Introduction to Plunger Lift Systems

During the producing life of a well, there will come a time at which the bottom hole
pressure and gas to liquid ratio will not support natural flow. At this time the operator
must select some form of artificial lift to remove fluid from the well so production can
continue. Plunger lift is a form of artificial lift which can be effectively used in
maintaining production levels and in stabilizing the rate of decline in production.

For plunger lift to be functional there must be sufficient gas present to drive the system.
Oil wells making no gas are not plunger lift candidates. However, there is an industry
misconception regarding how much gas and pressure is required to successfully operate
a plunger lift system. Because many engineers and field personnel have operated under
this misconception, large numbers of wells have been placed on more costly forms of
artificial lift, such as pumping units, than was necessary. As a result, optimum results
have not been achieved and a capital expenditures much larger than necessary have
been made.

As the flow rate and pressures decline in a well, lifting efficiency declines
geometrically. Before long the well begins to "load up" and "log off". This is a
condition whereby the gas being produced by the formation can no longer carry the
liquid being produced to the surface. There are two reasons this occurs. First, as liquid
comes in contact with the wall of the production string of tubing, friction occurs. The
velocity of the liquid is slowed and some of the liquid adheres to the tubing wall,
creating a film of liquid on the tubing wall (see Fig. 1(a)). This liquid does not reach the
surface.

Secondly, as the flow velocity continues to slow the gas phase can no longer support
liquid in either slug form or droplet form. This liquid along with the liquid film on the
sides of the tubing begin to fall back to the bottom of the well. In a very aggravated
situation there will be liquid in the bottom of the well with only a small amount of gas
being produced at the surface. The produced gas must bubble through the liquid at the
bottom of the well and then flow to the surface. Because of the low velocity very little
liquid, if any, is carried to the surface by the gas (see Fig. 1(b)).

The corresponding head of liquid in the bottom of the well exerts a back pressure
against the producing formation in a value equal to its weight effectively terminating the
well's ability to produce. Properly applied plunger lift systems have been able to bring
such wells back to life and to make them extremely profitable once again.
 Figure 1.

Once a well begins to load with liquid, the least expensive way to keep it flowing is to
use an intermitter. An intermitter is simply a controller at the surface which is used to
open and close the well, usually on a time signal. In using this technique the well is stop
cocked by shutting it in for a period of time to allow it to build pressure. After sufficient
pressure has been achieved, the intermitter opens the valve at the surface, allowing the
well to flow into the flow line. Because of the extra pressure in the well from the shut-in
period, the velocity in the production string of tubing is higher and some of the liquid is
able to be brought to the surface. There are a number of variations on this theme. One
such variation is where the well is continuously flowed to the sales line with an
intermitter and valve on a line to a pit or tank. Occasionally the intermitter will open
this line, bypassing the back pressure of the sales line and production vessel, and vent to
the pit or tank. Again the velocity is increased as the back pressure at the surface is
eliminated. Even in using this technique to unload wells there is fluid fall back. The
amount of fall back depends upon the depth of the well, size of the tubing, and velocity
of the fluid achieved in the tubing string. Generally, there will be between a 5% and 8%
fall back rate per thousand feet. Consequently in a 6500' well there can easily be a 50%
fall back rate. Keep in mind that any fluid that is not produced at the surface exerts back
pressure on the producing formation in the amount of its weight, thus hindering the
well's ability to produce.

Plunger lift uses this same intermitting technique, along with a free traveling plunger in
the tubing string used as an interface between the liquid phase and the gas phase.
Because of the action of the plunger in the tubing, there is less than a 5% fluid fall-back
rate over the entire length of the tubing string irrespective of well depth (see Fig. 1(c)).
As a result, the well can be operated at a lower flowing bottom hole pressure, as all
liquid is removed from the well bore, thus enhancing production.

SPRING ASSEMBLY
A plunger lift system is comprised of numerous component parts, the make of which
depends upon well parameters and surface equipment. Generally a bumper spring
arrangement is placed at the bottom of the well and is used as a shock absorber for the
plunger as it falls to the bottom of the well during the close cycle. The bumper spring
should be manufactured in such a way that it remains stationary in the bottom of the
well and does not travel in the tubing during the cycling of the system. Well Master
manufacturers both a "Seat Cup Spring Assembly" and a "Collar Stop Spring
Assembly". The seat cup spring assembly is a single piece unit comprised of a large
bumper spring for shock absorption and a cup hold down section that seats in a standard
API seating nipple, which becomes part of the tubing string. With the seating cups
forced into the seating nipple, the seat cup spring assembly remains stationary in the
bottom of the well. A ball and seat can be added to this unit to trap fluid in the tubing
string above this tool. This can be important on low pressure wells with good
permeability.

The collar stop spring assembly is similar to the seat cup spring assembly and serves the
same function, but the bottom part of it is manufactured from a type F collar stop
instead of a seating cup hold down. Its function is the same and is used in wells where
there is no seating nipple in the tubing string.

PLUNGER
The plunger in the system is the device that freely travels from the bottom of the well to
surface and back. There are numerous designs of plungers and Well Master's arsenal is
comprised of a variety of plungers for varying situations. The plunger is used as a
mechanical interface between the gas phase and the fluid phase in a well. With the well
closed at the surface, the plunger rests at the bottom of the well, on top of the spring
assembly. When the well is opened at the surface, with all production being through the
tubing, the well begins to flow and the pressure in the tubing decreases. Because the
trapped gas in the casing/tubing annulus remains at a higher pressure than the tubing
and the differential pressure between the two increases, the fluid level in the annulus
decreases as the fluid is pushed downward where it u-tubes into the tubing. The
mechanical tolerance between the outside diameter of the plunger and the inside of the
tubing leaves sufficient space for the fluid to bypass the plunger, allowing it to remain
resting on bottom. When all the fluid in the annulus is on top of the plunger, the stored
gas which is displacing it U-tubes into the tubing. As this occurs, the expansion
properties of gas cause the plunger to move up the tubing string with the fluid load on
top. A small amount of gas will bypass the plunger, but this is useful as it scours the
tubing wall of fluid, keeping all the fluid on top of the plunger. This small gas blow-by
also helps lighten the liquid load on top of the plunger so not as much pressure is
required under the plunger for lifting. If the system has been properly engineered,
virtually all the fluid can be removed from the well, which allows the well to flow at the
lowest bottom hole pressure possible. Production is consequently optimized.
LUBRICATOR
At the surface on top of the well head is a lubricator. The purpose of the lubricator is to
place the plunger in the well and to retrieve the plunger from the well without having to
kill the well or run special tools using wireline. Incorporated into Well Master's
lubricator is a manual catcher mechanism for this purpose, along with a heavy spring
and bumper pad to absorb the shock of the plunger at the surface in the event it surfaces
at a high velocity. A plunger sensor is also part of the lubricator. The plunger sensor is
used to detect plunger arrival at the surface sending a signal to the controller for various
control functions to help optimize production and reduce operating costs by minimizing
the field time required to "fine tune" the system. To help make the field personnel's job
even easier, Well Master has incorporated an "easy spin" lubricator top which can be
removed easily without tools for plunger inspection and exchange. The lubricator will
also have one or two flow outlets which are tied into the flow line. It is recommended
that a double outlet lubricator be used if the expected flow rate will exceed 200mcf/d or
if a pad type plunger is to be used. The dual outlet lubricator is designed to eliminate
freezing problems in the lubricator during the afterflow sales cycle (the flow time
following plunger arrival at the surface).

DRIP POT ASSEMBLY

The drip pot assembly is comprised of a small pressure vessel and a pressure reducing
regulator. The pressure vessel will knock out hydrates in the gas before it goes into the
regulator. The regulator reduces the casing pressure to 25 psi supply gas for the
controller and motor valve. This gas is sent to the controller, which in turn opens and
closes motor valves as a function of time, pressure, or both.

MOTOR VALVE
One or two motor valves are also part of the system at the surface. They are used to
open and close the well and are operated by the controller. As gas is placed on the motor
valve diaphragm, the valve opens. When this gas is exhausted, thus removing the
pressure, the motor valve closes. An internal spring in the valve causes it to remain
closed when no gas pressure is supplied to it.

CONTROLLER
The controller can be of several different types. Keep in mind that, regardless of the
simplicity or sophistication of the controller, its primary task is to open or close the
motor valve. This, in essence, opens and closes the well, which allows for the control of
well pressures and for effective fluid removal. Well Master's Model 50 controller was
designed as a low end controller to intermit a well or for plunger lift. For its price, it has
a number of features as standard items which are not found in more expensive units.
The Model 50 controller is primarily a timer with four different programmable time
cycles. It can also be connected to pressure switchs for well control via pressure. A
plunger sensor circuit is also included for control when plunger lift is used.

The Model 300 Production Management System controller is one of the most
sophisticated controllers on the market today and yet it's design makes it easy to learn
and use in the field. Well Master's philosophy for system, and in particular controller,
design is for maximum system utilization leading to optimum production. This can only
be done through great design flexibility to meet every conceivable contingency while
keeping things simple and easy to understand. Field personnel who do not understand
their equipment will not be able to optimize production for the operator. Please consider
the multifaceted benefits of the Model 300 Production Management System when
designing your plunger lift system. The pay-out on production increase using Well
Master's plunger lift equipment is impressive.

Engineering The System

There are a few parameters to keep in mind in the design of a plunger lift system.
Generally speaking, these are common sense principles which will help optimize
production when using plunger lift.

1. The production string of tubing should be the same inside diameter throughout
its length.

2. The well head should have the same inside diameter as the tubing.
3. The tubing should have a standard API seating nipple on bottom with no tail
pipe below it.
4. The bottom of the tubing should be landed at the top of the perforations or
usually no more than 1/3 of the way into the perforations from the top set of
perfs.
5. Check for any restrictions in the flow line at the surface. These may include
restrictive chokes, hi/low valve, orifice plate, etc. Hi/low valve trim and dump
valve trim may need to be changed to a larger size.
6. The formation must be able to produce at least 300 cubic feet of gas per barrel of
liquid per 1000 feet to be lifted, measuring from the perfs to the surface.
7. The well must be able to build pressure that is 1.33 times the combined pressure
of the sales flow line, liquid load, and plunger weight. For wells with flow line
pressures above 200 psi this constant must be increased.
8. The tubing string must be clean and free of tight spots or scale build-up.
9. Any packer should be removed.

Plunger Lift Applications

A well must have a minimum gas to liquid ration (GLR) of 300 cubic feet of gas per
barrel of fluid per 1000' (Ft.) to be lifted. For example, a 5000' well must produce 1500
cubic feet of gas per barrel of fluid for the system to have application. The higher the
GLR the more efficient the system. Remember to take into account all liquids produced
from the well when making calculations, and not just revenue producing liquids.

For single valve systems when the sales line pressure is 200 psi or below, the well must
be capable of building to a pressure that is 1.33 times the equivalent pressure of the
sales line pressure + liquid load + plunger weight. With line pressure above 200psig,
additional well pressure is required because volumetric gas expansion is less.
Line pressure complications can be avoided using a two valve system. The second valve
controls the low pressure/vent portion of the system. The vent valve is opened just
before fluid arrival at the surface and is closed either by plunger arrival or time. Because
the plunger is not working against sales line pressure, plunger travel is not impeded,
thereby ensuring efficient lifting of fluids with less gas lost during the lifting cycle.

Excellent candidates for plunger lift are wells that are going through a natural heading
cycle, wells that require blowdown to atmosphere to remove fluid before production can
be resumed, and wells that require occasional swabbing to bring back to production.
Almost any flowing well with a packerless completion, where a pressure differential
exists between tubing and casing, can be helped by installing a plunger lift system.
Plungers can also eliminate paraffin treating and cutting, as they generally will keep the
tubing clean of paraffin build-up.

If the reservoir drive mechanism is of the gas cap type or solution gas, a plunger lift can
usually take a well down to depletion. When replacing a rod pump with a plunger lift,
the operating costs of the lease decrease drastically; production often increases 20% or
more and production decline flattens and stabilizes.

It should be kept in mind that gas volume is more important than pressure. Liquid has
been successfully removed from wells using plunger lift with as little as 10 psi of casing
pressure at the surface. With today's modern plunger design and controller technology,
many more wells are excellent prospects for this form of artificial lift than was
previously thought.

Decline Curve Analysis

Figure 2 shows a typical decline curve for a well that has been placed on plunger lift.
Notice that the well began to load up with liquid following the shut-in period for
pipeline repairs in 1991. The natural decline for this well followed line "A" prior to the
shut-in period.
 Figure 2

Shortly after the shut-in period for pipeline repair the well produced with a decline
which approximated line "B". After the fifth month at this decline production dropped
dramatically along line "C". It would be safe to say that if the well hadn't been swabbed
that the decline would have continued as it did in 1992 after swabbing ceased. During
swabbing operations the decline again flattened as indicated by line "D", but not as flat
as it was prior to the shut-in for pipeline repairs

In May of 1992 a plunger lift system was installed and production immediately shot up
to a higher value with a marked flattening of the decline curve. Extending line "A", it
will pick-up and match the production rate and decline of the well while producing on a
plunger lift system. The graph shows the production that has been lost and possibly
never regained. It is believed that this is indicative of skin damage or formation damage,
resulting from liquid sitting in the well bore and not being effectively removed. An
excellent case can be made for the installation of a plunger lift system long before
severe loading occurs. Had the system been installed in 1990 or early 1991, this
operator would have been in a much better financial situation relative to this well.