All you want to know about plunger lift!

Training Overview Introductions Goals and Objectives How do plungers work? Why do we need plungers? Automation Capabilities How to detect a problem? What to do if there is a problem… Review QUIZ TIME! Field Training

Introductions Name Job Title One thing you love about plunger lift… One thing you hate about plunger lift…

Goals and Objectives Overall Goal To familiarize and train operators how to optimize production using plunger lift Objectives To encourage proper operation of PL equipment and software To minimize plunger equipment downtime To encourage operators to increase interaction with current method of artificial lift (plunger lift)

What does a plunger do?

Plunger Lift Overview Plunger Lift is a method of reducing liquid fallback in two phase production (liquid & gas) Plunger serves as a mechanical interface between these two phases (liquid & gas) Plunger increases efficiency of lifting liquids in gas/liquid production

Plunger Lift Overview While well is flowing, fluid accumulates in bottom of tubing string Well must be shut in to allow plunger to fall to bottom and to build pressure Liquid accumulates in tubing above plunger Gas pressure builds in casing & tubing After pressure builds to a sufficient value, flowline is opened

Controller/ Measurement Plunger Lift Overview Tubing Valve Controller/ Measurement Casing Valve Improve GLR to unload liquids, measure tubing flow and inject gas to keep at unloading rate Add plunger lift to increase efficiency of system Can switch control to tubing/casing flow

Plunger Lift Overview While well is flowing, fluid accumulates in bottom of tubing string Well must be shut in to allow plunger to fall to bottom and to build pressure Liquid accumulates in tubing above plunger Gas pressure builds in casing & tubing After pressure builds to a sufficient value, flowline is opened

Controller/ Measurement Plunger Lift Overview Tubing Valve Controller/ Measurement Casing Valve Improve GLR to unload liquids, measure tubing flow and inject gas to keep at unloading rate Add plunger lift to increase efficiency of system Can switch control to tubing/casing flow

Plunger Lift Overview While well is flowing, fluid accumulates in bottom of tubing string Well must be shut in to allow plunger to fall to bottom and to build pressure Liquid accumulates in tubing above plunger Gas pressure builds in casing & tubing After pressure builds to a sufficient value, flowline is opened

Plunger Lift Overview When well is opened, gas stored in casing as well as gas from formation create pressure differential across plunger Stored casing gas moves around end of tubing Plunger begins to rise with accumulated fluid above plunger Plunger arrives at surface with fluid slug

Controller/ Measurement Plunger Lift Overview Tubing Valve Tank Valve Controller/ Measurement Casing Valve Improve GLR to unload liquids, measure tubing flow and inject gas to keep at unloading rate Add plunger lift to increase efficiency of system Can switch control to tubing/casing flow

Plunger Lift Overview When well is opened, gas stored in casing as well as gas from formation create pressure differential across plunger Stored casing gas moves around end of tubing Plunger begins to rise with accumulated fluid above plunger Plunger arrives at surface with fluid slug

Controller/ Measurement Plunger Lift Overview Tubing Valve Tank Valve Controller/ Measurement Casing Valve Improve GLR to unload liquids, measure tubing flow and inject gas to keep at unloading rate Add plunger lift to increase efficiency of system Can switch control to tubing/casing flow

Plunger Lift Overview After plunger arrival, gas is produced for some period of time, depending on well Some wells afterflow for long periods Some wells afterflow for short periods Depends on GLR of well Well shuts in and cycle starts over again

Plunger Lift Cycles Pressure Buildup Shut-in Unloading Flowing-Loading

The plunger adds a mechanical seal Gas Flow

FB Demonstration Surface Equipment Downhole Equipment Receiver/Lubricator Preventative Maintenance Repair Plunger Plunger types Maintenance Downhole Equipment Collar Stop/Bumper Spring How does a CS/BS work? Automation Equipment Intermitter Valve Electronic Controller (ROC)

PLUNGER-LIFT OVERVIEW A typical system is comprised of a: Plunger Collar Stop Lubricator / Catcher Controller/ Motor Valve

Lubricator/Catcher Products Lubricator – Spring absorbs impact of plunger arriving at surface Catcher – Allows you to catch plunger in lubricator mechanically to either inspect or to change

Lubricator/Catcher Products

Plungers Our BeauFlex plunger is designed to provide maximum sealing integrity with minimum gas slippage. It’s sealing capability allows it to be used in wells where there is not enough gas to operate other types of plungers.

Plungers Ferguson Beauregard’s Mini-Flex plunger features 8 interlocking stainless steel pads to create a superior seal. The spring-loaded pads are always expanded yet have enough flex to allow the plunger to fall through minor tubing anomalies.

Plungers The Duo-Flex is designed for gas wells and high ratio oil wells where sealing efficiently is critical. With 16 interlocking stainless steel pads, it travels with less pressure and with less gas slippage.

Downhole Products Ferguson Beauregard down hole springs and stops are engineered and manufactured in a variety of configurations.

Why do I need a plunger?

Liquid Loading All gas wells, at some time during there producing life, will experience liquid loading problems Liquid Loading occurs when a well’s gas velocity is no longer able to carry the well’s fluids to the surface These fluids fall back and are suspended in the wellbore and/or accumulate in the bottom of the well This additional head increases the flowing bottomhole pressure(FBHP), reduces reservoir drawdown, and thus gas production

Liquid Loading The gas rate at which liquid loading occurs is called the Critical Rate, and is primarily a function of tubing ID and Flowing Tubing Pressure (FTP). Gas flow is in heads (slug flow) or bubble flow (gas bubbles through liquids) Loads up during flow

Liquid Loading Detection Decrease in Production Wells being swabbed, blown down, etc. Sales Charts Production Decline Curves Pressure difference between casing & tubing

Conclusions Plunger-Lift remains the most economical form of artificial lift Plunger-Lift also remains more time consuming and requires more monitoring than other forms of artificial lift. This can be reduced by the addition of plunger lift telemetry. There are several types of control methods other than conventional plunger lift that might be better suited for your situation. Not a cure all – Certain parameters must be met for a successful installation.

BREAK TIME! Take a 10 minute break!

Automation Capabilities Viewclient Up to the minute production info Plunger Settings Minute Histories

East Texas/North Louisiana Viewclient

Screenshot: Oletha/Pearwood

Production Screen with Plunger Settings Box

Minute Histories

Plunger Settings Tubing Setpoint (psig) Low Flow Setpoint (MCF) Low Flow Time Delay (min) Max Flow Setpoint (MCF) PID Valve Output (%)

Plunger Settings Tubing Setpoint Pressure setting that triggers valve to open after pressure build-up Should be at least the minimum pressure needed to unload the well (Turner Chart) Varies for each well

Plunger Settings Low Flow Setpoint Low Flow Time Delay Minimum rate well can flow without loading Should be at least the minimum rate needed to unload the well (Turner Chart) Low Flow Time Delay Amount of time well will flow after reaching Low Flow Setpoint Setting is useful since wells may spike up and down while unloading Each time the low flow rate is reached a timer begins and will shut once that rate or lower has lasted for the time setpoint Typically 10 or 15 minutes is used

Plunger Settings Max Flow Setpoint PID Valve Output Maximum flow rate the intermitter valve will allow when opening Prevents extremely high rates that over-range the meter PID Valve Output Displays percentage of the valve open If valve shows 0%, the well should not be flowing

Examples Leaking valves Valves not opening Valves not closing Opened bypasses Properly working valves

How to Detect a Problem… Troubleshooting How to Detect a Problem…

Common Problems Constant pressure build-up but valve is opening/closing Casing pressure is extremely high while tubing pressure is low or zero Well producing while PID valve output is 0% or closed Opened bypasses Well flowing too long and loads up

Field Operator Responsibilities Automation Tech Responsibilities Possible Causes Field Operator Responsibilities Plugged Orifice Supply Gas Problem plugged screens bad regulator Cut Out Seat/Trim Bypass Cracked Open Automation Tech Responsibilities Requires Recalibration Wiring Problem I/P Motor Valve Problem

Things to Remember… Don’t open the bypass unless someone is informed Never adjust I/P zero setpoint or spring tensions on valve Supply regulator needs to be 30-35 psig

COGZ Work Order Request Go to Start Menu →All Programs →Citrix ICA Client →MGROUP Program Neighborhood Insert User Name and Password Go to Houston Apps →COGZ Work Order Request Click “Add Request” →Insert requested information →Click OK

BREAK TIME! Take a 5 minute break!

Review How plungers work Why we need plungers Automation Capabilities Settings & Minute Histories How to detect a problem What to do if there is a problem

QUIZ TIME!

Name 2 of the 4 plunger settings that can be adjusted or changed Question 1 Name 2 of the 4 plunger settings that can be adjusted or changed

Question 2 What’s wrong?

Question 3 What’s wrong?

Question 4 If the field operator cannot fix a valve problem, what’s the next step?

Question 5 Plunger lift is great! True or False

Conclusion Plunger lift is a permanent part of our field Operators are required to interact with plunger equipment, settings, etc Everyone is here to help!!

Field Training How to check for a damaged valve How to replace a valve How to check for supply gas problems Then… LUNCH!

Questions?