Radical New Design In Casing Plungers Proves Successful - 3... · Radical New Design In Casing...

Gas Well Deliquification Workshop

Sheraton Hotel, Denver, Colorado

February 19 – 22, 2012

Radical New Design In Casing Plungers Proves Successful

Robert L. Moore, PE PAL PLUNGERS

Windel Mayfield, PAL PLUNGERS, Lone Star

Rubber

PAL PLUNGERS, Brownwood, Texas

Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop

Denver, Colorado

2

RECENT INNOVATIONS

NEW DESIGN CONCEPT

• CUPS ACTUATED AT BOTTOM OF CASING

• DESIGN COMBINES MECHANICAL AND

PNEUMATIC CONCEPTS

• CONCEPT OF PRESSURE AS LIFT MECHANISM

RATHER THAN VELOCITY

• IMPROVED ELASTOMERS FOR BETTER

PERFORMANCE


Denver, Colorado

3

TYPICAL TUBING PLUNGER


Denver, Colorado

4

Typical Field Assembly

4.5 “ System

Auto Catch

Simple Timer

LPG Supply


Denver, Colorado

5

VIDEO FULL SCALE MODEL


Denver, Colorado

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WIRELINE ACCESS TO WELL

• Access to

lubricator

with std.

hammer

unions


Denver, Colorado

7

OLD CUP AND NEW CUP DESIGN


Denver, Colorado

8

Lower cup

profile showing

expansion of

major diameter

of cup due to

the weight of

plunger

compressing

the spider ring

at the bottom

of the cup.

MECHANICAL ACTUATION


Denver, Colorado

9

UPPER CUP INFLATES


Denver, Colorado

10

REPLACED OLD WITH NEW

Casing had sqz cmt

leak repairs.

Fixed diameter

cups hung up on

descent.

No remedy


Denver, Colorado

11

GAS PRODUCTION RESTORED

0

10

20

30

40

50

60

70

80

90

1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

East

West

North

0

10

20

30

40

50

60

70

80

90

1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

East

West

North

BOATES GAS SALES

0

500

1000

1500

2000

2500

3000

3500

4000

4500

Jan04 Feb 04 Mar 04 Apr 04 May 04 Jun 04 Jul 04 Aug 04 Sep 04 Oct 04 Nov 04 Dec 04

MC

F P

ER

MO

NT

H

Install Casing

Plunger

Production Loss Due To

Bacteria


Denver, Colorado

12

PUMP JACK REPLACED

Oklahoma well

Completed Oct 2003

Perfs 7546-7772

Produced with rods

and 228 pump jack

Frequent mechanical

failures

Decision to try casing

plunger in 2005

Collar stop @ 7507


Denver, Colorado

13

GAS SALES

MARLIN RUTH 1-36

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

Nov

03

Dec

03

Jan

04

Feb

04

Mar

04

Apr

04

May

04

Jun

04

Jul

04

Aug

04

Sep

04

Oct

04

Nov

04

Dec

04

Jan

05

Feb

05

Mar

05

Apr

05

May

05

Jun

05

Jul

05

Aug

05

Sep

05

Oct

05

Nov

05

Dec

05

Jan

06

Feb

06

Mar

06

Apr

06

May

06

Jun

06

Jul

06

DATE

GA

S S

AL

ES

, M

CF

/MO

Install PAAL Casing Plunger


Denver, Colorado

14

OIL SALES

MARLIN RUTH 1-36

0

50

100

150

200

250

300

350

Oct

03

Nov

03

Dec

03

Jan

04

Feb

04

Mar

04

Apr

04

May

04

Jun

04

Jul

04

Aug

04

Sep

04

Oct

04

Nov

04

Dec

04

Jan

05

Feb

05

Mar

05

Apr

05

May

05

Jun

05

Jul

05

Aug

05

Sep

05

Oct

05

Nov

05

Dec

05

Jan

06

Feb

06

Mar

06

Apr

06

May

06

Jun

06

Jul

06

Date

OIL

PR

OD

UC

TIO

N, B

BL

S/M

O

Install PAAL Casing Plunger


Denver, Colorado

15

SIMPLIST WELL HEAD TO DATE


Denver, Colorado

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CASING PLUNGER INSTALLED


Denver, Colorado

17

REPLACED TUBING PLUNGER

• Pumper protested

• Csg @ 180 psi

• About 14 hrs/day

• Csg @ 80 psi

• Line @ 30 psi


Denver, Colorado

18

GAS SALES

CARNAGEY GAS SALES

0

200

400

600

800

1000

1200

1400

1600

1800

Oct

02

Nov

02

Dec

02

Jan

03

Feb03

Mar

03

Apr

03

May

03

Jun

03

Jul 0

3

Aug

03

Sep

03

Oct

03

Nov

03

Dec

03

Jan0

4

Feb 0

4

Mar

04

Apr

04

May

04

Jun

04

Jul 0

4

Aug

04

Sep

04

Oct

04

Nov

04

Dec

04

MC

F P

ER

MO

NT

H

Install Casing Plunger


Denver, Colorado

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FLUID (OIL + WTR) PRODUCTION

CARNAGEY FLUID PRODUCED

0

5

10

15

20

25

30

35

40

Dec 02

Jan 0

3

Feb03

Mar 0

3

Apr 03

May

03

Jun 0

3

Jul 0

3

Aug 03

Sep 03

Oct

03

Nov 03

Dec 03

Jan04

Feb 04

Mar 0

4

Apr 04

May

04

Jun 0

4

Jul 0

4

Aug 04

Sep 04

Oct

04

Nov 04

Dec 04

Jan05

BA

RR

EL

S P

ER

MO

NT

H

Install Casing Plunger

HYBRID CASING PLUNGER

• MANY WELLS PRODUCE FROM MULTIPLE

ZONES; CBM; AND NOW HORIZONTAL

• CASING PLUNGERS LIMITED TO TOP OF ZONES

• TUBING PLUNGERS CAN WORK LOWER

• MOST COMMON SOLUTION—ROD PUMP AND

JACK– OFTEN NOT COST EFFECTIVE

• PRODUCERS NEED SOLUTIONS

Feb. 19 - 22, 2012 2012 Gas Well Deliquification Workshop

Denver, Colorado

20

PART OF THE SOLUTION

• ADAPTED CONVENTIONAL CASING PLUNGER

TO HYBRID ARTIFICIAL LIFT

• SET CASING PACKER ABOVE TOP PERF AND

SMALL ID TUBING OVER ALL PERFS

• UTILIZED RESERVOIR PRESSURE TO LIFT

FLUID ONLY TO PACKER

• HELD FLUID WITH BALL AND SEAT

• REMOVED FLUID WITH CASING PLUNGER

FROM PACKER TO SURFACE

Feb. 19 -22, 2012 2012 Gas Well Deliquification Workshop

Denver, Colorado

21


Denver, Colorado

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PATENTED DESIGN CONCEPT

USE CUP

Packer

Add valve

Hollow stop

Small Dia.

Tbg

Gas flow will

lift fluid

Remove with

plunger


Denver, Colorado

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HYBRID FOR MULTIPLE ZONES

4 ½” 11.6 #/FT

CSG.

CONVENTIONAL

PERF 6026-6038

CSG STOP 6012

HYBRID PAL

PERF 6026-6038

PERF 6342-6346

CSG STOP 5966


Denver, Colorado

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STANDARD COLLAR STOP


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HOLLOW COLLAR STOP


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TAIL PIPE WITH P/T RECORDER


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HYBRID PACKER, VALVE ASSY.


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HYBRID PACKER ON TAIL PIPE


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HYBRID PACKER RELAXED


Denver, Colorado

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HYBRID PACKER COMPRESSED


Denver, Colorado

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P/T DATA FIRST TEST 17 DAYS


Denver, Colorado

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P/T DATA 2ND TEST 11 DAYS


Denver, Colorado

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MECHANICAL ASPECTS

• ALL DOWN HOLE TOOLS WERE SET AND RETRIEVED BY STANDARD WIRE LINE EQUIPMENT

• LOCATION STOP WAS PURCHASED

• CUSTOM PACKER SEAL WAS DESIGNED

• SMALL DIAMETER TUBING, BALL AND SEAT, OPTIONAL PRESSURE RECORDING PROBES WERE RUN ON STANDARD WIRE LINE

• DATA OBTAINED AND EVALUATED FOR MOST EFFICIENT DESIGN PARAMETERS

• HYBRID EFFECTIVELY REMOVES FLUID


Denver, Colorado

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REDUCED GRADIENT

• INITIAL GRADIENT AT BOTTOM PERF WAS 0.229

PSI/FOOT

• AVERAGE PRESSURE DIFFERENTIAL BETWEEN TOP

AND LOWER RECORDER WAS 2.25 PSI

• EFFECTIVE GRADIENT BETWEEN PERFS OF 0.007

PSI/FOOT

• GRADIENT ABOVE FLUID 0.0348 PSI/FOOT


Denver, Colorado

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3 YEAR GAS PRODUCTION

Elliott 1-23 Gas Prod, 3 Years

0

500

1000

1500

2000

2500

3000

3500

4000

Jan 07

Mar 0

7

May 0

7

Jul 07

Sep 07

Nov 07

Jan 08

Mar 0

8

May 0

8

Jul 08

Sep 08

Nov 08

Jan 09

Mar 0

9

May 0

9

Jul 09

Sep 09

Nov 09

Jan 10

Time

MC

F/M

ON

TH

Install Std. PAL, stop

above top perf.

Install HYBRID PAL, w ith 350

ft. tail pipe to remove fluid from

bottom perforations.


Denver, Colorado

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APPLICATION FACTORS

• SIZE AND CONDITION OF CASING AND ANY CASING

RESTRICTIONS

• DEPTH OF TOP PERF RELATIVE TO ALL PERFS

• SHUT IN BHP AND LINE PSIG

• FLUID VOLUME AND COMPOSITION

• GAS FLOW RATE

• HISTORICAL PRODUCTION DATA


Denver, Colorado

37

AVAILABILITY OF TOOLS

• 4 ½ ―PAL‖ SYSTEMS, 9.5, 10.5, 11.6 #/FT

• 5 ½ ―PAL‖ SYSTEMS, 14, 15.5, 17, 20 #

• HYBRID SYSTEM FOR 4.5 AND 5.5 csg

• MANUAL AND CONTROLLER OPTION

• CUSTOM SIZES CAN BE CONSIDERED

• SPECIALIZED TOOLS AVAILABLE

• CUSTOM RUBBER MOLDING SKILLS TO MEET ANY

DOWNHOLE NEED


Denver, Colorado

38

CONTACT DATA

• PAAL, LLC PAL PLUNGERS

• P.O. BOX 2329

• BROWNWOOD, TEXAS 76804

• 325-624-5460

• Robert L. Moore, 817-694-9807

• Windel Mayfield, 325-624-5460

CONCLUSIONS

• RADICAL NEW CASING PLUNGER DESIGN

PROVES SUCCESSFUL IN MANY GAS WELL

DELIQUIDIFICATION APPLICATIONS OVER

BROAD RANGE OF PRODUCTION CONDITIONS.

• CASING PLUNGERS ARE AN IMPROVEMENT IN

MANY TUBING PLUNGER WELLS.

• HYBRID DESIGN ENABLES FLUID REMOVAL

FROM MULTIPLE ZONES.

• HYBRID OFFERS GREAT POTENTIAL FOR FLUID

REMOVAL FROM CBM AND HORIZONTAL

WELLS.

Feb. 27 - Mar. 2, 2011 2011 Gas Well Deliquification Workshop Denver, Colorado

39


Denver, Colorado

40

Disclaimer

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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.

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Denver, Colorado

41

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Radical New Design In Casing Plungers Proves Successful - 3... · Radical New Design In Casing...

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