Completion
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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
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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
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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
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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)
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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
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Average Running Life For ESP “W.D”Average Running Life For ESP “W.D”
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Ras Fanar Field Location MapRas Fanar Field Location MapESP component failures
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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
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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
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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
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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)
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MARGINAL FIELDSMARGINAL FIELDS
LESS THAN
5 MILLION BBLS
OIL RESERVE
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CASE HISTORIESCASE HISTORIES
1- ZARIF FIELD
2- RAS EL HEKMA FIELD
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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
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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
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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
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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
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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
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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
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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
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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
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TO MELEIHA - EL HAMRA PIPE LINE
DEMULSIFIER INJ.
500 BBLS
TANK
500 BBLS
TANK
Ras El Hekma: Production System
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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
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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
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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
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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
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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)