In January 2006 El-Wastani Petroleum took a step outside the proverbial "box" and made a decision to use expandable technology as a solution for an existing problem. The well, Gelgel #2, located in the Nile Delta Field of South Manzala, was a prolific gas producer whose upper sand body had watered out. Along with the water came the inevitable sand production from this Miocene Age sandstone. The need to shut off the water and provide sand control within a limited work space was the challenge.

This paper will describe how the operator and service company used a one-trip expandable sand screen system to provide a solution for water shut-off and sand retention while allowing continued production of gas.

The paper will review the operator's investigation and decision-making process in selecting an expandable sand screen system for this project, whose objective was to install a 4-3/4-in. screen system to isolate the water section and allow the gas section continued production while providing a means of sand control during the process. Re-entry access through the producing sand was a critical success factor in allowing for future production logging as required.

The authors will discuss the results of the project, which indicated that the application of expandable technology was highly successful. The screen assembly, which included expandable screens and expandable packers, successfully isolated the desired zones. The water was reduced to an acceptable rate and gas rates returned to a respectable rate of 5MMSCFD, the highest gas producer in the South Manzala Field.


The South Manzala Field, located in the Nile Delta of Northern Egypt, is a designated gas field development for the independent operator El-Wastani Petroleum Company. There are currently six producing wells in this field. The Gelgel #2 is the most prolific gas producer in the entire field.

Gelgel #2 was placed on line for production in Septemeber 2004. Initial production came from commingling the IIA and IIB reservoir sand bodies. The IIA sand, located at a depth of 905 meters to 912.5 meters, and the IIB sand, located at a depth of 920 meters to 924 meters, initially produced at an average daily rate of 14mmscf/day until July of 2005 (see Figure 1). Very little water was produced during this period. The well flowed on a 0.875in. choke for the first few months and later increased to 1.719in. until it was shut in during July 2005.

Once an indication of sand production became an issue, the decision was made to isolate the lower IIB sand and produce the upper IIA sand body independently. Isolation was accomplished by setting a bridge plug between the two sand reservoirs.

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