200.3 Plunger Main

Plunger Lift
Introduction to Plunger Lift: System Below
LUBRICATOR ELECTRONIC
CONTROLLER
FLOW TEE
W/O-RI
W/O RI NG
MOTORIZED
BYPASS VALVE
BLEED VAL VE
VAL VE
EXT ERNAL
CATCHER CABLE
W/ARRIV AL
MAST ER SENSOR
VAL VE
PLUN GER
BUMPER SP RING
TUBING STOP
1
Plunger Equipment
Controller: Electronic-based system with control parameters to
determine under what conditions to open/close control valve
Transducer: Electronic device that emits an electronic signal to

be converted within controller to engineering units
Motor Valve: Diaphragm-operated device controlled by

controller to open/close sales/tank line
Lubricator/Catcher: Uppermost stopping point for plunger; acts

as shock absorber; catcher retrieves plunger for inspection
Arrival Sensor: Magnetic device strapped around lubricator to

detect
d t t plunger
l arrivals
i l Vibration
Vib ti sensors have
h been
b usedd
Bumper Spring: Shock absorber at depth
Plunger: Pig-type device that provides seal between gas and

liquid inside tubing to deliver fluid and gases to surface with
differential pressure. It travels entire length of tubing

Plunger Lift System Wellhead
2
Plunger Advantages
Requires no outside energy source if GLR and

pressure buildup minimums present; uses wells
energy to lift
Dewatering gas wells ***Primary
Primary Use
Rig not required for installation
Easy maintenance
Keeps well cleaned of paraffin deposits
Low-cost artificial lift method
Handles gassy wells*** Gas Wells primary
application
Good in deviated wells up to 30 degrees minimum
Can produce well to depletion but there are other
methods such as casing plunger and beam lift for
example that possibly can pull the well to lower
pressures
Plunger Limitations
GLRs to drive system

400 scf/bbl/1,000 feet no PackerSome have said
300 for this value
1,000-2,000 scf/bbl/1,000 with packer
Low-volume liquid potential
200-300 BPD max but usually much less for
dewatering gas wells
Solids can stick plunger
Requires surveillance to optimize: Short complete
cycles
l maximize
i i production
d ti
3
Conventional Plunger Cycle
1. Plunger acts as interface between liquids and
higher pressure gas below that drives plunger
upward
2. When surface control p parameters are met,, sales
valve opens and exhausts pressure to create
differential pressure across plunger.
3. CP-TP pressure then lifts liquids and plunger to
surface.
4. Sensors record plungers arrival, producing time
starts.
5. When producing time parameters are met, surface
valve closes; plunger goes to off cycle and falls to
bumper spring at bottom of well.
6. Return to item 2 (above) after pressure builds
during fall and pressure build-up period, if needed.

4
Bumper Springs
Used to prevent excessive shock
to plunger if it were to fall in dry
tubing
Types of bumper spring
combinations
No-go nose
Seating cups/standing valve
Collar stop
Tubing stop Longer for
Collet latch heavier
plungers !!
Hearn, Weatherford
Collar & Tubing Stops
Type A tubing stop

Type F collar stop
Used when tubing is
open ended
Hearn, Weatherford
Wireline set
Wireline retrievable

10
5
Hearn, Weatherford
Lubricator
Cushions plunger upon arrival into wellhead to prevent
damage Single or dual outlet
Catcher option
Sensor mount
Threaded outlets
Spring-loaded cap and striker
pad
3K and 5K psi rating

Serviceable top for springs
Plunger catcher
Dual flow or single
4140
H2S service available

11
Accessories
Motor valves
Sensor switch
Solar panels
Strap-on sensors
Drip pot w/ regulators
Control pilots
Pressure reducing
Differential control
Gas
G filters
filt
Hearn, Weatherford
12
6
Arrival Sensor
Electronic or magnetic switch that allows controller to

sense plunger arrival
Sensor
Switch
Solar-powered
systems
1.5-day recharging
capacity for stand-
alone systems
Solar systems
Solar-Powered sizing available
Systems
Hearn, Weatherford

13
Controllers: Many Options
14
7
Various Plungers
1. Pad Plunger
2. Brush Plunger
3. Bypass Plunger
4. Turbo (sand)
5. Turbulent Seal
6. Brush
7 Turbulent
7. T b l t Seal
S l
8. Wobble Washer
Bypass
1. 2. 3. 4. 5. 6. 7. 8. 9.
9. Turbulent Seal

15
Turbulent Seal Conventional Plunger
Poor seal, for

strong wells,
cheaper, no
moving parts,
may fall ~500
fpm
16
8
Pad Plungers: Common, Conventional
Good seal,
for weak
wells.
R
Requirei long
l
shut-in as
fall is slow.
Could be
150-250 fpm
fall time.
Rise time
could be
lower than
750 fpm and
still function
well

17
Two Piece Bypass Continuous Flow Plunger

If conditions right,
only 10 second shut-
in. Both components
fall against flow.
flow
Three weights of
materials available.
Use heaviest against
high flow rates. Now
owned by IPS.
For lower flows, both
If well
ell too weak
eak to components fall fast. Echometer
surface, then use pad system has trouble seeing two
plungers. piece components. Will return
Two piece now when cylinder hits bottom if well
available with pads? not shut in.

18
9
Brush Plunger: Tolerate Some Sand
19
Bypass Continuous Flow Plungers
Heavy plungers. Use

when more liquids
present to prevent
damage
damage.
Fast fall: Could be
2000 fpm.
Rods at surface open
bypass.
Mechanisms at bottom
open bypass when
plungers hit bottom
20
10
Bypass Plungers: Pad and Turbulent Seal
21
Additional Bypass Continuous Flow Plungers
FBI bypass plunger
Weatherford Rapid Flow

Plunger
22
11
Various Plungers
1. Travelling spring
2. Cutaway of
Neophrene Seal
under Pad
1
3. Rapid Fall Plunger
2
3
4. Spring with
Standing Valve 4
5. Plunger with 5
S i Internal
Spring I t l 6
6. Wobble Washer
7
Plunger
7. Swirl plunger
(sand)
23
Various Plungers
1. Travelling spring
2. Cutaway of
Neophrene Seal
under Pad 7
3. Rapid Fall Plunger 6

5
4. Spring with 4
Standing Valve
3
5. Plunger with
2
S i Internal
Spring I t l
1
6. Wobble Washer
Plunger
7. Swirl plunger
(sand)
24
12
Automatic Surface Plunger Catcher / Holder
If plunger falling
too soon you can
hold at surface
s rface
with controller
using this device
25
Plunger Auto-Catch
Auto Catch is easily added to
plunger lubricator.
Can run off of same solenoid as
control valve or in applications
where this is difficult can be run
with its own solenoid.
Solves Premature tripping
problems by keeping the
plunger in the lubricator even
when instantaneous flow rates
drop off.
Helps avoid freezing problems
as it is not necessary to flow Hearn, Weatherford
directly through the plunger.

26
13

Plunger Controllers
Plunger Controllers
A Plunger System Controls Two Factors
1) Length of Flow
2) Length of Shut-in
Essentially, a plunger system is an on/off switch!
28
14
29
Plunger Cycle
30
15
31
Problem
Problem: Input below data into Conventional Plunger Rules
of Thumb Spread Sheet and Analyze
32
16
Results
33
Problem
Input data into Foss

& Gaul Spread
Sheet and Analyze
34
17
Results: Foss & Gaul Problem
35
Objectives of Controller
Systems
18
Optimize Plunger Production
J.D. Hacksma, 1972,

User's Guide to Plunger Lift Performance
"The producing tendency of plunger lift is directly

opposed to that of the well. Plunger lift requires an
increase in casing pressure for increased production
whereas the well itself requires a decrease in casing
pressure for increased production. The compromise
that always yields the greatest production is found
when cycling the plunger at the maximum frequency
possible without killing the well."
37
Inflow Gas IPR

... the well itself requires a decrease in (average) casing
pressure for increased production..."
High Casing Pressure,
L
Lower Rate
R t
CP only little lower than
pressure at perforations
with no packer
Gas Rate, Mscf/D
38
19
Max Complete Cycles Gives Best Operation
39
Manually Set Controller
An on/off timer is set to flow and shut-in the well
Times set by operator

Operator determines flowing characteristics when at
well
Operator makes adjustments to shut-in and flow times
Expect trouble
40
20
Evolution of Plunger Cycle Controllers
Time cycle control

On time -- off time Hearn, Weatherford
Ti
Time cycle
l with
ith plunger
l arrival
i l recognition
iti
On time -- sales time -- off time
Auto-adjust time cycle
Adjust time settings by reacting to failure
Plunger traveling -- too fast, too slow, none
Result: Mere guessing at time required to achieve

wellhead pressures needed to lift plunger and fluid
against facility pressures and how long to flow well
before it experiences liquid loading again

41
Tubing Pressure as Control Parameter

Tubing pressure (TP) relevant point of measure in
almost every form of artificial lift
TP measured to indicate real-time flowing and
shut in conditions
shut-in
TP subtracted from the CP to calculate hydrostatic
fluid column pressure
Plunger lift shut-in cycle
TP can be used to initiate open cycle to try to lift a plunger
and its fluid column to surface
When
Wh th the annulus
l iis nott communicated
i t d (PKT set) t)
When production tubing is cemented in (slim hole)
When TP exceeds fluctuating line pressure by a
sufficient amount
Hearn, Weatherford

42
21
CHP as Control Parameter
Casing pressure (CP) used as direct indicator of
bottomhole pressure (BHP)
Used in calculation of
Hydrostatic fluid column in tubing
Lift capabilities
BHP
Plunger lift shut-in cycle
CP can be used to initiate an open cycle to try
to lift p g and fluid column to surface
plunger
When tubing placed too deep into
perforation
When CP exceeds fluctuating line pressure
by sufficient amount Hearn, Weatherford
43
Hearn, Weatherford
Initiate on cycle for plunger lift when:
1. Tubing pressure > or = on pressure limit Tubing pressure (TP) exceeds a value
2. Casing pressure > or = on pressure limit Casing pressure(CP) exceeds a value
3. Tubing line > or = on pressure limit TP exceeds value over LP
4. Casing line > or = on pressure limit CP exceeds a value over LP
5. Foss and Gaul Calculations CP to rise at correct velocity predicted
6. Load Factor (CP-TP)/ (CP-LP) < ~40%
44
22
Rules of Thumb Spread Sheet
Initial Conditions:
Unloading 14:13 Min
After-Flow 72:34 Min
Shut in 68:12
Shut-in
What would you
recommend to
improve the cycle?
Use the Rules-of-
Thumb Spread sheet
under folder SS on
your disk.
45
When to turn Plunger Flow Off
Initiate off cycle for plunger lift when:

1. Plunger has arrived (used on oil wells)
2. Casing pressure < or = off pressure limit (looks for
casing to fall below a set pressure)
3. HW < or = off pressure limit (looks for flow rate to
fall below a set differential in inches of water)
4. Flow Rate (Sometimes a calculated Turner Rate)
5. Casing-tubing > or = off pressure limit (looks for
differential between casing and tubing to increase)
6. Casing To Tubing Sway looks for the casing and
tubing
tub gppressure
essu e to start
sta t moving
o g apaapartt from
o eac
each
other.
7. Casing to Line > or = off pressure limit (looks for
differential between casing and line pressure to
increase)
Hearn, Weatherford
46
23
Velocity Controller Algorithm
Controller makes adjustments based on Plunger
Velocity
Pl
Plunger h a target velocity
has l i to:
keep the best seal
minimize gas slippage around the plunger
prevent liquid fallback
Controller changes length of flow and length of

shut-in to keep plunger at target velocity
However must test for min shut in time or large
slug with long build up can have same velocity as
small slug with short build up.

47
Summary of Velocity Control Algorithm
Summary of
Velocity
Controller Logic
Rise time can be
slower if very
good seal on
plunger
48
24
To Achieve Max Plunger Gas Production
Shut-in well the shortest amount of time possible (but long

enough for plunger to reach bottom)
Flow the well only until it begins to load with liquids
49
Plunger Cycles
Faster
Fastshorter
cycles, cycles,
smallersmaller slug sizes
slug of liquid, gives
lower lower
buildup
average casing
pressure and BHP
required, for more
results production.
in lower This does
average BHP,
NOT mean to travel in tubing faster when the valve
which results in more p production!!
opens There is still an optimum rise velocity
opens. velocity.
BHP
Slow Cycles Avg BHP
Faster Cycles
LowerAvgBHP
Time

50
25
Gas Well Inflow: Plunger Cycle
Most Cycles
Seek lowest average operating
pressure on casing
Smallest Liquid
Gives lowest average pressure on Loads
perforations
Lowest Casing
Gives maximum production of gas Buildup
Pressure
Most Inflow
From
Formation
51
Summary of Plunger Cycle
Maximum frequency means plunger to bottom of

well each cycle
Also flows long enough to bring in small slug of

liquid (1/2-1/6 of bbl?)
Then lowest average casing pressure is the goal

after above to steps are satisfied
52
26

Two Piece Plunger

Continuous Flow Plunger
The Conventional Plunger
Requires 30+ min shut-in for

plunger to drop to bottom
Requires shut-in time for

pressure to build
Daily production lost due to

shut-in times
54
27
The PaceMaker Plunger
Only requires ? ____? seconds of shut-in

Ball and piston both fall against flowrate
Allows longer flow time and constant rate

55
Two Piece Components
56
28
Two Piece Plunger Components
Two Piece
Plunger
Internals of
Wellhead
57
Continuous Plunger Cycle
58
29
Plungers that run on the Continuous Cycle
RapidFloTM
PacemakerTM
FreeCycleTM
McClain PlungerTM
59
Two Piece Plunger Operation
Casing P
Tubing P
Slug
Shut in for Size?
Flow Rate ~10 seconds
Cylinder,
Ball, Slug
Rising , Ball falls,
~750 fpm? Liquid

accumulates
Slug Arrival Cylinder hits
Cylinder Falls
ball

60
30
Two Piece Mechanical Components
LUBRICATOR
PISTON
SURFACE
BALL SPRINGS
BOTTOM HOLE
SPRING ANVIL
SHIFTING ROD
61
Low BHP behind Compressor
CONTINUOUS LOWER
SOAP INJECTION TUBING
COMPRESSOR POOR BOY

SETTINGS GAS LIFT
PACEMAKER
INSTALLED
62
31
Dewater Strong Well
PACEMAKER INSTALLED
63
Two Piece Operating Under Packer
PACEMAKER INSTALLED
Shivers Peeples Unit Well No. 5
900
800
700
600
MCFD/ FTP
500
400
300
200
100
0
1-Apr-02
1-Aug-02
1-Feb-02
1-Mar-02
1-May-02
1-Jun-02
1-Jul-02
1-Sep-02
1-Oct-02
1-Nov-02
1-Dec-02
1-Jan-03
1-Feb-03
1-Mar-03
MCFD FTP
64
32
Reduction in Cycle Time
BARRETT LS 004A-MV
450
PACEMAKER INSTALLED
400
350
300
250
200
150
100
50
0
02
02
02
02
02
02
02
02
02
02
2
03
03
03
3
00
00
00
00
00
00
00
00
00
20
20
20
20
20
20
20
20
20
20
20
20
20
/2
/2
/2
/2
/2
/2
/2
/2
/2
0/
7/
4/
1/
4/
1/
8/
2/
9/
6/
2/
9/
6/
26
/3
/7
/5
16
23
30
13
20
/1
/1
/2
/3
/1
/2
/2
/1
/1
/2
1/
1/
2/
10
11
12
9/
1/
1/
1/
2/
2/
10
10
10
10
11
11
11
12
12
12
GASVOL AVG_TUBING_PRESS_PSIG AVG_CASING_PRESS_PSIG AVG_LINE_PRESS_PSIG
65
Fall Data for Two Piece Ball

400 Mscf/D & 200 psi: Ball is predicted to fall at ~1000 fpm:
0.218 lbs, 1.378 dia, Titanium
Gas(0.65)
( ) - Various Vfall rates for Ball
1200
1000
ssure, psia
800
600 200fpm
400fpm
Pres
600fpm
400
800fpm
1000fpm
200 0fpm
Critical Rates
0
0 500 1000 1500 2000
Flow Rates, Mscf/D

66
33
Two Piece Ball Fall Example
1000 Mscf/D & 500 psi: Ball is predicted to fall at ~200+fpm
Gas(0.65) - Various Vfall rates for Ball
1200
1000
Pressure, psia
800
600 200fpm
400fpm
600fpm
400
800fpm
1000fpm
p
200 0fpm
Critical Rates
0
0 500 1000 1500 2000
Flow Rates, Mscf/D
Fall time: 10,000/200 fpm=50
mins

67
Installing Plunger System

Equipment
34
Mechanical Considerations
Mechanical Problems Lead to:
Higher GLR requirements
Higher casing pressure requirements
Failure of plunger system due to sticking or slow

arrival or fall
Loss of pressure due to hole in tubing for

instance
69
EOT vs. Perforations: Placement

Tubing placement is critical in wells with multiple
perforated intervals or massively thick reservoirs.
Tubing placed too deep can cause excessive fluid
transfer from annulus when plunger open cycle is
initiated, which, in turn, can cause
hydrostatic fluid column pressure behind
plunger.
loss of gas differential pressure interface on
plunger, causing it not to arrive.
tubing to load up.
Tubing placed too shallow can cause hydrostatic
head pressure (back pressure) on formation.
Hearn, Weatherford

70
35
EOT Placement Relative to Perfs
Ideal tubing placement will result in the well being unloaded to
the lowest possible perforation depth without putting the well in
danger of excessive loading.
Generally this will occur when the most prolific production zone
is completely uncovered (tubing @ bottom of zone)
The customer must distinguish which zone will be the best
performer and place the tubing to that depth to avoid that zone
having back pressure on it from liquid level.
If the above information is unavailable, experience has taught us
that being as deep as possible is best and in order to get plunger
system to run it may require optimization in the form of tubing
movementt whenh different
diff t zones are mostt active.
ti Ultimately
Ulti t l as
low as possible while still maintaining a GLR that will allow the
plunger to work.

Hearn, Weatherford
71
Where to Land the Tubing
Tubing Below Perfs Tubing Above Perfs

Dead When
Flowing Shut-in Opened
Well Flows Normally Well Shut-in Due to Fluid Pushed From Well Will Not Unload
Line Upset or Casing Into Tubing Liquid in Large Casing,
Loading When Well is Opened, Liquid Column Builds
Well Cannot Lift Liquid Above Perfs and Kills Well
Column
72
36
Downhole Equipment
Bumper springs
Seating cups, collar stop, tubing stop
With or without standing valve
OR
Only a tubing stop!OR

Some
S installations
i t ll ti employ
l a travelling
t lli bumper
b
spring to keep accumulations off spring
73
Wellhead Sleeved to same size as Tubing ID
For 2 3/8s Tubing
Tbg Plgr Valves

2.063
2-3/8 1.995 2.000 2.063
2-7/8 2.441 2.450 2.563
3-1/2 2.992 2.936 3.063
Various
1.995 Phillips & Listiak, SWPSC
74
37
Mechanical
Mechanical Problems/No annulus cause GLR and

P
Pressure i t to
requirements t increase
i l
or plunger
system to fail!!!
With no annulus can require 1000 to 2000 scf/bbl-

1000 for producing GLR
75
Conditions Lead to Mechanical Problems?

Well
Sand
Scale, Asphaltenes
Temperature
Phillips & Listiak, SWPSC
Tubing
Continuous I.D. (pkrs, anchors, crimps, scale, soap build up)
Packer in place or Tubingless Completion
Hole in tubing
Bottom of tubing
Do not place below perfs
Place just below best gas producing zone in long pay
Wellhead
Continuous I.D. (Valves, tees, landing threads, hanger)
Minimize unnecessary valves/tees
Piping must be "plumb
Use double outlet wellhead or lubricator
Flanged may be preferable to threaded joints (safety)
76
38
Conditions Leading to Mechanical Problems?
Surface Equipment
Tank and Separator capacities
Bottle necks, chokes, bends, tees, elbows, small
tubing
Flowline limitations-- pressure increases when
plunger on
Orifice plate sizing
Unable to monitor sales pressure
Compression
Centralized or single wellhead compression
Suction pressure control
Well fights-- correct compressor size,
synchronization Phillips & Listiak, SWPSC
High line pressure delays
By-pass valving
77
Facilities Constraints
Dont bringg on all wells at once

Use of two-piece plunger will upset wells much less
that use of convention plunger lift
Low pressure separators and low pressure lines are
better for plunger
No small lines or bends or elbows at the wellhead
78
39

Plunger Feasibility
Will Plunger Work in Given Well?
Selection: Enough GLR and BU Pressure?
Does the shut in well pressure to line pressure ratio

meet minimum requirements?
(CP-TP)/(CP-LP)<1/2 or so..Load Factor
Slug size is related to the difference between

Casing Pressure and Tubing Pressure
Rule of thumb; max line psi X 1.5 = minimum shut

in psi required
80
40
Plunger GLR Requirement
One guideline is that there should be a well

GLR of: 400 scf / (bbl 1000 ft).
Example:
Suppose the well in question has a measured GLR of 800 scf/bbl
Depth: 5000
Multiply 400 scf / (bbl 1000 ft ) by 5 for 5000 ft = 2000 scf/bbl
needed.
Si
Since 2000 scf/bbl
f/bbl is
i needed
d d andd onlyl 800 scf/bbl
f/bbl is
i measured
d
from the well, by this rule, the well is NOT a candidate for
plunger lift.
This guideline is approximate and does not consider the
pressure available from the well.
81
Problem
(a) For usual plunger applicaton:
Wells must make 400 scf/(bbl-1000)
(b) For more conservative or slim hole requirement:
W ll mustt make
Wells k 1000 scf/(bbl-1000)
f/(bbl 1000)
(c )For plunger with packer in place:
Wells must make 2000 scf/(bbl-1000)
A well depth is 7777 ft deep and makes 40 bbls-total/MMscf.
The well has 7 inch casing. Is it candidate for Plunger Lift as far as GLR
requirements go?
(A well is 9999 ft deep and makes 100 bbls-total/MMscf. Is it a candidate for

Plunger Lift? It has 4 casing.
(A well is 3333 ft deep and has packer in place. It makes 90 bbls-total/ MMscf. Is
it a candidate for Plunger Lift?
82
41
Plunger: Will It Work? Feasibility Chart
83
Will Plunger Work? Example

Example:
Depth: 8000
Casing buildup pressure in 3
hours: 250 psi
-
Separator pressure: 50 psi
Net operating pressure: 200
psi
Result: from chart, about
10,000 scf/bbl for the GLR is
needed for plunger operation
from the well. If not, then the
well is considered to NOT be a
candidate.

84
42
2 3/8s and 3 7/8s Charts
85
Feasibility Chart Problem for Plunger

Conditions: Well flows 200 Mscfd and makes 16 bwpd
and 4 bcpd. It is 4444 ft deep.
(a) is the well a candidate for plunger considering
for plunger it needs 400 scf/(bbl-1000)?
(b) Is the well a candidate for plunger considering
the chart above? The separator pressure is 100 and it
builds to 400 psi as a casing operating pressure?
(c) Does it need a plunger now? In other words is it
flo ing abo
flowing above
e or below
belo critical flow?
flo ?
(d) Does the well have enough pressure capability
to operate with plunger lift?
86
43
Plunger Operational Ranges: Weatherford
This Weatherford but some say use

Hearn,
bypass plunger if rate still more than
Weatherford
80% of critical rate.
87
Plunger Life Cycle
1. Well is flowing above critical with all flow

in Mist flow, no liquid gradient at any time.
2. Well begins to bubble and slug (Usually
high speed bypass candidate if +15 ft/s
velocity is available.)
available )
3. Well begins to have difficulty maintaining
seal due to velocity getting below 15 ft/s
(usually good application for padded
bypass plunger)
4. Well requires shut-in time to build
pressure to maintain velocity of plunger
(quick-drop application).
5. Well requires build time (conventional
plungerlift applicable as fall time is not
important)
6
6. Well requires substantial build time (high
efficiency seals require more fall time but
have a better seal).
7. Economics need to be reviewed for rod
pump, compression, chamber lift or other
forms of lift.
88
44
Plunger vs. Velocity Strings
Plunger vs Velocity String Performance Inflow
2.00 in ID
PSI 1.50 in ID
1100
1.25 in ID
1.00 in ID
1000
Plunger
900
800
700
600
500
400
300
200
100
0
0 10 20 30 40 50 60 70 80 90 100 110
Gas Rate (Mscf/d)
C:\PROGRAM FILES\PLTECH\PDA\EXAMPLE1.PDA
89
Line Out for Plunger Cycles
90
45
Control Plunger Cycle: Summary
If the plunger ascends too fast, it is assumed that:
Casing pressure is too high
Slug size is too small
Line
eppressure
essu e hasas fallen
a e
The controller may respond by:
Increasing flow time
Decreasing shut-in time
If the plunger ascends too slowly, it is assumed that:
Casing pressure is too low
Slug size is too large
Line pressure has increased
Plunger seal is becoming less efficient
The controller may respond by:
Decreasing flow time
Increasing shut-in time

91
E h
Echometer
t Plunger
Pl
System
New Analysis Technology
46
Echometer System to Track Plunger in Well
New Technology for Analyzing Plunger Lift
*Thanks to Lynn Rowlan w/ Echometer
93
Plunger Falling Through Gas and then Liquid
200 Ft/min 39 Ft/min

Gas Liquid
q
Plunger Hits Liquid
Plunger on Bottom
Zoom in on Axis From 40.554 to 13 mins

94
47
Count Collars for Depth Determination
95
Plunger Depth and Fall Velocity
Depth Axis
End - 131 ft/min
AXIS *Thanks to Lynn Rowlan w/ Echometer
Begin - 250 ft/min
Normally, Velocity Decreases as Plunger Falls Deeper into Well

96
48
Trouble Shooting by Tracking Plunger
1. Find holes in tubing of Gas wells or Plunger Lift

wells by monitoring tubing and casing pressure
while using acoustic to determine depth as
plunger is falling.
2. Collars can be counted from the time the
plunger starts falling to the time the pressure
increases.
3. Procedure determines depth to stuck plunger or
hole.

97
Hole in Tubing Shown
98
49
Adjustable By-Pass
Tite Spot at 60th Joint.. Sticks Plunger
Tubing Pressure Increases when Plunger

Sticks
Tubing Pressure Drops when Plunger Starts to

Fall
Shut-in
Begins

99
Hole in Tubing
1) Hole was 156 jts from surface or 5054' based on 32.4'

joint lengths
2) Hole measured with micrometer to be 0.160
0.160 by
0.125.

*Thanks to Lynn Rowlan w/ Echometer 100
50
Fall Velocity Slows in Deviated Well
Plunger Slowed from 200

ft/min once plunger goes
past Kick off Point 8234 Ft
What Effect Does Wellbore Deviation Have on Plunge Fall Velocity?

101
Horizontal Well Impacts Velocity

Viper Plunger Fall Slowed
Down from 344 to 280 ft/min
After going past Kick off Point
3861.55
What Effect Does Wellbore Deviation Have on Plunger Fall Velocity?

102
51
Horizontal Well Impacts Velocity
Dual Pad Plunger Increased
Speed from 230 to 450 ft/min once
Plunger Goes Past Kick Off Point
3904.2
Solid Plungers Decrease Speed VS Padded Plungers Increase Speed?

103
Deviated well bore configuration

Allows drilling of up to 22 wells
from one pad
Effects of inclination on fall
velocity
Plunger Lift Challenges

Fall velocities
Rise times
Optimization of Plunger Lift

What plunger will provide the
best results in my wells?
104
52
Pad Plunger in Highly Deviated Well #1
Velocity (fpm)
150 200 250 300 350 400 450 500
0
Plunger Fall
Velocity
500
W ll
Well
Inclination
1000
1500
2000
Depth (ft)
2500
3000
3500
4000
4500
5000
0 5 10 15 20 25 30 35 40 45
Well Inclination (degrees)

Williams 2008 First Quarter Earnings / February 21, 2008 105
/ 105
Brush Plunger in Highly Deviated Well #1

Velocity (fpm)
300 350 400 450 500 550 600 650
0
Plunger Fall
Velocity
500
Well
Inclination
1000
1500
2000
Depth (ft)
2500
3000
3500
4000
4500
5000
0 5 10 15 20 25 30 35 40 45
Inclination (degrees)

/ 106
53
Solid Plunger In Highly Deviated Well #1
Velocity (fpm)
300 350 400 450 500 550 600 650
0
500
1000
1500
2000
Depth (ft)
2500
3000 Plunger Fall

Velocity
3500 Well
Inclination
4000
4500
5000
0 5 10 15 20 25 30 35 40 45
Inclination (degrees)

/ 107
PCS Smart Plunger: Alternate to Echometer

Plunger contains
module to record
pressure and
temperature with time
Run plunger and collect
data
Remove plunger from
well and play data back
to computer
Make
M k analysis
l i on how
h
plunger was running
108
54
Safety Benefits of Tracking Plunger
1. Plunger
g Lift Tracking
g increases safetyy of plunger
p g lift operations
p
by knowing where the plunger is in the tubing.
1. If a plunger is not going to bottom and the well is pressured up,

then the plunger could surface dry at a very high velocity.
1. Arrival at high velocity can cause equipment damage and could

result in exceeding the mechanical integrity limits of the
lubricator
109
Safety Considerations
Excessive impact force will cause even the best lubricator to

fail.
Worn springs and excessive plunger velocities can lead to
f il
failure
Screwed joints on wellhead can come loose with hard plunger
impacts.. Flanged joints may not solve problem
Large diameter plungers most dangerous
High casing pressure cycles are most dangerous
Low liquid producers are most dangerous.
If stuck and high casing pressure and low tubing pressure, it
could be hydrate problem
problem.. Inject Methanol before opening or it
could release suddenly causing damage.
Never look down the tubing when well open.
Listening to well with ear on well to sense arrival could be
dangerous if well head failed
110
55
Some Failures.. Fast Arrival
111
I
Inspection
ti &
Maintenance
Plunger Operation
56
Mechanical Checks Phillips & Listiak, SWPSC
Plungers
Pad Type
Check for Looseness and Wear
Brush Type
Gauge O.D. with Gauge Ring Or Caliper (Temperature limits)
Bar Stock (use only as last resort)
Gauge with Calipers
Two Piece
Check Ball for indentations, sleeve for wear
Lubricator Shock Spring
p
Visual Inspection and Looseness in Catcher
O-Rings
Visual Inspection, Leaks
Sensor / MSO (Magnetic Shut Off)
Filter Element
Automated catcher if present

113

Tracking
Keep a History
Cycles / Trends
Optimize Production and Minimize Operator Time
Plunger Changes
Get most efficient use and life from plunger
Optimize Profit
Surface Shock Spring
Optimize Plunger Life
Reduce Cost (Spring Costs Much Less Than Plunger)
How to Track
Controller Cycle Forms
Plunger System Tracking Forms
Plunger well data linked directly to a database
Record # cycles or mileage such as 10,000-15,000 miles?
Failure Analysis
Determine the life span of plungers/shock springs
Reasons for frequent plunger changes
114
57
Track Plunger Changes
Budget, preventive maintenance, save money
Consider monitoring mileage travel of plungers before
changeout
P LU NGER SYSTEM TR ACKI NG
WELL NAME: _________________________________________
OIL DRIP BPD: _______ BW PD: _______
PLUNGER OK REPLACED
TYPE:____________________
DATE INSTALLED: _______________
DATE REMOVED: _______________
# OF CYCLES COMPLETED: _______________
CONDITION/REASON FOR CHANGE :___________________________
___________________________________________________
___________________________________________________
LUBRICATOR SPRING OK REPLACED

DATE REMOVED: _______________
# OF CYCLES COMPLETED: _______________
CONDITION/REASON FOR CHANGE: ___________________________
___________________________________________________
___________________________________________________
Phillips & Listiak, SWPSC MODULE OK REPLACED

DATE REMOVED: ________________
115
Plunger Speed
Industry Recommendations
Length
g of buildup,p casingg pressure
p
Length of flow, slug size
Changing line pressure?
Loss of slug during buildup?
Momentum of heavy plungers will do damage?
Use Foss and Gaul Spread Sheet to predict speed
vs. Csg BU Pressure
116
58
Casing Plunger
OPERATION WITH VERY

WEAK WELLS:
CONSIDER CASING
PLUNGER
117
Casing Plunger
IPS
Model

118
59
Casing Plunger Candidates
Liquid Loading Gas Wells with Tubingless

Completions
Swabbed wells, Coil tubing cleanouts
Minimum reservoir/pipeline differntial of 175 kpa
Remote access wells
Multiple zones, deviated wells, restricted casing
formation fines will hinder the operation of a casing
plunger
119
Casing Plunger Preparation
Surface Preparation
120
60
Standing Valve for Plunger Well?
Disadvantages:
1 Cant
1. C t push
h fluids
fl id outt off tubing
t bi
2. Could plug?
3. Pull partially wet string?
Advantages:
1. Holds fluids over plunger
2. More efficient lift
121
Plunger Location after fall through Gas/Liquid
Fluid is presumed in tubing at end of

flow cycle so plunger falls through
fluid and has slug over the plunger
to begin with
122
61
Why loose fuid?
IF FLUID FALLS OUT OF TUBING

PAST TUBING THEN NO LIQUID
LOAD FOR NEXT CYCLE:
1. PLUNGER IMPACT PUSHES
FLUID OUT
2. BUBBLES FLOATING INTO
TUBING PUSHES FLUID OUT OF
TUBING
3. BUILD-UP PRESSURE DROPS
CASING LEVEL BELOW TUBING
END
4. OTHER??????

123
Keep Fluid in Tubing?
SOLUTION TO PREVENT LIQUID

FROM DROPPING FROM TUBING
OVER PLUNGER?
ONE METHOD IS LOW

PRESSURE BLEED FROM
TUBING TO KEEP TUBING
PRESSURE LOW COMPARED TO
CASING.
124
62
Keep Fluid in Tubing
SOLUTION TO PREVENT LIQUID

FROM DROPPING FROM TUBING
OVER PLUNGER?
ANOTHER SOLUTION:
USE STANDING VALVE WITH CUT
SEAT. THE CUT SEAT ALLOWS
YOU TO PUSH OUT FLUIDS
FROM THE TUBING BUT STILL
HOLDS LIQUIDS IN TUBING FOR
MOST PART BEFORE NEXT
CYCLE!
125
Spring Loaded Check Valve
Spring loaded ball & seat allow fluid

retention but eliminate high loads
126
63
FB Spring Loaded Check Valve
You have to look close to see the passage way around
the seat if the differential pressure exceeds the spring
force. The housing has slots milled in it to form a cage
for the seat. Under normal conditions the seat will be
held against the housing by the spring and the ball and
seat will function as a check. However if the well gets
loaded up all that is needed is to equalize the tubing and
casing pressures and the fluid will flow around the ball
and seat back into the reservoir until the head of the fluid
in the tubing equals about 20 psi. Alternately, the tubing
can be pressurized and all of the fluid forced back into
the reservoir
reservoir.
We currently use this on our 2 and 2 bottom stops.
We also have one designed for 1 tools.
I tried to send images of the solid model but have been
unable to get the quality needed to see any detail. If this
does not answer your questions please let me know.

127
Other Systems
64
Side String Gas Injection for Plunger
OPERATION WITH VERY

WEAK WELLS:
WELLS
-
CONSIDER SIDE
STRING PLUNGER
Re: PLSI, Midland TX
129
Plunger Enhanced
Chamber Lift
PECL
65
PECL
131
PECL
132
66
PECL
133
PECL - Surface
134
67
Progressive Plunger Lift System
By adding a second set of plunger
equipment and staging your lift
cycle you essentially produce the
well with two plunger systems.
The system includes from bottom
to surface
1. A typical bottom hole bumper spring
2. A solid ring plunger for the bottom
stage
3. An ILA (see right) made up of two
bumper springs (one facing up/one
down) a sealing component, a check
valve and a tubing stop.
4. Another plunger to lift for the upper
stage (usually a double pad)
5. A Lubricator to receive the upper

plunger.
135
What makes good candidate for Progressive

Primarily used in wells that have GLRs
below what is necessary to lift a
conventional plunger system.
Generally wells that barely make the
required gas for lifting a plunger from
bottom with the required fluid loads.
Wells that shut in on arrival due to
significant inflow of fluid during lift cycle.
Field Trials indicate that it decreases lift
gas by 1-3 Mcf per Barrel.
Also used in wells which are depleted to
the
th point thatt th
i t th they no llonger can lift using
i
available casing pressure builds.
Wells that have previously been
considered Rod Pump Candidates.
136
68
Set Depth for Progressive Plunger Lift
As a general Rule ILA is set at 65% of the total depth
from surface to PSN.
Actual optimal depth is can also be calculated.
1
1. Establish approximate gradient of well
2. Use pressure at 65% as a start point as the
pressure for the lower stage and line pressure as
upper stage and complete Foss and Gaul
Calculations.
3. Adjust Depth as necessary to establish the same
gas requirement
i t for
f the
th upper and
d lower
l stage
t
using fine adjustments.
Once these Calculations are done the well can be
identified as a good candidate and the install depth
can be chosen.

137
69

200.3 Plunger Main

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200.3 Plunger Main

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Plunger Lift

Introduction to Plunger Lift: System Below

Transducer: Electronic device that emits an electronic signal to

Motor Valve: Diaphragm-operated device controlled by

Lubricator/Catcher: Uppermost stopping point for plunger; acts

Arrival Sensor: Magnetic device strapped around lubricator to

Bumper Spring: Shock absorber at depth

Plunger: Pig-type device that provides seal between gas and

Plunger Lift System Wellhead

Requires no outside energy source if GLR and

GLRs to drive system

Conventional Plunger Cycle

Collar & Tubing Stops

Type A tubing stop

3K and 5K psi rating

Electronic or magnetic switch that allows controller to

Controllers: Many Options

Turbulent Seal Conventional Plunger

Poor seal, for

Two Piece Bypass Continuous Flow Plunger

Bypass Continuous Flow Plungers

Heavy plungers. Use

Additional Bypass Continuous Flow Plungers

FBI bypass plunger

Weatherford Rapid Flow

3. Rapid Fall Plunger 6

A Plunger System Controls Two Factors

Essentially, a plunger system is an on/off switch!

Input data into Foss

J.D. Hacksma, 1972,

"The producing tendency of plunger lift is directly

Inflow Gas IPR

Gas Rate, Mscf/D

Manually Set Controller

An on/off timer is set to flow and shut-in the well

Times set by operator

Time cycle control

Result: Mere guessing at time required to achieve

Tubing Pressure as Control Parameter

Initiate on cycle for plunger lift when:

When to turn Plunger Flow Off

Initiate off cycle for plunger lift when:

Controller changes length of flow and length of

Summary of Velocity Control Algorithm

Shut-in well the shortest amount of time possible (but long

Flow the well only until it begins to load with liquids

Slow Cycles Avg BHP

Summary of Plunger Cycle

Maximum frequency means plunger to bottom of

Also flows long enough to bring in small slug of

Then lowest average casing pressure is the goal

Two Piece Plunger

The Conventional Plunger

Requires 30+ min shut-in for

Requires shut-in time for

Daily production lost due to

Only requires ? ____? seconds of shut-in

Two Piece Components

Continuous Plunger Cycle

Two Piece Plunger Operation

~750 fpm? Liquid

Low BHP behind Compressor

COMPRESSOR POOR BOY

Two Piece Operating Under Packer

OIL DRIP BPD: _ BW PD: _