Plunger Lift

Development of AI controllers has allowed abnormal pumping conditions to be accurately identified remotely. Due to the geometry of most rod lifting systems corrective actions need to be undertaken manually at the well location. This paper introduces an automated approach to implementing corrective actions with the use of a non-fixed stroke length rod pumping system. The focus includes case studies where manipulating the stroke length is used to rectify the abnormal pumping condition without the use of additional equipment or service rig intervention.

The oil and gas industry has used Variable Frequency Drives (VFDs) for decades to match production to inflow. In sucker rod pump applications, it is well understood that optimizing pumping speed dramatically improves pump efficiency and failure rate. However, the same technology provides the opportunity to make multiple speed changes in a pumping cycle.

This study evaluates a 3-1/2 in. tubing well converted from continuous gas lift to plunger-assisted gas lift (PAGL) using a bypass plunger that initially failed to complete cycles under flowing conditions. The objective is to diagnose the root cause, determine operational boundaries for PAGL in 3-1/2 in. tubing, and assess the feasibility of PAGL relative to tubing replacement and higher gas-injection strategies using field data and plunger lift mechanistic models.

Operators of marginal plunger lift wells face significant challenges in optimizing performance while managing tight economic constraints. These wells, characterized by lower flow rates, are often highly sensitive to operational costs, making it difficult to justify investments in advanced digital automation and control systems. Yet, these wells represent a substantial portion of production assets and have the potential to benefit greatly from enhanced efficiency, reduced operational expenses, and extended productive lifespans.

Large-scale plunger lift operations demand surveillance methods that can balance proactive optimization with targeted field intervention. To replace route-based monitoring, Occidental Petroleum developed an integrated closed loop control program as well as SCADA based exceptions for its 2,000+ plunger lift wells. Plunger Lift Artificial Intelligence (PLAI) delivers proactive plunger lift optimization by blending real time well data with machine learning and decision logic, enabling timely alerts and automated setpoint updates.

The plunger lift process can be divided into four distinct cycles: buildup, upstroke, after flow, and liquid discharge. One key parameter that can be measured for optimizing oil production is the total gas flow rate produced during the liquid discharge cycle. Typically, the only known parameters are the controller’s on and off time, so post-processing is required to identify the liquid discharge period and quantify the observed flow rate.

Downhole springs are one of the few components in a plunger-lift system that operators expect to run for a year or longer without intervention—making reliability, durability, and serviceability essential. Industry experience shows that the most common failures occur at threaded connections near the cage and neck, often leading to full-assembly replacement and unnecessary expense. This paper introduces an interlocking downhole-spring design engineered to eliminate these weak points, extend run life, and significantly reduce replacement costs.

Plunger Lift has always been recognized as the most economical form of Artificial Lift for removing liquids from natural gas wells and producing higher GLR oil wells.  With the recovery of oil and natural gas prices plunger lift has become an increasingly popular lift choice.  When combined with gas lift (PAGL) it can increase the efficiency and extend the economic life of wells. This school will cover the various applications across different production parameters.  Topics will include the following:

Plunger lift, gas lift, (GAPL)(PAGL), and sucker rod pumping are a few common forms of artificial lift that are heavily reliant on valves to maintain a seal in the system to extract fluids efficiently from the wellbore. 

This paper will outline the increase in well production performance when using a horizontal check valve on wells with Gas Liquid Ratios (GLR’s) conducive to plunger lift systems installed optimally in horizontal wells, also highlight design improvements when using these same valves in vertical situations.

The I-Plunger is designed for Gas Wells and is an Instrumented Plunger that records pressure, temperature, depth, and plunger velocity. Information from the tool is collected and graphically presented for detailed analysis as well as a quick reference guide.