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Gas Well Deliquification Workshop Plunger Lift: SCSSSV Applications William Hearn, Weatherford Stathis Kitsios, Ewout Biezen Sachin Shinde, Dick Klompsma, NAM

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Gas Well Deliquification Workshop

Plunger Lift: SCSSSVApplicationsWilliam Hearn, Weatherford

Stathis Kitsios, Ewout Biezen

Sachin Shinde, Dick Klompsma, NAM

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

2

Agenda

• Background of plunger lifting below SCSSSV(Surface Controlled Sub Surface Safety Valve)

• Main components of Plunger system for SCSSSVapplication

• Experience of Plunger below SCSSSV

• Learning & way forward

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

3

Plunger lifting Background

•Plunger lifting common method of unloading LL wellsacross the world.

•Need for effective deliquification of mature wells withinNAM suffering from liquid loading in the tubing.

•New plunger technology developed to cope with presenceof SCSSSV

•World first plunger installation below SCSSSV in 3 NAMwells

4

Plunger lifting below subsurfacesafety valve: operating cycle1. Liquid Loading

• Plunger hangs in open position under SSSV

• Liquid in liner+tubing builds up

• Flowrate declines

2. Shut-in• Well automatically shuts in (ROV)

• Plunger falls

3. Shut-in build-up• Plunger reaches bottom and closes

• Short build-up

4. Unloading (plunger travel)• Well automatically opens (ROV)

• P lifts plunger+liquid in closed position

5. Flowing well• Plunger hangs in open position under SSSV

1 42 3 5

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

55

Plunger lift design: SafetyLiftSystem Components

The SafetyLift System is comprised of four majorcomponents:

• Bottom Hole Assembly

• Upper Landing Assembly

• Plunger

• Remote operated valve with Controller Unit

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

66

Plunger lift design: SafetyLiftSystem Components

• Standard Double Bumper Spring

• G-PackOff-Optional

• Type ‘A’ Tubing Stop

• MP-1 Standing Valve Optional

• Installed using standard wirelineprocedures

• Installed at a pre-determined depth inrelation to the well perforations

Bottom Hole Assembly

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

77

HOW: SafetyLiftSystem Components

• Installed directly attached to SSSV inone run

• MP-1 Standing Valve threaded directly totubing retrievable SSSV

• Inverted Bumper Spring designed forSafetyLift™ plunger.

Upper landing assembly

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

8

SafetyLift System Components:Plunger

• Body Componentsmachined to driftthrough 2.750” diameterof the Safety ValveLanding Nipple

• T-Pad Elements speciallydesigned for increasedcollapse

• Plunger designed withfewer connections thanstandardplunger for increasedreliability

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

9

Controller Unit• Controller: Based on input-signals like flow rate and

pressure it determines optimum well-shut-in moment

• Pneumatic actuator: Converts electrical signal ofcontroller into pneumatic signal to activate ROV.

• ROV: Remote operated valve.

Main operating parameters

1. On-limit Pressure

2. Off-limit Flow

3. Plunger-fall time

4. Off-time

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

10

Plunger Trial wells 4, 5 & 39 Three 3½” vertical wells selected for first trials with known

tubing loading problems

Plungers collapse to install below landing nipple safetyvalve (2.75” minimum ID, expand to 2.922” tubing ID)

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

11

Well 4Well- 4

0.00

5000.00

10000.00

15000.00

20000.00

25000.00

30000.00

35000.00

40000.00

45000.00

01/03

/2007

20/04

/2007

09/06

/2007

29/07/2

007

17/09

/2007

06/11

/2007

26/12/2

007

14/02

/2008

04/04

/2008

24/05

/2008

13/07

/2008

01/09

/2008

21/10

/2008

10/12

/2008

29/01

/2009

20/03

/2009

09/05

/2009

28/06

/2009

17/08

/2009

06/10/2

009

25/11

/2009

14/01

/2010

Q(m

³/d

ay)

Increased operatorintervention

Auto I/P

Plungerinstalled

controller setting

stuckROV

plungerinstalled

solenoidfailure

Plunger removed/auto I/P

Modif ied plunger

Possibleplungerfailure

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

12

Well-4

0.00

5000.00

10000.00

15000.00

20000.00

25000.00

30000.00

35000.00

40000.00

45000.00

01/0

3/200

7

20/0

4/200

7

09/0

6/200

7

29/0

7/200

7

17/0

9/200

7

06/1

1/200

7

26/1

2/200

7

14/0

2/200

8

04/0

4/200

8

24/0

5/200

8

13/0

7/200

8

01/0

9/200

8

21/1

0/200

8

10/1

2/200

8

29/0

1/200

9

20/0

3/200

9

09/0

5/200

9

28/0

6/200

9

17/0

8/200

9

06/1

0/200

9

25/1

1/200

9

14/0

1/201

0

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

50.00

Q (m³/d)THP (bar)

Increased operatorintervention

Auto I/P

Plungerinstalled

controller setting

stuckROV

plungerinstalled

solenoidfailure

Modified plunger

Plunger removed/auto I/P

Possibleplungerfailure

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

13

Well 4

• Past failure with damaged flapper pin on 2 occasions

• Weatherford redesigned and delivered the modifieddesign plunger within 6 weeks which was installed inJune 2009

• Completed more than 1000 cycles before suspectedcurrent failure (planned to be pulled out for inspection)

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

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Design modifications

Increased Pin Diameter withcalculated improvement toimpact strength of 42%.

Increased width of protectivesleeve for high speed impactprotection

Added radii atback to spreadimpact across thefull surface

Tightened Tolerance inplunger body ID for pin forminimal movement duringimpact.

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

15

Well 5

• Past failure with damaged flapper pin.

• Modified plunger installed in June 2009. In August2009, plunger found damaged with sheared flapper.

• Well has a scaling problem causing the plunger gettingheld up in the tubing- dry run of plunger.

• No plunger in the well now

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

16

Well 39

• Modified plunger installed in Sep 2009. Well did notproduce with plunger.

• Plunger return was heard in ½ min. ROV was leaking.

• Plunger found damaged; deformed pin due to impactwhich then got stuck due to tight tolerance.

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

17

Well 39

Strange pressure behaviour

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

18

Third Generation Plunger Design

New Design

More Robust Design both in Spring and ImpactResistance

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

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Conclusion & way forward

• Better understanding of plunger selection criteriagained from NAM, Weatherford experience.

• Second generation plunger showed improvedmechanical robustness in Well 4 before failure.

• Third generation plunger being designed to improveoperational reliability especially for offshore trials.

• The newest type of plunger planned to be run bybeginning 2nd quarter 2010.

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

2020

SafetyLift System

QUESTIONS?

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

21

Copyright

Rights to this presentation are owned by the company(ies) and/orauthor(s) listed on the title page. By submitting this presentation tothe Gas Well Deliquification Workshop, they grant to the Workshop,the Artificial Lift Research and Development Council (ALRDC), andthe 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 beas directed by the Workshop Steering Committee.

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

Other uses of this presentation are prohibited without the expressedwritten permission of the company(ies) and/or author(s) who own itand the Workshop Steering Committee.

Feb. 22 - 25, 2010 2010 Gas Well Deliquification WorkshopDenver, Colorado

22

DisclaimerThe following disclaimer shall be included as the last page of a Technical Presentation orContinuing Education Course. A similar disclaimer is included on the front page of the Gas WellDeliquification Web Site.

The Artificial Lift Research and Development Council and its officers and trustees, and the GasWell Deliquification Workshop Steering Committee members, and their supporting organizationsand companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) ofthis 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 theproducts or services referred to by any presenter (in so far as such warranties may be excludedunder any relevant law) and these members and their companies will not be liable for unlawfulactions and any losses or damage that may result from use of any presentation as a consequenceof 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 materialsare those of the author and not necessarily those of the Sponsoring Organizations. The author issolely responsible for the content of the materials.

The Sponsoring Organizations cannot and do not warrant the accuracy of these documentsbeyond the source documents, although we do make every attempt to work from authoritativesources. The Sponsoring Organizations provide these presentations and/or training materials asa service. The Sponsoring Organizations make no representations or warranties, express orimplied, with respect to the presentations and/or training materials, or any part thereof, includingany warrantees of title, non-infringement of copyright or patent rights of others, merchantability, orfitness or suitability for any purpose.