By

M. Ghareeb (Lufkin Middle East)

Luca Ponteggia (Agip, Italy)

K. F. Nagea (Agiba Petroleum company)

Beam Pumping System Efficiency Improvement in Agiba’s Western

Desert Fields

G U

L F O

F S

U E

Z

GU

LF O

F A

QA

BA

CAIRO

MELEIHA

W. RAZZAK

M E D I T E R R A N E A N S E A

EL HAMRA

W E S T E R N

D E S E R

T

ASHRAFI

0 100 km.

ALEX.

MATRUH

RED SEA

ZARIF

EL FARASRAML & R. SW

S I N A

I

FARAS SE

Production History of Western Desert Fields

0

10000

20000

30000

40000

50000

60000

70000

Jan-

85

Jan-

86

Jan-

87

Jan-

88

Jan-

89

Jan-

90

Jan-

91

Jan-

92

Jan-

93

Jan-

94

Jan-

95

Jan-

96

Jan-

97

Jan-

98

Jan-

99

Jan-

00

Jan-

01

Jan-

02

Jan-

03

Jan-

04

Jan-

05

Date

Ava

rag

e D

aily

Pro

du

ctio

n, B

PD GROSS, BPD

NET, BOPD

SR85%

PCP1%

ESP13%

N.F1%

W.D. Artificial Lift Systems

Initial Reservoir Data and Fluid Properties For Meleiha Fields

Res Press.

psi

Res. T oF

visc. cp Pb, psia Bo, rb/stb

Rs, scf/stb

API

MW 2250 195 0.85 450 1.125 250 38

Aman 2300 196 0.8 240 1.175 100 40

NE 2250 193 0.8 480 1.26 210 40

SE 2350 198 0.4 1170 1.6 790 42

36,500 lbsstructure rating

66% loaded

912,000 in-lbsreducer rating61.5% loaded

75 hpElectrical ultra high slip

motor48% loaded

86- H T S (N97) sucker rods 60.3% loaded 30-250-RWBC- 24- 4

2.75” seating nipple at +/- 5000 ft

3.5” Tubing

Tubing anchor catcher

Target production

+/- 1000 BPD / well

Average Static Reservoir Pressure

0

500

1000

1500

2000

2500

1985.5 1986 1986.5 1987 1987.5 1988 1988.5 1989 1989.5

Date

Pre

ssur

e ,P

SIA Two Years Later What

Was Happening?

•Upper part of the 7/8” and in the 3/4 “string. •Fatigue failure plus unscrewed couplings

Very Low Equipment Running Lives

•Rod parting

•Unscrewed and leaking valves•Pump stuck

•Down hole pump problems

S.Rod 55%

D.H.P 43%

Other2%

1988, Failures Distribution

•Fast decline in reservoir pressure

•Down hole pumps were bottom hold-down type

•One size of D.H.P. restricted the flexibility

•Lack of experience with sucker rod system

•Mishandling of high tensile type rods

•Weak monitoring system

The Main Factors Affecting the Equipment Performances

•Limitations of subsurface pump design

S.Rod 31%

D.H.P 47%

Other 23%

T. wear 21%

S.U 1%

Where we were in 1993?

Failure Analyses

Failures are divided into four major categories :

•Sucker Rod and polished rod failures

•Down hole pump failures

•Tubing wear

•Surface Pumping Unit failures

• Tensile failures (applied load exceeds the tensile strength of the rod ) or

• Fatigue Failures

All sucker rod, pony rod, and coupling failures are either

Fatigue Failures

Sucker Rod Failures

1. Mishandling2. Gas or fluid pound 3. Design problem4. Wear or rubbing on tubing5. Corrosion6. Operating problems

Common Rod Failure Causes

• Improper handling during pulling and running

• Tools

• Pull rod in double and lay down on racks

• Improper coupling make-up

• Low experience of pulling unit crew

Mishandling

• Stuck Pump

•Traveling and standing valves damage (unscrew).

Down Hole Pump Failure

•Standing Valve

Unscrew

• Mutual friction between sucker rod coupling and tubing inner surface • Tubing and/or sucker rod buckling

• Using 1” sucker rods as a sinker bar with full size 2 3/16” coupling

• The high water cut wells creates less lubrication and cooling between sucker rod and tubing

Common Tubing Failure Causes

Coupling wear Due to tubing

Movement

Corrective Action• Reservoir support and water shut off

• Acquire appropriate data and determine true cause of failure

• Sucker rods • Downhole Pumps

• Tubing wear

• Gas Interference

Reservoir Support by Water Injection

0

500

1000

1500

2000

2500

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

Date

Pres

sure

,PSI

A

Water Injection

Determining Reason For Failures

• Perform failure analysis

• Track failure occurrences

• Execute corrective action

Sucker Rod Handling

•Pull the rods in stands and hang in the derrick

•Use sucker rod power tong

•Transport sucker rods in special sucker rod baskets

•Pulled sucker rods are fully inspected and stored as per API standards

•Translate the API standard procedures for rod handling to Arabic and train all relevant personnel

•Upgrade pump materials

30-250 RWAC 24-4

30-175 RHAC 24-4-2

30-225 RHAC 24-4-2

30-200 RWAC 24-4

Downhole Pumps

•Used top hold-down Pump

•Introduced different sizes of subsurface pumps

Modified the Insert pump Anchor

Where are we Today?

Item Size TypeD . H. P. 30-250-RWAC- 24- 4

30-225-RHAC- 24- 4-230-200-RWAC- 24- 4

30-175-RWAC- 24- 4-2

RWACRHACRWACRHAC

Rod string 87 High tensile strength (140,000 to 150,000 Ib)

Grad “D”

Rod coupling Standard size Class T

Tubing 3.5 “ * 9.3 Ib/ft

Surface unit MII - 912 D - 365 – 144MII - 640 D - 365 – 144MII - 465 D - 365 – 144MII - 320 D - 365 – 144C - 912 D - 365 - 144

Mark-IIMark-IIMark-IIMark-II

Conventional

Prime mover 75 HP100 HP

Electrical ultra high slip

Well Monitoring

• Service contract for Dynamometer and fluid level

• Pilot test for well controller

Well Head Temperature As A Relation Of Production Rate (GOR From Zero Up To 100 Scf/Stb)

0

200

400

600

800

1000

1200

60 80 100 120 140 160Well head temperature, oF

Prod

uctio

n ra

te, b

pd

Zero water cut

Zero up to 20 % water cut

20 up to 50 % water cut

50 up to 80 % water cut

Beam Unit Maintenance by specialized crew

The Future Plan?

Install Well Controller

• As fields mature alternate solutions must

be determined• Acquire appropriate data to determine true

reason for failures• Continuous monitoring • Flexible operating design

Conclusions

Applicable Solutions

•Proper handling techniques

•Top-hold-down pumps

•Reduce gas and fluid pounding

•Seat pumps below perforations

•Tubing anchors >3000’

•Appropriate packer selection

•Sinker bars

Team work and sharing of technology is the key of success for any

improvement

By

M. Ghareeb (Lufkin Middle East)

Luca Ponteggia (Agiba Petroleum company)

K. F. Nagea (Agiba Petroleum company)

Beam Pumping System Efficiency Improvement in Agiba Western

Desert Fields