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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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
3
TYPICAL TUBING PLUNGER
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
4
Typical Field Assembly
4.5 “ System
Auto Catch
Simple Timer
LPG Supply
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
5
VIDEO FULL SCALE MODEL
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
6
WIRELINE ACCESS TO WELL
• Access to
lubricator
with std.
hammer
unions
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
7
OLD CUP AND NEW CUP DESIGN
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
9
UPPER CUP INFLATES
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
10
REPLACED OLD WITH NEW
Casing had sqz cmt
leak repairs.
Fixed diameter
cups hung up on
descent.
No remedy
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
15
SIMPLIST WELL HEAD TO DATE
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
16
CASING PLUNGER INSTALLED
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
17
REPLACED TUBING PLUNGER
• Pumper protested
• Csg @ 180 psi
• About 14 hrs/day
• Csg @ 80 psi
• Line @ 30 psi
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
19
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
22
PATENTED DESIGN CONCEPT
USE CUP
Packer
Add valve
Hollow stop
Small Dia.
Tbg
Gas flow will
lift fluid
Remove with
plunger
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
23
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
24
STANDARD COLLAR STOP
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
25
HOLLOW COLLAR STOP
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
26
TAIL PIPE WITH P/T RECORDER
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
27
HYBRID PACKER, VALVE ASSY.
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
28
HYBRID PACKER ON TAIL PIPE
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
29
HYBRID PACKER RELAXED
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
30
HYBRID PACKER COMPRESSED
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
31
P/T DATA FIRST TEST 17 DAYS
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
32
P/T DATA 2ND TEST 11 DAYS
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
33
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
34
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
35
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.
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
36
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
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
Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
40
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Feb. 19 – 22, 2012 2012 Gas Well Deliquification Workshop
Denver, Colorado
41
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