Addressing Stuffing Box Leaks at Daleel Petroleum-Oman

Abstract The operator operates predominantly with sucker rod pumps in their northern Oman field, characterized by diverse reservoir conditions, including high Gas-Oil Ratio (GOR) depleted reservoirs, high water cut, and hydrogen sulphide (H2S) wells. These conditions have posed significant challenges, particularly with rapid stuffing box (SB) leaks, leading to elevated maintenance costs, increased oil deferment, and significant environmental impacts due to H2S release and oil slippage. This paper explores the methodologies employed to address the stuffing box leak issue, detailing practical and cost-effective solutions with a focus on environmental protection and H2S containment. The challenge of stuffing box leaks not only results in oil losses but also raises serious environmental concerns due to the release of H2S, a hazardous gas, and the risk of oil contamination. To address these issues, a comprehensive investigation was conducted to identify root causes, encompassing surface beam pump completion and reservoir elements. The investigation facilitated integrated solutions to maintain continuous SB lubrication by optimizing well flowing pressure, enhancing installation and maintenance procedures, and implementing specialty stuffing boxes. In response, various measures were trialed, including a stuffing box leak detector, a polished rod lubricator, and a self-lubricating stuffing box, along with improved polished rod specifications. The combined cost-effective solutions led to a substantial improvement in stuffing box and polished rod performance over a two-year period. The number of stuffing box leaks was significantly reduced by 86%, and corrective SB maintenance dropped by 42%, even with an increased number of beam pump wells. Consequently, the environmental impact and health and safety risks to personnel were significantly mitigated, primarily through the prevention of H2S release and reduction in oil slippage. Moreover, the reduction in oil deferment and optimized resource utilization for maintenance teams highlight the effectiveness of the implemented solutions. This paper presents an in-depth investigation of stuffing box leaks under diverse reservoir conditions, offering integrated, cost-effective, and proven solutions based on data from over 400 beam pump wells over a two-year period, with a strong emphasis on environmental protection and H2S containment.