Historical Review of Artificial Lift in Egypt By M. Ghareeb (Lufkin Middle East) I. F. Zahran (Egyptian Petroleum corporation)

outline The history and the future application of the artificial lift system in the Egyptian oil fields. The main operating problems. The actions taken to overcome or improve these problems. Special emphasis is given to the artificial lift systems in the marginal fields.

EGYPT Oil / Condensate & Gas PRODUCTION SAFFRON SIMIAN SETTI SCARAB HAPY ROSETTA N. BALTIM EL TEMSAH NW. QARA BALTIM WAKAR&KERSH SETH MATRUH. N. ABU QIR ABU MADI PORT FOUAD ABU QIR EL WASTANI TAO MANGO OBAYIED W. ABU QIR THEKAH EMRY RAS KANAYES ALEX. W. ABU MADI KAMOSE FALAK DORR AMAN TAREK EL HAMRA. KHILALA W. TUT TUT UM BARKA M. NE KANAYES E. DELTA MELEIHA DISUQ Salam YADMA QANTARRA HOURS LOUTS RAZZAK TANTA S. UMBARKA KHALDA M. SE N. ALAMEIN ALAMEIN KARNA ISMAILIA HAYAT ZAHRA BARDY E. RAZZAK SAFIR YASSER AGHAR CAIRO BED-15 N. ABU GHARADIG NE. ABU GHARADIG S. DABAA BED-4 WD-19 ABU GHARADIG BED-2 BED-3 WD-33 QARUN DARAG SUDR SITRA – 1&3 BED-1 WD-33/1 W. QARUN MATARMA SITRA – 5 ASL GPC ABU SENNAN WARDA BENI SUEF N. OCTOBER RAS BADRAN RAHMI OCTOBER ABU RUDEIS AMER SIDRI BAKR FEIRAN BELAYIM M. W. GHARIB BELAYIM L. RAS GHARIB GS-300 EL AYUN JULY UM EL YUSR RAMADAN KAREEM BADRI MORGAN KHEIR NESSIEM SHUKHEIR WALI YOUNS GS 365-373 GARA M. AMAL GH 376 E. ZEIT SIDKI SHOAB ALI GAZWARINA HILAL ZEIT BAY BAHAR-NE RAS EL ESH ASHRAFI RAS EL BAHAR GEMSA GEMSA-SE TAWILA GEISUM E. MALLAHA OIL FIELDS FELEFEL RABEH WADI SAHL GAS FIELDS HURGHADA HAREED EGYPT Oil / Condensate & Gas PRODUCTION

Oil and Gas Wells 89 % 11 %

Artificial Lift Systems

History of The Artificial Lift System

Selection of Artificial Lift Production rate Experience Capital Cost Availability Well Completion

Common Artificial Lift Completion Single Zone completion Commingle completions Selective completion

Pump Problems Resulted from: Pumped off Gas Interference Solids (sand, debris) Corrosion Scale

Beam Pumping System Low production wells Shallow wells Low gas oil ratio wells 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

Failure History of Sucker Rod Pumping Components

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

Electrical Submersible Pumping System (ESP) Offshore High volume wells Water production wells Medium to Low volume wells (1000 -200 BFPD)

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

Average Running Life For ESP “W.D”

Ras Fanar Field Location Map ESP component failures

Ras Fanar ESP Failure Frequency

Average Total System Efficiency for the Different Artificial Lift Systems for WD Area (end of 2000)

Average Total System Efficiency for the Different Artificial Lift Systems for WD Area (end of 2004)

Average Total System Efficiency for the Different Artificial Lift Systems for ED Area (end of 2000)

MARGINAL FIELDS LESS THAN 5 MILLION BBLS OIL RESERVE

CASE HISTORIES 1- ZARIF FIELD 2- RAS EL HEKMA FIELD

ZARIF FIELD WESTERN DESERT 55 Km From Meleiha Field MEDITERRANEAN SEA RED SEA WESTERN DESERT 55 Km From Meleiha Field 6 Oil Producing Wells 1 Water Source Well 1 Water Injector Well 2500 Bopd 30 % Water Cut

Zarif Field: Reservoir Pressure Performance

Zarif Field: Jet Pumping System power fluid to wells Main manifold Vessel Triplex unit

Zarif Field: Water Injection System GENERATOR TRANSFORMER SWITCH BOARD CHEMICAL INJ. UNIT WELL Z-9 (ESP) WELL Z-6 SOURCE INJECTOR

Zarif Field: History of the Lifting Cost Jet pumping Beam pumping

RAS EL- HEKMA FIELD 70 Km From Meleiha Field 1 Oil Producing Well MEDITERRANEAN SEA RED SEA WESTERN DESERT 70 Km From Meleiha Field 1 Oil Producing Well 250 Bopd 16 % Water Cut

WELL COMPLETION 3 1/2" Tubing 7" Casing Setting nipple S.S.D Packer Landing nipple Perforated joint Setting nipple 7" Casing 3 1/2" Tubing

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

Ras El Hekma: Production System TO MELEIHA - EL HAMRA PIPE LINE 500 BBLS TANK 500 BBLS TANK DEMULSIFIER INJ.

Conclusion and Recommendations 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.

Historical Review of Artificial Lift in Egypt By M. Ghareeb (Lufkin Middle East) I. F. Zahran (Egyptian Petroleum corporation)