Optimize and Troubleshoot Plunger Lift WellsOptimize Production 1. Develop an artificial lift...

Gas Well Deliquification Workshop

Sheraton Denver Hotel

Denver, Colorado

February 24 - 26, 2014

Optimize and Troubleshoot Plunger Lift Wells

David Cosby, P.E.

Shale Tec LLC

Why optimize

Planning

Optimize production

Detect & troubleshoot

Sustain peak production

CONTENTS

2 February 24 - 26, 2014

2014 Gas Well Deliquification Workshop

Denver, Colorado

3

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Daily Production

NATURAL DECLINE CURVE

No missed plunger cycles?

Meets daily production

goal ?

Produce at or above 80 % of AOF?

500 to 1000 fpm plunger

cycle ?

20% production increase?

Rapid payback ?

What is an optimized well?

Why Optimize?

ESTABLISH A PRODUCTION TARGET !

“An optimized plunger lift well is a well that is operating at the maximum number of cycles necessary to generate

the lowest average flowing bottom hole pressure with the available reservoir energy.”

ALRDC Guidelines and Recommended Practices

February 24 - 26, 2014 2014 Gas Well Deliquification Workshop

Denver, Colorado

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Flow Rate (Mscf / D)

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ABSOLUTE OPEN

FLOW !

Inflow Performance Relationship

46 % of AOF

- 60 psi

42 mcf /d

Why Optimize? Why is it important?

$ 60,480 / year @ $ 4/mcf

“Gas Well Deliquification” by Lea, Nickens, Wells “Natural Gas Engineering Handbook” by Guo, Ghalambor

79 % of AOF


Denver, Colorado

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DAILY PRODUCTION

CASING PRESSURE

NATURAL DECLINE CURVE

LOST PRODUCTION

FL

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RA

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(m

cf)

PR

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SU

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(p

si)

LIQUID LOADED DECLINE CURVE

$ 187,200 / year @ $ 4/mcf

LOST PRODUCTION

Why Optimize? Why is it important?


Denver, Colorado

Planning

6

“Problems are nuggets to be

mined, not garbage to be

buried”

Mental Models

“Getting the Right Things Done” by Pascal Dennis

“Creating a Lean Culture” by Dennis Mann

“The Toyota Way” by Jeffery K. Liker


Denver, Colorado

Fire Fighting / Squeaky Wheel

Where are we now?

Where do we need to

go?

How do we get there?

1. Define True North 2. Develop the plan 3. Deploy the plan 4. Monitor the plan 5. Solve the problems 6. Improve the system

Planning Understand the mess!

1. Target? Actual? Gap? 2. What prevents us from meeting our target? (fishbone) 3. What are the causes in order of importance? (pareto) 4. What actions will address the most important causes? (A3)

7

What’s the

Process? How can

you tell it’s working?

What are you doing to improve it?


Denver, Colorado

What is the gap ? Dashboard – one 11” X 17” page

Planning

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OT Contract

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Near Miss

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Safety

GOAL


Denver, Colorado

Why are we missing

production targets?

Machine

Method Material Man

Well Frac’d into

Management

Time per well

Liquid loaded

Drill rig on site

Not enough people

Limited technology

No standard processes

9

What are the causes? Fishbone !

Planning

Insufficient data

Restrictions

Sanded in

Absenteeism

Training

Motivation

Equipment failures

Line pressure issues

Well Conditions

Equipment

Inadequate resources

Fire fighting culture

Poorly defined goals

Non-Optimized Wells


Denver, Colorado

10

What are the causes in order of importance ?

Planning

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LiquidLoading

Notoptimized

SurfaceEquipment

Personnel Pipeline Sanded-in Unknown Frac'd Into

Wells producing below production target

Pareto Frequency of Occurrence

$ 500,000 / yr

$ 350,000 / yr

$ 120,000 / yr

Freq

uen

cy o

f O

ccu

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Denver, Colorado

1. WHY are the wells liquid loaded?

Artificial lift was not installed prior to lost production

2. WHY was artificial lift not installed to prior to lost production?

We did not know the wells were about to liquid load

3. WHY didn’t we know the wells were liquid loading?

All of our resources are focused on operating existing plunger lifted wells

4. WHY are we spending so much time on existing plunger lift wells?

Our operators are untrained and we only have on-site control

5. WHY don’t we train our operators and invest in automation ? ? ?

11

What is the root cause? 5 Why’s !

Planning


Denver, Colorado

PLAN Understand the problem

“A problem well defined is a problem half solved”

1) Is the problem statement clear and accurate?

2) Has the systemic root cause been identified?

DO Implement the plan

3) Has irreversible corrective actions been implemented for all root causes?

CHECK Follow-up

4) Has a plan been identified to verify the effectiveness of all corrective actions?

ACT Adjust

5) Has a plan been identified to standardize and save all lessons learned across all groups?

12

What engine drives a solution? PDCA !

Planning


Denver, Colorado

CONTINUOUS PROCESS

ENGRAIN IN COMPANY CULTURE !

13

What’s the plan? A3 – one 11” X 17” page !

Planning

Performance, Gaps, Targets Show last years results Are we getting better or worse? Show 1, 3, 5 year targets Tell the story with a chart!

FOCUS: Production

SIGNATURES: Author: Version and Date:

Reflection on 2013 activities

Assess 2013 activities. What worked, what did not? Please explain!

Rationale for 2014 activities How does last year affect this year? Any new factors to consider? What are our 3-4 areas of emphasis? How will these benefit us?

Follow-up, Unresolved issues How will we check and report ? Any unresolved issues, questions,

support needed? What will we do about it?

2013 Action Plan


Denver, Colorado

Optimize Production

14 February 24 - 26, 2014


Denver, Colorado

15 February 24 - 26, 2014


Denver, Colorado

Optimize Production

1. Develop an artificial lift strategy

2. Install AL before production is lost

3. Standardized PL configuration

4. Set meaningful production targets

5. Remove restrictions

6. Prioritize wells daily

7. Optimize

8. Troubleshoot with DATA! Train Wide and Deep !

Real Time DATA !

Be Proactive !

Lowest FBHP !

16 February 24 - 26, 2014


Denver, Colorado

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A.L. GENERALLY NOT REQUIRED

BBLS / D

MC

F /

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GLR = 10

GLR = 5

GLR = 3

CONSIDER Multi-Stage PL Gas Assist PL Plunger Assisted Gas Lift

For 7500 ft to BHS 400 scf / Bbl / 1000 ft = GLR of 3

Higher GLR wells are easier to operate, resulting in less non

productive time

90 Mcf/d / 30 bbls/d = 3.0 GLR 150Mcf/d / 30 bbls/d = 5.0 GLR

300 Mcf/d / 30 bbls/d = 10.0 GLR

Barnett Shale Example

Actual Critical Flow Rate

Optimize Production Artificial Lift Strategy

17 February 24 - 26, 2014


Denver, Colorado

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Months

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Production Type Curve

Actual Critical Flow Rate

Install AL Here!

Optimize Production Install BEFORE production is lost

Emergency shut off

Sand cut probe

18 February 24 - 26, 2014


Denver, Colorado

Dual master valve Dual outlet lubricator Platform to reach lubricator Pressure transducer type, location Pressure gauge type, locations Solenoid supply – clean / dry gas! Control valve type, trim, material Ball valve model number Hammer union locations

Controller location and attachment Connection to EFM - trench or radio? Communications with office Lightening suppression

Optimize Production Standardize installation configuration

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19 February 24 - 26, 2014


Denver, Colorado

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IPR CURVE

DECLINE CURVE

CP

Flow Rate

Operating at : 40 % of Absolute Open Flow

or 80 % of Absolute Open Flow?

Target based on: Liquid loaded decline curve

or Long term natural decline curve

Optimize Production Set meaningful production targets

Prioritize wells daily Production

Address shut-in wells first Address wells producing below target

Leading indicators of future problems

Missed arrivals Fast or slow arrivals Low battery voltage Increasing close times Pressures trending higher Ignored preventative maintenance Reliance on Trial and Error

20

“Lifting costs reduced up to 75% with automation”

GWD Denver 2011 XTO / Ferguson Beauregard

presentation


Denver, Colorado

Exceptions Maintenance &

Milk runs

VS

Remove Restrictions Bottom hole spring Motor valve opening Scale, Paraffin 90 Deg elbows Chokes Orifice plates

Optimize Production Restrictions and Exceptions

21

CP

TP

Optimize Production Optimize


Denver, Colorado

Plunger Lift Calculator Daily cycles required Lift pressure required

Select Plunger Fall time less than time to build pressure

Cycle plunger & record Liquid load Lift pressure Plunger velocity Production made Open & Close time

Consider particulates

Approximately 500 to 1000 fpm

Adjust to achieve 1. Sufficient lift pressure to open when fall time expires. 2. Achieve & maintain #1, then increase sales time. 3. Use faster falling or better sealing plunger as needed. 4. Control velocity with liquid load & lift pressure. Ensures least backpressure on formation, thus most inflow

from reservoir into well bore

Minimal sales time on initial cycles

Optimize production, not velocity

Consider auto-catcher for rapid

fall plungers.

“Simple on/off controllers are not effective for optimization of a plunger system.” ALRDC

22

Liquid Volume in Tubing

Plunger Fall Time

Minimum CP required

Cycles per day required

Max possible liquid production

Gas volume required


Denver, Colorado


23 February 24 - 26, 2014


Denver, Colorado

FOUR STAGES Fall (Gas, Liquid) Pressure Build Plunger Rise Production

Plunger Fall Time Varies with gas/liquid in tubing, tubing pressure, well condition

(paraffin, scale) Too short fall time – fast arrivals and liquid loading Too long fall time – lost production

Pressure Build Stage Operate at lowest casing pressure practical (least backpressure) Use Foss and Gaul equation to estimate required pressure

EchoMeter

Plunger Rise Time “Fast enough to avoid stalling, slow enough to avoid damage” 500 to 1000 fpm is a guideline. Optimize production.

Production Stage Same amount of liquid in the tubing on every cycle Little to no sales time until pressure build stage time is zero Critical velocity or increase in CP to indicate liquid in tubing Allow lateral leg to unload for horizontal wells

Well Master app

Consider opening on: Lift Pressure

% of Foss and Gaul Load Factor

Consider closing on: Flow rate

% of Critical flow rate Casing pressure rise


Plunger free cycling

Casing Pressure

Tubing Pressure

Line Pressure

Flow Rate

UNCONVENTIONAL PLUNGER EXAMPLE Very short close time (Ex: 1 to 5 min)

Plunger falls against flow Only round trip times recorded Excessive plunger velocities possible

24 February 24 - 26, 2014


Denver, Colorado


Troubleshoot

25 February 24 - 26, 2014


Denver, Colorado

1. DETECT RAPIDLY o Real time alarms (Cry-out) o E-mail, text

2. DIAGNOSE WITH DATA o Then prescribe!

3. LOOK FOR VARIANCE 4. SOLVE ROOT CAUSE o Formal brainstorming, Pareto, Fishbone, 5 Why

5. BECOME A LEARNING ORGANIZATION o Reduce time between occurrence, detection and return to full production

26

Troubleshoot

CP

LP

FR

Lift Pressure

Liquid Load

CLOSE

OPEN

ARRIVAL

LATERAL UNLOADS

TP


Denver, Colorado

27

Troubleshoot Common Problems

Plunger fails to surface

Stuck in lubricator Worn plunger Not enough pressure Too much liquid Bad arrival sensor or cable Plunger stuck in tubing Grease in tubing from WH valves Rapid fall plunger – shift rod stuck

Slow arrivals

Worn plunger Not enough pressure Too much liquid Tubing restrictions Wrong plunger type

Fast arrivals

Fall time too short Plunger hung in WH Tight spot in tubing Too much pressure Not enough liquid

Control valve will not open

Motor valve leak

Liquid in gas supply line Debris in solenoid valve Solenoid valve malfunction Solenoid vent line plugged

Control valve will not close

No gas supply pressure Clogged gas supply filter Liquid in gas supply line Debris in solenoid valve Solenoid valve malfunction Hole in Motor Valve diaphragm

Obstacle in Motor Valve trim Cut, worn trim (sand, particulates) Consider ceramic trim


Denver, Colorado

28

Short battery life

Inspect battery Inspect wires to solar panel Inspect solar panel

Clean 45 Degree angle Facing south

Radio malfunction (amps)

Catcher will not trap plunger

Inspect / replace spring and or ball

Fishing neck mushroomed

Lubricator spring worn, stuck or too stiff

Excessively fast plunger runs

Flow longer

Motor valve closed, flow rate not zero

Motor valve leak Calibrate flow meter

Lubricator top seeps / leaks

Lubricate threads Inspect “O” ring Grease “O” ring

Flow rate increasing at end of afterflow

Fall time elapsed, CP not rising, OFF time remains

Reduce shut-in time or open at a lower lift pressure

Fast, dry plunger runs. Liquid in tubing on

each cycle

Fall time too short

Missed run every 6 weeks or so – no other

issues

Meter tech on site - shut in meter run


Denver, Colorado


Casing Pressure

Tubing Pressure

Line Pressure

Flow Rate

Control Valve Closed Tubing declines Flow rate observed

Control Valve Leak

29 February 24 - 26, 2014


Denver, Colorado


Casing Pressure

Tubing Pressure

Line Pressure

Flow Rate

Control Valve Closed Line pressure declines

Possible Dump Valve Leak

30 February 24 - 26, 2014


Denver, Colorado


Casing Pressure

Tubing Pressure

Line Pressure

Flow Rate

Control Valve Open Well closed when flow

rate is increasing Flow longer

31 February 24 - 26, 2014


Denver, Colorado


Casing Pressure

Tubing Pressure

Line Pressure

Flow Rate

Control Valve Closed Casing and tubing equalize Pushing liquid out of tubing

Shorten close time or add a standing valve

32 February 24 - 26, 2014


Denver, Colorado


33



Denver, Colorado

Training is not enough! o Develop skill sets required for each critical position. Train and evaluate skill. PDCA!


34

Demonstrated Learning

Skill Operator A Operator B Operator C

Well site safety Complete Required Complete

Basics of liquid loading Complete Required Complete

Basics of plunger lift Required Required Complete

Well requirements for plunger lift Required Required Complete

Surface and sub-surface equipment Required Required Complete

Preventative maintenance Required Required Complete

Controller and graphical user interface screens Required Required Complete

Optimizing plunger lift wells Required Required Complete

Troubleshooting plunger lift wells Required Required Complete

Formal problem solving processes Required Required Complete

EchoMeter - Track / locate plunger, tubing integrity, fluid levels Required Required Complete

Formal team building skills Required Required Complete

E-mail, text, excel, etc …. Complete Complete Complete


Denver, Colorado

Plunger Lift Certification

I. Basic II. Intermediate III. Advanced

Communicate clear responsibilities o Central optimizer (Example)

o Selects plunger lift algorithm and plunger o Selects set points o Monitors pressures, plunger cycles and production o Notifies field operator of current and potential issues

o Field operator (Example) o Well site safety o Coordinates all on site activities o Preventative maintenance and repairs o Occasionally monitors plunger arrivals


35

BOTH are critical to sustained peak production!

Who’s responsible

for production?


Denver, Colorado

Implement a preventative maintenance program o Inspection point, pass/fail criteria, technique, frequency for:

Plunger (Replace BEFORE production is lost) Lubricator (Spring, catcher, “o” ring, connection to WH) Bottom hole spring (Blockage?, Worn?) Control and dump valves (No leaks!) Arrival sensor, pressure transducers, wiring Drip pot or gas scrubber (Check daily, drain) Supply gas to solenoid valves (Clean, dry gas !) Battery, solar panel, wiring Orifice plate Flow meter Tubing integrity (EchoMeter or pressure test)


36

Guidelines & Recommended Practices Use of Plunger Lift for Deliquifying Gas Wells

ALRDC


Denver, Colorado

37 February 24 - 26, 2014


Denver, Colorado

Summary

38

Plunger Lift Considerations

OPTIMIZE PRODUCITON

Summary


Denver, Colorado

Linkedin Group

“Plunger Lifted Gas Wells”


39

“Good To Great: Why Some Companies Make the Leap …. And Others Don’t”

by Jim Collins

“Problems are nuggets to be

mined, not garbage to be

buried”


Denver, Colorado

Copyright

Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Gas Well Deliquification Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to:

– Display the presentation at the Workshop.

– Place it on the www.alrdc.com web site, with access to the site to be as directed by the Workshop Steering Committee.

– Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee.

Other use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Gas Well Deliquification Workshop where it was first presented.

40


Denver, Colorado

Disclaimer

The following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Gas Well Deliquification Web Site.

The Artificial Lift Research and Development Council and its officers and trustees, and the Gas Well Deliquification Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Gas Well Deliquification Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained.

The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials.

The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose.

41 February 24 - 26, 2014


Denver, Colorado

Optimize and Troubleshoot Plunger Lift WellsOptimize Production 1. Develop an artificial lift...

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