Beam Pumping System Efficiency Improvement

In Agiba’s Western Desert Fields

By
Luca Ponteggia (Agiba Petroleum company)
M. Ghareeb, Artificial Lift Expert, Lufkin Middle East

Abstract:

Beam pumping systems were introduced in the Meleiha oil fields in 1986 as
the most suitable means of artificial lift. Initially low running lives were reported, but
continuous improvement efforts have increased them significantly. Improvement
included surface and subsurface equipment (re-sizing, modification, monitoring,
completion, analysis, handling, & operating procedures).

This study will cover the operational performance of the sucker rod system,
the experience gained through its application with problem analysis, and solutions
adopted throughout 19 years of operation to optimize the system efficiency.

1- Introduction

Western desert fields have more than 104 oil producing wells with an average
of +/- 57,000 BFPD (+/-31,000 BOPD) distributed over five main fields. All wells are
artificially lifted except for one is flowing and sucker rod pumping is the main lifting
system. Figure-1 shows the distribution of the different artificial lift methods.

N.F
ESP
1%
13%
PCP
1%

SR
85%

Figure-1: Different production systems for Agiba’s W. D. Fields

The productive zones are mainly concentrated in the Baharia formation where
there is a sequence of oil bearing zones. Figure-2 is a location map showing Agiba’s
operating areas.
 MEDITERRANEAN SEA
MATRUH

ALEX.

EL HAMRA
MELEIHA

Cairo
ZARIF W. RAZZAK

EL FARAS A
I N
RAML &
R. SW
S
FARAS SE
I

G
U
R

LF
E
S

QABA
O
E

F
D

OF A
N

SU
R
E

E
T

GULF
S
E
W
T
0 100 km.

ASHRAFI RED
SEA
Figure-2: location map

Agiba production began in December 1984 by using temporary production

facilities and crude was transported to the Elhamra terminal by trucks. In November
1986 permanent facilities were commissioned and crude was transported to Elhamra
through a 16-inch pipe line (166 km). Figure-3 shows the production history of the
Western desert fields. Sucker rod systems were introduced at that time in the
Meleiha oil fields as the most suitable means of artificial lift.

Bbls Bbls
45,000 180,000,000

40,000 160,000,000

35,000 Avg. 140,000,000

cum.
30,000 120,000,000

25,000 100,000,000

20,000 80,000,000

15,000 60,000,000

10,000 40,000,000

5,000 20,000,000

0 0
Apr-88
Oct-88
Apr-89
Oct-89

Apr-92

Apr-93
Oct-93
Apr-94
Oct-94

Oct-95

Apr-97

Apr-98
Oct-98
Apr-99
Oct-99

Oct-00

Apr-03
Oct-03
Apr-04
Oct-04
Oct-86
Apr-87
Oct-87

Apr-90
Oct-90
Apr-91
Oct-91

Oct-92

Apr-95

Apr-96
Oct-96

Oct-97

Apr-00

Apr-01
Oct-01
Apr-02
Oct-02

Figure-3 shows the production history of Western desert fields

Initially, very low running lives were reported for subsurface equipment.
Continuous efforts by monitoring and analyzing the failures, in addition to the
introduction of technology, overcame most of the problems and extended pump
efficiency and running life. Well performance was analyzed by using computerized
dynamometer and echo-sounding tools. Furthermore, some performance curves
were developed in-house to assist in predicting well production rates from wellhead
temperatures, which allow for troubleshooting.

2
2- System Design

2.1 Initial production

Table (1) shows the initial reservoir data and fluid properties for the Meleiha
fields. The sucker rod system design was introduced to provide maximum possible
production in a depletion drive reservoir (fast decline in reservoir pressure with
production).

Table 1 Initial reservoir and fluid proprieties

Res Res. visc. Pb, Bo, Rs, API
Press. Temp cp psia rb/stb scf/stb
psi oF
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

2.1.1 Surface and subsurface equipment sizing

In 1986 all the Meleiha fields were almost virgin and they showed the
capability to produce +/- 1000 BFPD per well. Therefore the equipment was selected
based on 1000 BFPD as the target production rate. Based on wells productivities
and bottom hole conditions the pumps setting depths were chosen to be +/-5000 ft.
Technical and economical studies performed at that time showed that class III
surface pumping units were the most efficient means of artificial lift. The goal was to
minimize using workover rigs to pull and run tubing in case of any problems with the
subsurface pump, therefore insert type pumps were chosen. A tapered (86) High
tensile strength (140,000 to 150,000 Ib) rod string was the best selection. Ultra high
slip motors were installed on all Meleiha units and have gained wide acceptance
as the prime mover of choice. The motor has four torque modes to generate different
amounts of slip and is also equipped with a timer, which allows the user to adjust the
pumping time according to the wells capability.

Table (2) Initial surface and subsurface equipment

Item Size Type
D . H. P. 30-250-RWBC- 24- 4 RWBC
Rod string (86) 41.2 % * 1” High tensile strength
40.2 % * 7/8” 18.6 % * 3/4” (140,000 to 150,000 Ib)
Rod coup. Standard size Class T
Tubing 3.5 “ * 9.3 Ib/ft
Surface unit M - 912 D - 365 - 144 Mark-II
Prime mover 75 HP Electrical ultra high slip

3
2.1.2 Well completion design

Figure-4 shows the main completion design where the wells are equipped
with 3 1/2 inch tubing. The tubing is anchored to 7 inch casing with a mechanical
anchor catcher and is kept in tension with 15,000 Ibs of over pull (Figure 4a). The
pump is seated in a 2.75 inch seating nipple and most of the wells have the
described completion except some that may produce from two different zones. In
these wells the anchor catcher is replaced by a packer for a selective completion
system. (Figure-4b).

2.75”
seating
nipple

Anchor SSD
catcher

Packer

Figure-4a Figure-4b
Figure-4: sucker rod well completions

3-System performance and evaluation

Initially very low equipment running lives were reported. Rod parting
combined with down hole pump problems represented the highest percentage of
failures. Rod parting was mainly concentrated in the upper part of the 7/8” and 3/4“
strings. All the failures reported were fatigue or rod parting due to unscrewing of the
coupling. Down hole pump problems were mainly due to valve leaks (travelling and
standing), pump connection unscrewing or pump sticking. Sucker rod parts and
pump failures can be easily repaired in a reasonable time by pulling and running a
rod string or pump after replacing or repairing the damaged one. But when a stuck
pump is found, workovers are the only remedial job that can be applied. A workover
rig is much more expensive compared with a pulling unit and the well down time has
a bigger impact on the production level. Stuck pump problems dramatically
increased in the Meleiha field which affected the production performances and the
cost per barrel.

After root cause failure analysis the main factors affecting the equipment
performances were highlighted:

4
a- The reservoir is a depletion drive type and the fast decline in reservoir pressure
was affecting the pump intake pressure. Therefore, the gas and fluid pounding
problem became a serious issue and the decrease in the dynamic fluid level
consequently increased the peak polished rod load due to increasing the net lift.

b- The use of one size and type of down hole pump reduced the ability to match
pump production with the wells capability. Even after reducing the surface pumping
parameters (stroke length and strokes per minute) to a minimum.

c- Since all pumps were bottom hole down type, pump sticking increased due to
sand and debris in the fluid.

d- Lack of experience with sucker rod pumping was affecting the failure analysis.

e- Mishandling of high tensile strength rods caused sucker rod failures.

f- Bad fluid data due to out of date technology.

3.1 Failure analyses

Figure-5 shows the distribution of typical failures in sucker rod installations in

the Western desert fields. Failures are divided into four major categories, which are:
1. Sucker Rod and polished rod failures
2. Down hole pump failures.
3. Tubing wear.
4. Surface Unit Failures

Tubing wear.
D.HP. 17%
47%
S.U
2%

S.Rod and P.Rod

34%

Figure-5: Typical failure in sucker rod installations in W.D fields

3.1.1 Sucker rod failure analysis

5
 The rod string used in the beginning was an API 86 (18.6 % of 3/4”, 40.2 % of
7/8" and 41.2 % of 1"). Due to fluid/gas pound, and improper handling & store, rod
parting frequently occur, in the top of the 7/8" and 3/4" rods. As mentioned earlier,
due to the fast decline in reservoir pressure and the wells capability to produce the
desired production, a time clock was introduced. This also caused an increase in the
frequency of rod parting. Due to the timer the rod string transferred from static (well
off) to dynamic conditions with a full load (well on) every 18 minutes or 72 times a
day. Another important cause of rod parting was the handling. This type of rod if
damaged, can easily loose it’s high strength properties, in fact all the failures
reported were fatigue in nature. (Figure-6)

Figure-6: Typical shape of sucker rod failures for W. D wells

3.1.2 Down hole pump failure analysis.

As mentioned before, all the pumps were standardized to be 2.5 " RWBC. So
as to handle well production at the time, and minimize spare parts and handling tool
requirements.

Due to the fast decline in the reservoir pressure, gas and fluid pounding
became a serious problem causing traveling and standing valve damage.

After retrieving the pumps, it was found that either the traveling or standing
valve unscrewed. The traveling valve could be dealt with in a short period of time
unless it dropped inside the pump, in that case it would require a round trip. In the
case of the standing valve, the seating assembly would stay in the seating nipple
and need another trip to fish it. Fishing a standing valve usually required additional
wire line operations to fish the ball when it unscrewed at its bottom connection. The
success of the fishing was not guaranteed and sometimes the well was down for up
to four days to recover the standing valve. Well down time was mainly due to
pulling /running operations and wire line fishing jobs for standing valves. The
situation was improved by putting the well on a timer, dependant on its productivity.
In spite of the improvement, another problem appeared during the downtime when
sand and debris would settle around the barrel causing a stuck pump. A temporary
solution was introduced by scheduling wells that were working on timers, to have the

6
pumps unseated once a month for washing the sand and debris into the rat hole.
After the pump was unseated twice, we had to pull it to replace the seating cups.

The other main problem was stuck pumps which existed only in the Bottom
Hold-Down type. This BHD creates the possibility of sand & debris accumulating in
the dead area between the pump and the tubing wall. Such problems have been
overcome by introducing the Top Hold-Down pump (figure 7 shows the two different
types). The pump anchor system is used in the following:

1 - To put the wells with tubing leaks back (without a work-over).

2 - To convert the wells without seating nipples to a sucker rod system (without a
work-over).

Figure-7: Bottom and top hold-down pump assemblies

3.1.3 Tubing wear failure analysis

The main reason behind tubing wear is the movement of rods and rod
couplings within the production string. There is also some movement of the tubing
resulting from the pump action which results in wear between the tubing and casing
if the tubing is unanchored.

Sucker rod movement inside the tubing, lead to a mutual friction between the
rods and tubing which created the tubing wear that grew as a longitudinal crack
along the tubing joints. Figure-8 shows an example of tubing wear resulting from this
friction.

Figure-8: Example of tubing wear

7
 An investigation was conducted and the conclusion was that all the reported
tubing failures had longitudinal cracks with an average length of 10 ft. and all the
cracks were in the lower part of the tubing (up to 500 ft above the pump seating
nipple). This tubing interval was located against the sinker bar portion of the sucker
rod string.

The reason behind this problem has been investigated and summarized as follows:

1- These cracks were created as a result of friction between the sucker rod string
and tubing. They are located in the lower portion of the tubing because the tubing
string typically buckles at this depth (just above the anchoring point). Buckling in
the lower portion above the anchoring position results from the use of a hydraulic
or mechanical packer or anchor catcher with insufficient tension.
2- Using 1” sucker rods as a sinker bar with full size couplings, which creates the
possibility of friction with the tubing inner wall. (Figure 9 shows relative sizes of
sucker rod couplings in 3-1/2 in. tubing with contact area).
3- The high water cut wells were producing free water, which created very poor
lubrication and cooling between the sucker rods and tubing.
4- The produced water had a higher thermal coefficient then the oil, so it increased
the buckling effect of the tubing.

2.992 inch

2.1875 inch

0.4
inch

2.992 inch

1.9375 inch

0.527 inch

Figure 9: Relative sizes of sucker rod couplings in 3-1/2 in. tubing

Statistics for tubing leakage over the last 9 years are shown by Figure-10

8
 25

20

15

No. of workover
10

0
1995 1996 1997 1998 1999 2000 2001 2002 2003
Year

Figure-10: Number of workover due to tubing leak over the last 9 years

3.2 Gas interference problems

Pumping free gas significantly decreases the beam pumping systems overall
efficiency. This directly contributes to higher lifting cost as well as indirectly
accelerating the deterioration of surface and subsurface equipment. Consequently,
the process of lifting will be economically unfeasible. There are several techniques
that can be applied in order to improve the pump efficiency in gassy wells. Pumping
below perforations has proved to be the most successful.
Gas interference reduces the volumetric efficiency and in the worst case the well
stops pumping due to gas lock.
Mechanical gas separation (down hole gas separator) can help in reducing
gas interference by minimizing the quantity of gas entering the pump. Different types
of separators are available on the market.
In Agiba applications some of the NE wells, SE, Zarif, Faras and Ramel fields
are the highest gas to oil ratio (GOR) wells (over 300 SCF/STB). In 1988 Agiba
ran poor-poy type gas separator tests for two of the SE wells (SE-1 and SE2).
They did not show any significant improvements and this technique had some
limitations:
 It was not effective for wells producing over 300 BOPD.
 It Impedes possible wire-line operations in the well in which it is used
 For pump intake pressure above the bubble point, the gas separator
deteriorates total volumetric above the bubble point, the gas separator
liberation of gas due to increasing the pressure losses.

Seating the pump or at least the intake below the perforations is the most
efficient technique if the well conditions allow for it. In 1998 Agiba with GPC
engineers tried and succeeded to run 23 wells below the perforations. The technique
helped to bring back some of the GPC wells which it shut in due to high GOR. Two
years later, Agiba began to apply the process for some of the Meleiha wells (M-8,
SE-6). Since it proved to be very efficient most of the Faras, Raml and Zarif field
wells were running below perforations. Application of the technique created the
following advantages:
 Increased pump submergance which resulted in more production.

9
  Created a natural gas-separation, which improved the pumps mechanical
performance.

There are some limitations to this technique, which is not recommended for sandy
wells where pump-sticking problem arise.

3.3 Scale deposition problem

It was observed that scale formation problems started to appear in some of
the Meleiha and Raml field wells. Chemical analysis showed that it was the calcium
carbonate (CaCO3) type. Such scale precipitates in the upper part of the tubing
(surface down to about 300 ft). Presence of scale restricted operations during pulling
and running of the subsurface pump. In some cases it created stuck pumps and then
a work over was needed.
Some deposits had low solubility but solutions of acids could often be used to
remove such scales. The reasons for this problem have been analyzed and the
conclusions are as follows: -
1. Pressure drop at the wellhead (below 100 psi).
2. High formation water production.
3. High temperature (over 120 oF).

To prevent scale formation inside the well, it was found that increasing the
wellhead pressure to 150 psi would significantly improve the situation. If scale
existed, the removal was always done mechanically by a gauge cutter & home made
wire brush. However, chemical treatment is under study as an economical and
operational solution.

4. Corrective Action:

As illustrated in the failure analysis, several modifications in the system design

and equipment types were introduced in all the fields. Conventional geometry in
addition to smaller size M-II pumping units have been used. The big change is in the
rod design and the size & type of the down hole pump. Several things contributed to
that change such as the discovery of new fields with new fluid properties and
formation parameters. Table (3) shows the current surface and subsurface
equipment.

10
Table-3: current surface and subsurface equipment
Item Size Type
D . H. P.  30-250-RWAC- 24- 4  RWAC
 30-225-RHAC- 24- 4-2  RHAC
 30-200-RWAC- 24- 4  RWAC
 30-175-RWAC- 24- 4-2  RHAC
Rod string (87) with 18 joints of 1” rod  High tensile strength
as sinker bars (140,000 to 150,000 Ib)
 Grade “D”
Rod coup. Standard size Class T
Tubing 3.5 “ * 9.3 Ib/ft
Surface unit  M - 912 D - 365 – 144  Mark-II
 M - 640 D - 365 – 144  Mark-II
 M - 465 D - 365 – 144  Mark-II
 M - 320 D - 365 – 144  Mark-II
 C - 912 D - 365 - 144  Conventional
Prime mover  75 HP Ultra high slip
 100 HP

As shown in table-3, four different sizes of subsurface pumps are currently

used. This gives different scenarios to match with well production in order to
maximize efficiencies. All the pumps are top hold-down and by running this style, the
stuck pump problems were eliminated. Agiba has pioneered the modifications of the
anchor to install at the top of the pump. This modification is tested and applied in
more than 200 wells without any problems.

Introducing smaller sizes of subsurface pumps led to a significant reduction in

the peak polished rod loads. This allowed Agiba to use grade ”D” sucker rods which
improved rod failure problems. Grade “D” are less sensitive to handling, fluid and /or
gas pounding problems than the high tensile strength rods.

Regarding tubing wear elimination, two different philosophies should be applied

simultaneously. The first is to prevent tubing movement during a pumping cycle. For
that purpose two methods can be used:

1. Tension Tubing anchors

After the anchor is set in place a predetermined tension is applied at the surface.
The required pickup can be determined from special charts. Pickup should be
measured in inches and not in pounds because of the unreliability of weight
indicators. Tubing anchor catchers are considered the most effective tool if applied in
the correct way.

11
 2. Tail pipes
A tail pipe is used to add more weight below the pump to eliminate tubing buckling.
The length of the tailpipe can be calculated using the follow equation:

Where:
G = fluid spec. Gravity
D = working fluid level, ft
Ap = plunger area, in2
Mp = unit weight of tail pipe, lb/ft
Lp = length of tail pipe, ft

This technique was tested in a couple of wells (non-selective producing wells).

The reason for using a tail below the pump seating nipple is to keep the tubing
string in tension. Tail pipes are not recommended for use in gassy wells if the
pump and tubing are set above the perforations. This would force all the gas to
come up the annulus and through the pump.

For the purpose of extending the tubing and/or rod running lives, different
techniques are available. The application of rod guides is one of the common
techniques applied in Egypt. Two different types of rod guides were tested in the
Agiba oil fields, fiber glass and spiral metal types. The experience proved that it was
not an effective solution for our condition due to the following difficulties:

a. The used fiber glass rod guide is of the two piece type and when one side
wore out the other side dropped in the hole and stuck between the rod and
tubing causing a stuck string. In most cases a work over was required to pull
the tubing string.
b. It required fixed regular schedules for round trips to replace the worn-out
guides

c. In case of rod failure at the top of the rod guide, there was no possibility for
fishing and the work-over became the only possible solution.

d. The installing of rod guides created much more friction, which increased the
loads and stresses in the sucker rod string and the possibility of rod failure.
Due to high loads, there was no way to increase pumping parameters in order
to increase production.

e. The difficulty to keep guide inventory since the required quantity may exceed
the double number of round trips for all wells.

12
Conclusions and Recommendations

The following can be concluded from the analysis of the failure problems and
the actions taken.

1. Care in handling of the sucker rods, especially the high tensile grade is the most
important factor in reducing the rod parting.
2. For depletion drive reservoirs, care must be taken in the lifting system design for
it to be operationally flexible with fast changes of reservoir characteristics.
3. The use of top hold down pumps helps in reducing the frequency of stuck pumps.
4. The prevention of gas and fluid pounding helps in increasing the system
efficiency by reducing equipment failures.
5. Wellhead temperature is a much more useful tool for quick well monitoring and in
time problem prediction than wellhead pressure.
6. Seating pumps below the perforations is helpful in wells with low fluid levels
and/or high gas/oil ratio.
7. For the selective producing wells it is recommended to use the mechanical
packer combined with new tubing, in order to create the maximum possible
tension in the tubing string.
8. Sinker bars were best used to control buckling in the rod string.
9. Controlling mechanical wear by using tubing anchors for wells >3000 feet
deep. The anchor should be as close to the pump as possible.

Acknowledgments

The authors wish to express their thinks to Agiba Petroleum Company for
permission to publish this paper. Especially thanks for all Agiba workers for their help
and advice.

References
1. Brown, K. E. “The technology of artificial lift methods”, Vol. 2A, Petroleum Publishing Co.,
Tulsa, Ok. 1980
2. Schmidt Z. and Doty D. R., ”System Analysis for Sucker Rod Pumping” SPE 15426 presented
at the 61st Annual Conference and Exhibition of the Society of Petroleum Engineers held in
New Orleans, LA, October 5-8, 1986.
3. M. Ghareeb “Sucker Rod: efficiency improvement in Meleiha field”, paper published and
presented at the 1st Arpo convention, Milan, Italy Nov. 1995.
4. M. Ghareeb et-al “A Novel Correlation for Estimating Well Production Rate” SPE paper 77953
published at Asia Pacific Oil & Gas conference and exhibition, Melbourne, Australia 8-10
October 2002.
5. M. Ghareeb and L. Peitto "Cost control & development and production of Egyptian western
desert marginal fields”. Paper published and presented at EUROPIC conference , Milan ,Italy
Feb. 1997
6. M. Ghareeb et-al “Artificial lift optimization in mature and marginal fields (Agiba W.D. case
history)” paper published and presented at the 12th exploration & production conference,
Cairo, Egypt, Nov. 1996.
7. Brown, K. E.,: The Technology of Artificial Lift Methods, The Petroleum Publishing Co.
Tulsa Oklahoma, Vol. 2a, pp. 9-94 1980.
8. Zhang Y. and Farquhar R., Laboratory Determination of calcium carbonate Scaling Rates for
Oilfield Wellbore Environments., SPE paper 68329 (2000).

13