andidate Wells - Web viewEnd of Tubing (EOT) Wellhead. Continuous ID (valves, tees, landing threads, hanger, wrong wellhead size) Unnecessary valves or tees. Piping not “plumb

What is Plunger Lift?

Plunger Lift is an artificial lift method that uses the wells own energy (gas and/or pressure) to lift accumulated fluids from the tubing and annulus.

The system operates through a series of shut-in periods and flow periods, intermitting the well. Intermitting alone is very inefficient due to the fluid fall back during the flow cycle. The rule of thumb for intermitting is approximately 10% of the fluid slug is lost for every 1,000 ft of lift. A plunger utilizes an interface seal between a fluid in the tubing and stored gas in the annulus. The head gas is blown down creating differential pressure across the plunger, which brings both the plunger and accumulated fluid to the surface.

Seal efficiency is critical for effective plunger operation. The amount of fluid and gas being produced must be taken into account when selecting the plunger type. The more fluid being produced the better the seal efficiency must be.

The Benefits of Plunger Lift are:

Low capital cost.

No rig required to install.

No fuel cost.

Low maintenance.

Stabilized well production.

Minimal well downtime.

Can be moved to other wells.

To meet a variety of needs, we offer a complete selection of conventional, bypass, and staged systems that cover a wide range of applications efficiently and productively:

Conventional Plungers (brush, padded, bar stock)

Bypass Plungers (fast drop and bypass styles)

Staged Plunger Systems

Controllers and Automation Systems

Complete System Design and Training (classroom and field)

andidate Wells

Plunger Lift is appropriate for wells exhibiting the following conditions:

Wells with unstable production (liquid loading).

Wells being intermitted, swabbed or vented.

Gas locked pumping wells.

Wells with large differential between the casing and tubing flowing pressure.

Wells with liquid to gas ratios (LGR) less than 150 bbl/mmcfd.

Typical Maximum

Operating Depth 8,000 ft TVD* 21,000 ft TVD*

Operating Volume 1-5 BPD‡ 200 BPD‡

Operating Temperature 120°F 500°F

Wellbore Deviation N/A 35 degrees Conventional 70 degrees Bypass

Corrosion Handling Excellent

Gas Handling Excellent

Solids Handling Poor to Fair

GLR Required2-3/8" = 400 SCF† / BBL§ /1,000 ft Lift

2-7/8" = 600 SCF† / BBL§ / 1,000 ft Lift

Service Wellhead Catcher or Wireline

Prime Mover Type Well’s Natural Energy

*TVD - True Vertical Depth    ‡ BPD - Barrels per Day    † SCF - Standard Cubic Feet    § BBL - Barrels

Mechanical considerations that may lead to problems:

Well

Sand

Scale

Temperature

Tubing

Continuous ID (packers, anchors, crimps, rod cut, scale, soap buildup)

Packer or tubingless completions

End of Tubing (EOT)

Wellhead

Continuous ID (valves, tees, landing threads, hanger, wrong wellhead size)

Unnecessary valves or tees

Piping not “plumb”

Not using flanged master valves for safety

Surface Equipment

Tank and separator capacities

Bottle necks, chokes

Flow line limitations (pressure increases when plunger is flowing/arriving)

Orifice plate sizing

Compression

Centralized or single wellhead compression

Suction pressure control

Wells “fight” for line space – correct compressor size, synchronization

High line pressure delays

By-pass valve configuration

For assistance in evaluating whether a plunger lift solution would benefit your well, please complete and submit a Well Design Support Form for comprehensive analysis.

Bypass or Freecycle Plunger Lift Systems

Bypass plungers are meant for “good” wells. This plunger type is dependent on gas rate instead of build pressure. Since the advantage to running these plungers is greatly reduced shut in times, the well does not build enough pressure to cycle the plunger. The rule of thumb for successful operation is that the well MUST produce a minimum of 70% of the surface critical rate.

There are two types of Bypass plungers: Continuous Flow and Quick Falling. Continuous Falling plungers are designed to fall against flow. These are wells that have just started showing signs of liquid loading and by “sweeping” the tubing walls of accumulating fluid the well will continue to flow naturally.

Quick Falling plungers are designed for good wells that are operating at the minimum gas requirement (70% of surface critical rate). These wells require a very short shut in time to overcome low gas velocities due to liquid loading. Where a Conventional plunger may require a minimum of 45 minutes of shut in time to fall and build pressure, these wells may only require 10 – 20 minutes. Therefore, the Quick Falling plunger has been designed to fall at a much faster rate to get to the bottom hole spring. These plungers will typically fall at rates of approximately 700 – 900 ft/min.

The most important operating parameter for these plungers is After Flow. Similar to a Conventional plunger lift, once the plunger has lifted the fluid to the surface the well must be given some time to accumulate fluid for the next cycle.

Note: Due to the bypass areas of these plungers, it is highly recommended that an auto-catch assembly be run. This will ensure that the plunger is held in the lubricator until the controller signals the plunger to fall. Failure to run the auto-catch may result in reduced gas rates, due to the plunger restricting flow, and possible dry cycling of the plunger.

Conventional Plunger Lift Systems

As the well is shut-in and the plunger falls to the bottom, pressure begins building up in the casing. Additional time should be given in the beginning to account for any extra accumulation of fluid in the tubing. The rule of thumb for initial fall time is 200 ft/min (depth to the spring / 200 = minimum fall time required).

When pressure is enough to lift the plunger and the liquids to surface are at a reasonable velocity (rise velocity of approximately 650 - 750 ft/min) against the surface pressure, the surface valve will open.

The motor valve at the surface will open and the plunger and fluid slug will begin to rise.

The gas in the annulus expands into the tubing to provide the lifting pressure. At this point, the well is now producing during the rise time to add to the energy required to lift the plunger and fluid slug. This is referred to as the “On Cycle.”

The plunger arrives in the lubricator and is held in place by the flow of fluid and gas and pressure below. The well is now allowed to flow for a set period of time. This is referred to as After Flow or Delay Time.

After Flow is critical to the plunger cycle for two reasons. One, the well is now allowed to flow at the maximum rate for the operator to sell gas. Two, the well is able to bring more fluid in from the formation so that the plunger has fluid to bring to the surface on the next cycle. If no fluid is available, the plunger will run dry and the risk of plunger and/or surface equipment failure increases.

As the gas flow starts to drop and the gas velocities in the tubing decrease, the liquid begins to accumulate in the bottom of the well. The casing pressure begins to rise, indicating a pressure drop in the tubing. If the flow is allowed to continue too long, a fluid slug will accumulate that will require a high casing pressure buildup to lift it. This could cause the plunger to not arrive on the next cycle.

The motor valve closes and the plunger begins to fall. The plunger hits bottom (stops on the bumper spring) and the cycle begins again.

Lubricators

The lubricator is the main component of any plunger lift system. It is

what accepts the plunger as it travels to the surface. The lubricator is securely installed to the top of the wellhead in ALL plunger lift system installations. The dual outlet configuration allows for optimal flow of gas and fluids during the plunger lift cycle. All flow from the well is diverted through it to the flowline.

With the potential of considerable impact when the plunger arrives at surface, the lubricator incorporates a spring-loaded receiver to dissipate this energy at arrival. The lubricator serves as pressure control equipment and is outfitted with a catch assembly that allows for the plunger to be caught at surface for inspection and removal purposes. This catching action can also be automated with the use of pneumatics.

Features & Benefits

The top cap has an API ACME #6 thread vs. a standard 8 rd thread. This provides a much safer

connection when high impacts are seen at the surface.

The main lubricator is 3,000 psi WP. All lubricators are hydrostatically tested to 5,000 psi as per

ASTM testing standards. 5,000 psi, sour service and flanged configurations are also available.

The catch assembly is a “dog” style catch rather than a ball or pin style. This helps ensure that the

plunger is caught every time with the plunger as high up in the lubricator as possible for easy and

safe removal for inspection.

Standard lubricator strings are made of 17-4 Stainless Steel to be able to handle low levels of sour

service.

Available in 1-1/2", 2-1/16", 2-3/8", 2-7/8" and 3-1/2" sizes.

The plunger lift lubricators are available in two different pressure ranges and two different temperature ranges. The first is the Dual Port Regular-Temp Lubricator with a 24.1 MPa Maximum Allowable Working Pressure (MAWP), this lubricator is rated for a temperature range of -29 to 82 degrees Celsius. The second, more durable, lubricator is the family of Dual Port Low-Temp Lubricators. The MAWP for this lubricator family is 34.5 MPa and they are built for the harshest of environments. The working temperature range for the low-temp rated equipment is -46 to 82 degrees Celsius.

The lubricator is securely installed to the top of the wellhead in ALL plunger lift system installations. The function of the lubricator is to receive the plunger as it ascends to surface. Due to the potential of considerable impact when the plunger arrives at surface, there is the need for a spring-loaded receiver to dissipate this energy at arrival. The lubricator serves as pressure control equipment and is outfitted with a catch assembly that allows for the plunger to be caught at surface for inspection and removal purposes. This catching action can also be automated with the use of pneumatics.

Conventional Threaded Lubricator

What parts belong to conventional threaded lubricators and what goes with flanged?

The lubricator is the main component of any plunger lift system. It is what accepts the plunger as it travels to the surface. All flow from the well is diverted through it to the flowline. The spring housed in the top of the lubricator is designed to help cushion the force of the plunger as it arrives into the lubricator. The dual outlet configuration allows for optimal flow of gas and fluids during the plunger lift cycle.

Features & Benefits

The top cap has an API ACME #6 thread vs. a standard 8 rd thread. This provides a much safer

connection when high impacts are seen at the surface.

The main lubricator is 3,000 psi WP. All lubricators are hydrostatically tested to 5,000 psi as per

ASTM testing standards. 5,000 psi, sour service and flanged configurations are also available.

The catch assembly is a “dog” style catch rather than a ball or pin style. This helps ensure that the

plunger is caught every time with the plunger as high up in the lubricator as possible for easy and

safe removal for inspection.

Standard lubricator strings are made of 17-4 Stainless Steel to be able to handle low levels of sour

service.

Available in 1-1/2", 2-1/16", 2-3/8", 2-7/8" and 3-1/2" sizes

Specifications

Dimensions: Approximate length is 38 inches (97cm.) OAL. Length of Cross is 22 to 27 inches (depends on design). (56 cm. to 68 cm.)

Weight: 36 to 71 Lbs. (16 to 33 Kg) Note: (Variations in weight occur with options used.)

Materials: Lubricator cross, top and cap are 4130 & 4140 steel meeting design specifications.

Threads: Cross Pins are 8 rd EUE. Top Cap is Acme #6 Thread. Flow outlets are 11-1/2V NPT and the Needle valve is 1/2" NPT.

Hardness: RC 20 to RC 27. Variation is due to window in specifications. Equipment can be manufactured to exact Brinnel or Rockwell hardness to comply with customer specifications.

Flow Outlets: Forged Steel weld type flow outlets with 3,000 psi WP. These are tested to 5,000 psi when they have been welded to cross yielding a lubricator working pressure of 3,000 psi per ASTM testing standards.

Pressures: Completed Lubricators are individually hydrostatically tested to 5,000 psi yielding a working pressure of 3,000 psi per ASTM testing standards.

Surface: Surfaces exposed to the elements and UV exposure are both primed and painted to protect from the elements. Optional coatings are available and quoted per your requirements.

Sealing Elements:

The top and cross are sealed by O-rings as is the catch assembly. Viton seals are available in both 70 and 90 durometer to meet customer specifications.

Flanged Lubricator

What parts belong to conventional threaded lubricators and what goes with flanged?

The lubricator is the main component of any plunger lift system. It is what accepts the plunger as it travels to the surface. All flow from the well is diverted through it to the flowline. The spring housed in the top of the lubricator is designed to help cushion the force of the plunger as it arrives into the lubricator. The dual outlet configuration allows for optimal flow of gas and fluids during the plunger lift cycle.

Features & Benefits

The top cap has an API ACME #6 thread vs. a standard 8 rd thread. This provides a much safer

connection when high impacts are seen at the surface.

The main lubricator is 3,000 psi WP. All lubricators are hydrostatically tested to 5,000 psi as per

ASTM testing standards. 5,000 psi, sour service and flanged configurations are also available.

The catch assembly is a “dog” style catch rather than a ball or pin style. This helps ensure that the

plunger is caught every time with the plunger as high up in the lubricator as possible for easy and

safe removal for inspection.

Standard lubricator strings are made of 17-4 Stainless Steel to be able to handle low levels of sour

service.

Available in 1-1/2", 2-1/16", 2-3/8", 2-7/8" and 3-1/2" sizes

Specifications

Dimensions: Approximate length is 38 inches (97cm.) OAL. Length of Cross is 22 to 27 inches (depends on design). (56 cm. to 68 cm.)

Weight: 36 to 71 Lbs. (16 to 33 Kg) Note: (Variations in weight occur with options used.)

Materials: Lubricator cross, top and cap are 4130 & 4140 steel meeting design specifications.

Threads: Cross Pins are 8 rd EUE. Top Cap is Acme #6 Thread. Flow outlets are 11-1/2V NPT and the Needle valve is 1/2" NPT.

Hardness: RC 20 to RC 27. Variation is due to window in specifications. Equipment can be manufactured to exact Brinnel or Rockwell hardness to comply with customer specifications.

Flow Outlets: Forged Steel weld type flow outlets with 3,000 psi WP. These are tested to 5,000 psi when they have been

welded to cross yielding a lubricator working pressure of 3,000 psi per ASTM testing standards.

Pressures: Completed Lubricators are individually hydrostatically tested to 5,000 psi yielding a working pressure of 3,000 psi per ASTM testing standards.

Surface: Surfaces exposed to the elements and UV exposure are both primed and painted to protect from the elements. Optional coatings are available and quoted per your requirements.

Sealing Elements:

The top and cross are sealed by O-rings as is the catch assembly. Viton seals are available in both 70 and 90 durometer to meet customer specifications.

Dual Port Low-Temperature Lubricator – Bowen Cap

Similar to the Penta-Cap version listed above, this threaded lubricator is designed and fabricated in Red Deer, Alberta to work in the harshest environments.

It is designed to API 6A specifications - categorized to PSL 1 guidelines, material class AA.

The material used in the fabrication of this lubricator must meet an average impact value of 20

Joules as outlined by the Charpy V-notch test allowing for low-temp service (-46 to 82 degrees

Celsius).

The Bowen cap style lubricator improves the pressure control aspect of the lubricator due to the

presence of an o-ring seal coupled with the threaded connection.

In addition, the Bowen thread allows for ease of wireline connection when completing any downhole work. Lubricator is outfitted with two 2” NPT outlets, heavy duty plunger lift catch and two ½” NPT bleed off ports.

Flanged Dual Port Low-Temperature Lubricator – Bowen Cap

This flanged inlet/threaded dual port outlet lubricator is designed and fabricated in Red Deer, Alberta to work in the harshest environments.

It is designed to API 6A specifications - categorized to PSL 1 guidelines, material class AA.

The material used in the fabrication of this lubricator must meet an average impact value of 20

Joules as outlined by the Charpy V-notch test allowing for low-temp service (-46 to 82 degrees

Celsius).

The flanged inlet connection of this lubricator is provided to easily connect to a flanged

wellhead/master valve while maintaining the welded criteria on the tree – no threaded connection to

the wellhead.

Lubricator is outfitted with two 2” NPT outlets, heavy duty plunger lift catch and two 1/2” NPT bleed off ports.

Flanged Dual Port Low-Temp NACE Lubricator – Bowen Cap

This flanged inlet/flanged dual port outlet lubricator is designed and fabricated in Red Deer, Alberta to work in the harshest sour service (NACE) environments.

It is designed to API 6A specifications - categorized to PSL 2 guidelines, material class DD.

The material used in the fabrication of this lubricator must meet an average impact value of 20

Joules as outlined by the Charpy V-notch test allowing for low-temp service (-46 to 82 degrees

Celsius).

For designated classification of service, the lubricator is designed and regulated by NACE MR0175

guidelines.

The flanged inlet connection of this lubricator is provided to easily connect to a flanged

wellhead/master valve while maintaining the welded criteria on the tree – no threaded connection to

the wellhead.

Lubricator is outfitted with two R24 flanged outlets, heavy duty plunger lift catch and two 1/2” NPT

bleed off ports.

Penta-Lift Casing Lubricator

The Penta-Lift Lubricator is available in either 114.3mm or 139.7mm sizes and is installed directly onto the wellhead valve (i.e. Demco or mud valve). The lubricator has proven to be very robust and is very “wellhead” friendly. It is fabricated with a 5” Hydrolex union so the plunger can be easily accessed for inspection. The Hydrolex fitting also allows wireline and service rigs to adapt easily to the lubricator with their existing B.O.P.S so it does not have to be removed from the well head. The 114.3mm Penta-Lift lubricator is also equipped with 8rd 114.3mm short casing thread internally that can be used for connection purposes. Completed with no welds and with a working pressure of 12.1 MPa it has proven to be very robust and popular with our customers.

Penta-Lift Casing Bleed-Off Sub

The Penta-Lift Bleed-Off Sub is available in either 114.3mm or 139.7mm sizes and is installed directly onto the top of the wellhead valve (i.e. Demco or mud valve) and below the Penta-Lift Casing Lubrcator in the desired application. The Bleed-Off Sub was designed in conjunction with a customer to address the potential issue of not being able to effectively depressure the lubricator section below the Casing Plunger when removing the Plunger for inspection purposes. By

installing the Bleed-Off Sub it is possible to depressure both above and below the Plunger once the Lubricator section has been isolated. In most all cases it is possible to depressure the Lubricator by opening the two (2) 1/2" NPT ports to atmosphere on the Lubricator however if the internal valve in the plunger is NOT tripped, it is possible to have trapped pressure (gas) below the plunger and above the wellhead valve. The addition of the Bleed-Off Sub negates this potential due to the presence of two (2) 1/2" NPT ports that allow for depressuring of the area below the Plunger.

Specialty Lubricators

Pentagon Optimization Services prides itself in the ability to meet all customer requests based on unique wellhead configurations and pressure control requirements. With the assistance of Nexus Engineering & Machine Inc and a fully capable machine shop, Pentagon is able to meet any specific requirement to meet customer requests in a timely manner (typical turnaround time is four – eight weeks). Lubricator shown – Flanged Single Port Low-Temperature NACE Lubricator for a dual completion wellhead.

Tubing Plungers

The plunger is the heart of the system. It creates a mechanical seal between the fluid in the tubing and the gas pressure in the annulus, which allows for fluid to be carried to surface. The seal is critical to the efficiency of the system.

A plunger style is selected based on the amount of fluid being lifted and the gas pressure available. The more fluid produced the better the seal efficiency needs to be.

Lufkin carries a wide variety of plungers to work in conjunction with common tubing sizes.

Products

Continuous flow or Bypass plunger

Bullet plunger

Pad plunger

Brush plunger

Spiral plunger

Tornado plunger

Turbo Flow plunger

Recoil plunger

Staged plunger lift system

Options

Sour gas service available

All standard mandrels 4140 HR-HT at a 26 Rc

All standard plungers available with recoil sub

Pad plunger pads are 17-4 ss investment casting to a 38 Rc

Tubing sizes:

1-1/2"

2-1/16"

2-3/8"

2-7/8"

3-1/2”

Continuous Flow or Bypass Plunger Lift System

A Continuous Flow or Bypass plunger system improves production by allowing continuous well operation while removing liquid build-up. The system is designed to fall against the natural flow of the well and sweep accumulated fluid from the tubing walls rather than fluid built up at the end of the tubing string. As a result, the system is dependent on gas rate vs. built up pressure energy.

These plunger styles operate using a valve mechanism. When the plunger falls to the bottom of the well the bumper spring closes the valve to allow the plunger to drive back to the surface. Once arriving in the lubricator, the valve is actuated back open and is ready to start back down the well to begin the next cycle. This style plunger is available in padded and tornado body styles.

Complementary equipment includes the pneumatic catcher (auto-catch) to manage the plunger drop cycles.

Features & Benefits

Combats declining gas flows, increasing liquid production, and high operating costs associated with

problem wells.

Requires little or no shut-in time.

Maximizes flow rates.

Works well with on-site compression.

Eliminates line pressure spikes.

Maintains a low flowing bottom hole pressure.

Valve design helps ensure the plunger falls to the bottom against the flow with minimal off times.

Special detent grooves on the valve rod prevents the valve from closing prematurely (against fluid

slugs or high gas rate) during the fall cycle and that the valve stays closed during the up cycle.

FC4 Continuous Flow Plunger

The FC4 is a Continuous Flow or Bypass style plunger that combats declining gas rates, increases liquid production, and reduces high operating costs associated with problem wells. The special grooves of the valve system prevent premature opening and closing during the plunger cycle.

The high bypass area allows the plunger to fall against flowing in excess of 800 mcfd. The grooved body style provides an enhanced turbulence seal preventing slippage during the rise cycle making the plunger extremely efficient.Complementary equipment includes the pneumatic catcher (auto-catch) to manage the plunger drop cycles.

Features & Benefits

Locking mechanism ensures the plunger reaches the spring before shifting closed and reaches the

surface without prematurely opening and losing fluid load.

Specially designed grooved body provides exceptional seal efficiency to help maximize production.

A single pad section can be added for wells with higher fluid rates.

Minimal off time results in more stable flow with little to no gas or pressure spikes at the surface.

Maintains the lowest flowing bottom hole pressure possible.

Penta-Cycle Continuous Flow Plunger

The Steel Solid Ring Penta-Cycle plunger consists of a fishneck that allows wireline to retrieve the plunger from the tubing string if necessary. The main section of the plunger consists of a solid ring section similar to the solid ring plunger. Unlike both the solid ring and quick trip plunger, the penta-cycle plunger consists of an internal valve that when opened at surface with the assistance of a trip rod in the lubricator, will allow the plunger to descend to bottom against the flow of the well. Once the plunger reaches bottom, the valve (piston) closes to allow the plunger to ascend to surface unloading the well of liquid. Due to the design of the plunger, the well requires minimal shut-in (i.e. 30 seconds) to allow the plunger to begin its descent therefore maximizing the producing time of the well. The implementation of this style of plunger is based on the current producing conditions and the resulting evaluation. A ‘rule of thumb’ is the flowing velocities must exceed 3.5 – 4.0 meters per cycle to support this application.

Bullet Plunger

The Bullet plunger is a quick falling style of Bypass plunger that allows the plunger to fall at a much higher speed than a regular Conventional plunger. This is due to the bypass area through the plunger.

Lufkin’s new locking mechanism allows the internal shifting rod to be locked in both the open and closed position. This greatly reduces the chance for the shifting rod to be opened or closed prematurely due to fluid weight above the plunger or from gas or fluid flow from below the plunger.

Complementary equipment includes the pneumatic catcher (auto-catch) to manage the plunger drop cycles.

Features & Benefits

Fall speeds between 700 – 900 ft/min allow the plunger to reach the spring in less than half the time of a Conventional plunger.

Locking mechanism ensures the plunger reaches the spring before shifting closed and reaches the surface without prematurely opening and losing fluid load.

Tornado body design provides exceptional seal efficiency to help maximize production.

Internal shifting rod eliminates the need to have additional items inside of the lubricator.

Pad Plunger

Lufkin Pad plungers are extremely durable and can be used in nearly all types of situations. Pads are available in single, dual and triple pad configurations. The spring-loaded pads are able to expand and contract to keep a consistent seal with the tubing walls providing minimal slippage of gas and fluid. The pads are made from interlocking 17-4 heat-treated stainless steel castings. The mandrels are designed, engineered and manufactured in our Houston facility by highly experienced machinist. 4140 hot rolled, heat-treated steel and 302 stainless steel make up the pad springs.

Features & Benefits

High efficiency due to metal-to-metal seal (Friction Seal).

Spring-loaded pads can collapse to run past anomaly.

Works best in lower GLR wells.

Best suited to low-pressure wells.

Excellent wear-ability due to the expansion of the pads as they wear.

Can run single, double, or triple pad depending on depth of well and amount of fluid production.

Penta-Seal Dual Pad Plunger

The dual pad Penta-Seal plunger consists of a fishneck that allows wireline to retrieve the plunger from the wellbore if necessary. The main section of the plunger consists of two padded sections. Each section consists of three vertical pads and the tri-pad interlocking design minimizes gas slippage between and beneath the pads which allows for a superior lifting efficiency. Beneath the tri-pad sections are springs which extend the pads to an outer diameter that allows continual contact with the tubing walls thus providing for a better sealing ability. The spring design also allows the plunger to conform to tubing abnormalities and slight deviations from a consistent tubing internal diameter. The dual pad Penta-Seal plunger offers the highest level of sealing efficiency when compared to longevity of the plunger however it cannot be used in wells that are prone to asphaltene/paraffin accumulation. The dual pad Penta-Seal plunger contains Pentagon-shaped wear indicators on the pads that indicate whether the plunger needs to be replaced based on wear of the pads

Brush Plungers

The Lufkin Brush plunger has a flexible, over-sized, brush spirally wound onto a solid mandrel filling the tubing to create an excellent seal even when tubing irregularities are present. The flexibility of the brush allows the plunger to travel without damage to the tubing, clearing both liquid and sand from the wellbore.

Lufkin Brush plungers are ideal for carrying small amounts of solids and not damaging internally coated tubing strings.

Features & Benefits

High efficiency seal (wet seal).

Good for wells that produce small amounts of solids.

Can be used in irregular tubing IDs due to the flex of the brush.

Good to 250°F bottom hole temperature.

Spiral Plunger

Solid Spiral plungers are a good choice for wells with a higher gas to oil ratio and wells producing scale, salt or paraffin. Designed and machined at the Lufkin facility using 4140 heat-treated, hot-rolled steel, they are both durable and cost effective. All Spiral plungers are available in 8" or 16", hollow bored or with sand grooves to meet customer specifications.

Features & Benefits

Designed with no moving parts and machined to the tolerance of the tubing, allows for maximum

efficiency and durability.

Plunger grooves are spaced to allow optimal turbulence in the seal as it travels to the surface.

Ideal for wells that produce solids such as sand, salt or paraffin.

Tornado Plunger

The Tornado plunger is an impressively adaptable plunger. It effectively removes formation sand, frac sand and paraffin. The specially designed undercut grooves enhance gas turbulence, increasing the seal efficiency. The plunger is available with a rifled nose and heel, which further increases efficiency by generating a vortex of gas and fluid. The Tornado is made of hardened alloy steel increasing its life and durability. It is available for sour service.

Features & Benefits

Under cut grooves enhance the turbulent seal and greatly reduces slippage compared to regular bar stock or sand plungers.

Improved production for low LGR wells compared to pad plungers due to reduced frictional drag.

Rifling provides more uniform wear in deviated wells.

urbo Flow Plunger

The Lufkin Turbo Flow plunger is a specially engineered combination plunger designed to lift moderate fluid rates with greater efficiency than a traditional dual pad plunger. The specially designed grooves on the bottom of the plunger reduce the amount of frictional drag normally seen due to the metal on metal contact from a traditional pad. The groove combination creates an increased turbulent seal at the bottom of the plunger, while the pads on the top provide a solid seal for

any fluid accumulated on the top of the plunger. The combination has proven successful in enhancing production on wells thought to already be optimized with a standard dual pad plunger.

Features & Benefits

Enhanced efficiency due to the combination of pad & Turbo grooves.

Reduced frictional drag on rise cycle ensures more efficient arrival times with less slippage.

All stainless steel components.

Best suited to wells with liquid to gas ratios of 80 – 100 bbl/mmcfd.

Recoil Plunger

The Recoil plunger provides the user with the ability to plunger lift a well without using a bumper spring. This is extremely useful in testing a well for its capability to run a plunger without the need of wireline service. Slickline work and BHP testing can also be conducted by simply catching the plunger at the surface and removing it. The stainless steel spring can be inspected on any plunger arrival through the examination holes on the customized nosepiece. Every Lufkin plunger can be modified into a Recoil plunger.

Features & Benefits

Provides the least amount of downhole restrictions possible (no fixed spring).

Remedial work can be easily performed by simply catching the plunger at surface.

Works best on higher GLR wells.

Saves money on wireline installation costs since nothing is required downhole.

Plungers - Casing

This will be a general page for casing.

Penta-Lift Casing Plunger

The Penta-Lift plunger is available in either 114.3mm or 139.7mm casing sizes. The plunger is based on a positive-seal design and therefore is not ‘velocity dependent’, it is ‘pressure dependent’. The plunger is either available with two elongated positive seal elements or three standard positive seal elements. The clearance between the outer diameter of the elements and the internal diameter of the casing wall ranges from 0.005” – 0.030”. The tight clearance provides the seal and the resulting pressure differential between the lifting gas and the load fluid. The plunger is equipped with an internal valve, this is opened upon arrival at surface and allows for the descent of the plunger.

Collar Stop Assembly

The installation of the collar stop (114.3mm or 139.7mm) assembly is required for all Penta-Lift Casing plunger lift system installations. The collar stop assembly is set downhole in the casing string and is used to stop the descent of the casing plunger as it travels downhole. The location of the collar stop will depend on the completion of the wellbore (i.e. single or multiple set of perforations). Ideally, the collar stop will be set at the first collar recess above the bottom set of perforations to ensure the plunger has the potential to remove the greatest hydro-static head of load fluid on sand face. This may not be an option based on zonal contribution and the inflow of the bottom zone.

Bottom Hole Assemblies

The bottom hole assembly of a plunger system will typically comprise of two components. The bumper spring, which is used to absorb the shock of the plunger falling from surface, and a hold down component. The hold down component is meant to keep the spring in place so it cannot travel up and down in the tubing string. This can be either seated in a nipple or landed inside of a tubing collar or the tubing itself with either a collar stop, tubing stop or cup assembly. The spring can also be designed to float in the lower tubing section.

Bumper Springs

The bottom hole assembly of a plunger system will typically comprise of two components. The bumper spring, which is used to absorb the shock of the plunger falling from surface, and a hold down component. The hold down component is meant to keep the spring in place so it cannot travel up and down in the tubing string. This can be either seated in a nipple or landed inside of a tubing collar or the tubing itself with either a collar stop, tubing stop or cup assembly. The spring can also be designed to float in the lower tubing section.

Features & Benefits

All springs come standard with 17-4 stainless steel springs.

Entire spring assembly is available in stainless steel.

Can be free fall set from surface using a cup seat hold down.

Ball & Seat option for trapping fluid.

Wireline retrievable.

Springs are shot peened to remove any possible stress fractures.

Sour service equipment available.

Staged Plunger Lift Systems

Conventional plunger lift relies heavily on pressure and velocity to function. Historically, if the well

could not build enough pressure energy in an acceptable amount of time the well was deemed to not be a plunger candidate. However, the velocities in the tubing string may be adequate enough higher up. Meaning if the plunger was landed higher in the tubing string it would be able to effectively unload fluid. Staged plunger lift is simply a method to get accumulate

The standard system is comprised of a standard bottomhole spring assembly landed at the end of the tubing string, a bar stock style plunger to allow for easier slippage of fluid and gas around the plunger, a stage assembly, and a superior sealing plunger at the top (dual pad). The stage assembly has a dual acting seal assembly - a pack-off style to provide an effective seal to the tubing and a standing valve assembly to prevent slippage through the spring.

Features & Benefits

Works well with packer completions.

Works well in slim hole or tubingless completions.

Good option for wells with tapered tubing strings.

Reduced shut in time compared to single plunger application when less lift gas is available.

Existing plunger lift wells with inconsistent runs are excellent candidates.

EXAMPLE:

A 10,000 ft TVD* well capable of producing 4 bbl fluid per cycle utilizing 2.875" EUE tubing. Using conventional plunger lift “rules of thumb” the well must be able to produce 16 mcf within a reasonable time frame to trip the plunger and associated fluid to surface.

By setting the plunger stage assembly at 8,000 ft TVD* and lifting 1/2" of the fluid, the resulting gas requirement is now 6.4 mcf within a reasonable time frame. Reasonable Time Frame—Depth / 500 ft per minute velocity.

Through the use of Lufkin proprietary software design program, we are able to determine the optimal stage placement(s) for each application.

*TVD - True Vertical Depth

LIFTManager™ Controller

The LIFTManager plunger lift controller is user-friendly with multi-option functionality. The “basic” unit is very easy to operate and comes configured with the control method(s) specified by the user. The system can be set up to be as simple as intermittent control or as sophisticated as an auto adjusting differential pressure control.

Modes of Operation:

Intermittent

Time control (on/off)

Pressure control (2 pressures)

Differential Pressure Control

Auto adjust feature

Hi/Lo option

Basic Time Control

Auto adjust feature

On/Off/Afterflow

Hi/Lo option

Secondary pressure control for on cycle

Single or dual valve option

Tank wait option

Features & Benefits:

Easily installs with standard two-bolt valve bracket.

Four lines of display allows for quick collection of historical data.

Travel time history

Pressure history

Current measures pressure(s)

Calculates longest, shortest and average off time

Valve and plunger count (intermit mode)

High/Low external pressure switch shutdown supported.

Controller program easily upgraded for individual or all control modes.

Basic time control with dual valve option can be used for intermittent gas lift / plunger lift assist

applications.

User-friendly keypad.

Battery operated with solar charger option.

EVO I Controller

The EVO I controllers were designed in-house at Pentagon Optimization due to the short-falls of other controllers currently on the market. The

EVO I is a self-optimizing controller and is designed to deliver optimal performance with extremely simple operation. The EVO I is designed for either one to two motor (pneumatic or electric) valves. The four-line display clearly indicates the items selected and allows for increased information displayed. The following features are:

Extremely User-Friendly – built in conjunction with the Producing Industry

Optical Dial is used rather than a keypad thus eliminating faceplate issues

Four Line Display for increased information display

Proper Time Optimization – optimizes to a minimum Off time value before Afterflow is adjusted

Dual Valve Abilities

Operates Electric Valves on a six volt pulse

Operates either negative or positive solenoids

Best Battery Fault Protection in the Industry

Battery & Solar Panel designed for Northern Climate – Solar Panel leads the industry at a six

watt rating

Longer Battery Life than competing controllers through cell equalization

Back-Light Display for viewing in low light environments

Holds 25 Plunger Lift Arrivals – each arrival is date and time stamped

Real-Time Clock

Incorporated Service Date Option

Early-Arrival Protection and Critical Early-Arrival Protection

Five (5) Modes of Operation – three (3) in Optimization mode

Tracks 14 Days of Sales Time

Firmware can be specifically tailored to meet the client’s request

Additional special features include:

RS-232 / RS-485 Communication Port

Analog Inputs/Outputs

Digital Inputs/Outputs

The EVO I controller are CSA Class I Division I approved and is compatible with the following accessories:

Solar Panel – Industry Leading 6-Watt Rating

Plunger Lift Arrival Sensor

Pressure Switch Gauge

EVO II Controller

Communicate with the EVO I with your pre-existing SCADA packages! Now you can install true, dedicated plunger lift algorithms and have it all at the office with the touch of a button. Through Modbus language support you can operate the EVO II just as if you were standing in front of it, have access to live readings and full control of your plunger lift wells.

Did You Know?

The EVO series of controllers are the safest controllers on the market. Pentagon has overcome many new CSA certification standards for Class I Div I zones. The EVO line of controllers cannot be shorted-out across the battery leads due to internal circuitry in the battery. The six-watt panel allows for ample power in any northern light conditions and the battery voltage is cycled once a week at 7.5 volts to allow for cell leveling. This will give us the leading edge in rechargeable gel cell life cycles making the EVO number one in North America for safety and longevity!

EVO I - APC 1000 Controller Retrofit

Pentagon Optimization has taken all the appropriate steps to engineer and manufacture a CSA Class I Division I approved retrofit package for the APC 1000 controller.  Due to the inherent shortfalls of the APC 1000 controller that include items such as solenoid malfunctions and the need for additional solar panel connections for the northern climate, Pentagon Optimization has designed the solution to rectify all these issues. We are proud to introduce the ‘EVO I Retrofit’ for the APC 1000 controller.  Gone are the days of malfunctioning valves and the need for two, sometimes three, solar panels for the great Canadian climate.

By installing the ‘EVO I Retrofit’ package, the client will realize and benefit from all the features listed in the ‘EVO I Self-Optimizing Controller’ above.  This is completed by simply replacing the faceplate of the APC 1000 to the EVO I retrofit, upgrading of the solar panel from the 1.5 watt to the 6.0 watt and changing out of the existing battery. This allows for a very cost-effective solution to the problems inherent with the APC controller while maintaining the current installation of the control box itself, another cost-savings.  All this and not to mention the addition of all the great features and upgrades mentioned above.

EVO II Controller

Communicate with the EVO I with your pre-existing SCADA packages! Now you can install true, dedicated plunger lift algorithms and have it all at the office with the touch of a button. Through Modbus language support you can operate the EVO II just as if you were standing in front of it, have access to live readings and full control of your plunger lift wells.

Did You Know?

The EVO series of controllers are the safest controllers on the market. Pentagon has overcome many new CSA certification standards for Class I Div I zones. The EVO line of controllers cannot be shorted-out across the battery leads due to internal circuitry in the battery. The six-watt panel allows for ample power in any northern light conditions and the battery voltage is cycled once a week at 7.5 volts to allow for cell leveling. This will give us the leading edge in rechargeable gel cell life cycles making the EVO number one in North America for safety and longevity!

EVO I - APC 1000 Controller Retrofit

Pentagon Optimization has taken all the appropriate steps to engineer and manufacture a CSA Class I Division I approved retrofit package for the APC 1000 controller.  Due to the inherent shortfalls of the APC 1000 controller that include items such as solenoid malfunctions and the need for additional solar panel connections for the northern climate, Pentagon Optimization has designed the solution to rectify all these issues. We are proud to introduce the ‘EVO I Retrofit’ for the APC 1000 controller.  Gone are the days of malfunctioning valves and the need for two, sometimes three, solar panels for the great Canadian climate.

By installing the ‘EVO I Retrofit’ package, the client will realize and benefit from all the features listed in the ‘EVO I Self-Optimizing Controller’ above.  This is completed by simply replacing the faceplate of the APC 1000 to the EVO I retrofit, upgrading of the solar panel from the 1.5 watt to the 6.0 watt and changing out of the existing battery. This allows for a very cost-effective solution to the problems inherent with the APC controller while maintaining the current installation of the control box itself, another cost-savings.  All this and not to mention the addition of all the great features and upgrades mentioned above.

Plunger Lift Training

At Lufkin, we provide the best technical expertise in design, installation, optimization and troubleshooting. However, our work does not stop there. Training our clients about the basic operating principles of plunger lift and gas lift systems is a necessary step to ensure safe and productive operations. We provide a variety of comprehensive product training options tailored to meet your needs. Our training options are comprised of:

Lunch and learns

One-day seminars

Field training

In-house and on-site training based on production, well evaluation and operation

Practical field service

Custom programs to meet your specific needs

Contact us at [email protected] to learn more about our training options.

Plunger Lift Well Design Form

Click on the image of the English unit or metric unit version of the Plunger Lift Well Design Form to download it. Once it is downloaded you have two options to complete the form:

Fill out the interactive fields on the digital form.

Print out the form and fill it out by hand, or

Once the form is completed, you have two options to return it:

E-mail the competed form as an attachment to [email protected], or

Fax the completed form to 281-445-1134.