THE UNIVERSITY OF THE

WEST INDIES
ST. AUGUSTINE

RESEARCH METHODS
PENG 6023
EVALUATION AND OPTIMIZATION OF
WELLS ON PLUNGER LIFT SYSTEMS AND
WELLS WITH PARAFFINIC
ACCUMULATIONS IN THE MAIN
SOLDADO FIELD

DEPARTMENT OF

Name: Saaeed Yusuf Ali

CHEMICAL ENGINEERING

ID#: 809001287
Supervisor: Dr. Raffie Hosein
Academic Year 2015/2016
1

ABSTRACT
Plunger lift is a low cost artificial lift technique that utilizes reservoir energy for lifting liquids from
primarily liquid loaded gas wells. Its use was extended to oil wells with high gas-oil ratios and
wells that stop producing due to paraffin deposition in the production tubing string. The current
plunger lift systems utilized at Petrotrin are representative of intermittent gas lift with the
assistance of a plunger. These systems are used to produce the wells and simultaneously prevent
paraffinic accumulations. When compared to the traditional method of gas-assisted plunger lift
this present method is considered inefficient. In this study, plunger lift performance on 10 wells
will be evaluated and optimized using the Foss and Gaul (1965) model for traditional gas-assisted
plunger lift. Plunger lift systems for 5 additional wells that are currently plagued with paraffinic
accumulations will be designed and optimized based on the results obtained from the
aforementioned wells.

ANTICIPATED TABLE OF CONTENTS

ABSTRACT.
ACKNOWLEDGEMENTS.
LIST OF FIGURES.
LIST OF TABLES
LIST OF EQUATIONS ...
1.0

2.0

INTRODUCTION
1.1

Background...

1.2

Objectives of Study....

LITERATURE SURVEY....
2.1 Cruse Formation Properties
2.2 Removal of Liquids from Gas Wells
2.3 Improved Efficiency of Intermittent Gas Lift Wells.
2.4 Formation and Deposition of Paraffin/Wax in an Oil Wells Production Tubing
2.5 Removal and Prevention of Paraffin/Wax from Wells Production Tubing
2.6 Production from Extremely Low Pressure Reservoirs...
2.7 Plunger Lift Components and Operation Cycle.
2.8 Design and Optimization of Plunger Lift.

2.9 Advantages and Disadvantages of Plunger Lift.

3.0

METHODOLOGY...

4.0

RESULTS AND DATA ANALYSIS.

4.1

Evaluation of 10 Wells......

4.2

Gas Requirements For Current Operation (Intermittent Lift with Assistance Of

Plunger).
4.3

Modelling 10 Wells for Traditional Gas Assisted Plunger Lift Operation Using Foss

and Gaul Model................

4.4

Plunger Lift Optimization of 10 Wells...

4.5

Plunger Lift Design for 5 New Wells...

5.0

DISCUSSION..

6.0

CONCLUSIONS.

7.0

RECOMMENDATIONS

REFERENCES..
APPENDICES
.

1.0 INTRODUCTION
1.1.

Background

Plunger lift is an artificial lift method originally developed to solve liquid loading problems in
wells. Plunger lift operation includes the cyclic travel of a piston (plunger) from the bumper
spring, at the bottom of the well, to the wellhead at the surface; resulting in the removal of liquid
that has accumulated at the bottom of the wellbore. Plunger lift utilizes the reservoir energy and
gas energy that builds up in the annulus in order to lift the accumulated liquid and prevent liquid
loading. The plunger acts as a solid interface, separating the accumulated liquids, above the
plunger, from the gas that provides the energy for lifting the liquids, below the plunger. This solid
interface prevents the development of intermittent slug production from the wellbore and also
reduces the fallback of the accumulated liquids (Chava 2008). Plunger lift can be applied to a wide
range of cases, such as: to remove liquids from gas wells, intermittent lift in high gas-liquid ratio
(GLR) oil wells, to remove paraffin and scale from wells and to improve the efficiency of
intermittent gas lift wells (Ferguson and Beauregard 1982).
According to Mohammed (2014), reviews and evaluations of several wells producing fluids from
the Upper Cruse Formation in Petrotrin Trinmar Operations Main Soldado field; indicated that
these wells had problems of low productivity and high operating costs, for reducing wax
accumulations in the production tubing string. Many of these wells were placed on routine
cleanouts where wireline interventions such as gauge cutters and pin scrapers were used for dewaxing purposes, in conjunction with expensive chemical injection systems for reducing wax
build-up. In response to this problem, Petrotrin evaluated several different methods of artificial
lift by: comparing advantages and disadvantages, predicting production rates through
simulations programs, performing economic analyses and analyzing methods for minimizing wax
accumulations. Subsequent to this evaluation, plunger lift was recommended as the most
economical method for producing these wells and were installed on a number of them
(Mohammed 2014).
Mohammed (2014) found that the plunger systems installed were very efficient when it came to
preventing paraffinic accumulations due to the fact that the wells experienced no downtime after
5

its installation. However, Mohammed (2014) concluded that the wellhead pressure charts
showing casing head and tubing head pressure trends for some wells showed that the plunger
lift systems were operating inefficiently under the current settings. Based on the operational
sequence of the casing and flowline motor valves, the mode of operation on these wells were
representative of intermittent lift with the assistance of a plunger rather than gas assisted
plunger lift operation. In this mode of operation, the gas requirements are usually relatively
excessive and the production rates are relatively less.
Mohammed (2014) used the Foss and Gaul (1965) model for traditional gas assisted plunger lift
to evaluate and optimize plunger lift systems on two such wells (S-126 and S-145) located in the
Main Soldado field; as a result, new plunger lift systems were designed and proposed for two
other wells (S-131 and S-151) in this field based on the findings from the first two wells. The total
oil production gain from all four wells were calculated to be approximately 277 bopd requiring a
gas injection rate of approximately 533 MSCFD (Mohammed 2014).

1.2.

Objectives of Study

The major objectives of this study are:

1. To evaluate the efficiency of the plunger lift systems on ten (10) wells in Petrotrin Trinmar
Operations Main Soldado field based on the existing system parameters, operation, and
well productivity variables such as production rates and well downtime.

2. To optimize the performance of existing plunger lift systems on these ten (10) wells.
3. To determine if plunger lift systems can also be introduced and installed on five (5) other
wells that exhibit paraffinic accumulations based on expected production rates and
evaluation of these ten (10) wells.

2.0 LITERATURE REVIEW

Plunger lift is a well-known artificial lift method which integrates a piston (plunger) that uses the
energy exerted from expanding gas for its upward motion. This lift method is used: to remove
liquid from gas wells, in intermittent lift of high gas liquid ratio (GLR) oil wells, to improve
efficiency of intermittent gas lift wells and used to remove paraffin and scale from wells. The
plunger: reduces liquid fallback, acts as a partial seal between gas and liquid, and utilizes gas lift
energy more efficiently (Mower et al. 1985).
2.1 Removal of Liquids from Gas Wells
Liquid loading is the primary cause for the reduced production rates exhibited by many low
volume gas wells. When liquid accumulates in the wellbore, it results in an added back pressure
on the reservoir and effectively reduces production (Wiggins et al. 1999). According to Chava et
al. (2009), a common problem encountered in gas wells, is liquid loading, which is a direct result
of a reservoir losing its capability to lift the co-produced liquids up the production tubing. Lea et
al. (2007) stated that in gas wells, liquid loading is an indication that the wells are at a low velocity
and the droplets of liquid in the gas flow are no longer being entrained with the gas or being
lifted by it.
According to Oyewole and Garg (2007), approximately forty plunger lift systems in Colorados
San Juan North Basin have experienced a production increase of more than 4 MMcfd. Most of
these wells were either on temporary abandon (TA) status or on a plug and abandon (P&A) list.
The overall gas and anticipated production from these wells were not enough to justify the
installation of more expensive methods of artificial lift to de-liquefy wells. After the installation
of these plunger lift systems, production increased to more than 200 Mcfd on some wells, and a
production increment of over 300% was observed on other wells (Oyewole and Garg (2007).
2.2 Improved Efficiency of Intermittent Gas Lift Wells
Plunger lift efficiency is negatively impacted by a reduction in reservoir pressure and GLR. One
way to minimize the effects of these impacts on the performance of plunger lift systems is by
combining intermittent gas lift and plunger lift operation. A plunger-assisted intermittent gas lift
7

system injects gas into the space (annulus) between the casing and production tubing to increase
the annular pressure. After this pressure builds to a certain value, it is released to provide energy
to lift the liquid slug and plunger up the production tubing (Bello et al. 2011).
Intermittent gas lift was used by an operator to produce some wells in a field located in the Gulf.
In an attempt to reduce the amount of gas injected into the wells to produce them, plunger lift
systems were proposed to decrease the quantity of gas used. The plunger minimized the gas
slippage through the liquid load and prevented liquid fall back (Hassouna 2013). The production
and gas requirement data for the wells, prior and subsequent to the plunger lift installation can
be seen in Table 1 in the Appendix.
2.3 Formation and Deposition of Paraffin/Wax in an Oil Wells Production Tubing
The higher melting point waxes found in petroleum are the principal constituents of paraffin.
When these waxes separate from solution in the crude oil in the form of very fine crystals, they
tend to agglomerate and form granular particles of wax roughly the size of table salt. Oil has a
tendency to " sweat " or drain from the wax particles, therefore the hardness of the paraffin and
the quantity of oil associated with the wax are influenced by the length of time during which
accumulation has taken place and the manner in which it was deposited (Reistlr Jr. 1935).
Temperature and evaporation of volatile components are the two main factors governing the
solubility of crude wax in crude oil. A reduction in temperature decreases the solubility of paraffin
in crude oil and a loss of the lighter ends, which are the better solvents for crude wax, reduces
the quantity of paraffin a given type of oil can transport in solution (Brown 1940). When paraffin
builds up in a well, its effective diameter is decreased to a minimum resulting in an increase in
the flowing bottom hole pressure and a decrease in flowing tubing pressure. When these
conditions are prevalent the well will cease to flow (Narvaez and Ferrer 1991).
2.4 Removal and Prevention of Paraffin/Wax from Wells Production Tubing
In Venezuelas Anaco Santa Rosa area, well (RM-2l) exhibited severe paraffinic accumulations.
The primary mode of operation on this well was a gas lift system. Every 90 days, well workovers
had to be executed with an associated average production reduction of approximately 30 bbl/d,
8

over the year. Subsequent to the installation of the plunger lift system, the well, was able to
produce constantly for 24 months without wireline intervention or any downtime. Due to this
positive feedback, a decision was made to implement this installation in 17 additional wells. In
the year 1990 these installations were completed. The results obtained for all other wells with
plunger lift systems in this area, were similar to those observed in the initial wells.
2.5 Production from Extremely Low Pressure Reservoirs
According to Beauregard and Morrow (1989), before the introduction of light weight, high
efficiency seal plungers, the applicability of plunger lift systems were limited to wells with
relatively high bottom hole pressures. These advancements in plunger lift technology has
permitted the operation of plungers in many reservoirs that would not have been candidates
before. In Wyoming, a major operator was experiencing difficulty in pumping wells with declining
pressures and very gassy conditions. These wells were completed at 10,000' and with 2-7/8"
production tubing. Plunger lift systems were successfully installed on these wells, there by
effectively increasing their economic limits. Plungers are operated with less than 200 psi casing
pressure and produce into a 35 psi sales line (Beauregard and Morrow 1989). In Oklahoma, the
Northeastern McClain County have numerous wells that utilize plungers in the Osborne
Formation. These wells are completed at 8900' with 2-3/8" production tubing. They are
successfully operated with 200 psi casing pressure and produce into a 35 psi sales line.
(Beauregard and Morrow 1989).
2.6 Plunger Lift Components and Operation Cycle
Rowlan et al. (2009) listed the components of a typical plunger lift system and gave a brief
description of their respective functions as follows:

Controller: Used to determine the conditions for motor valve opening and closing.

Motor Valve: A device used to open and close the sales line.

Lubricator/Catcher: Shock absorber at the plungers highest point on the tubing string.

Bumper Spring: Shock absorber at the plungers lowest point on the tubing string.

Plunger: Pig-type device that produces the liquid slug by functioning as a seal/barrier
between the gas from the annulus and the liquid inside the production tubing.
9

Figure 1 in the Appendix shows a typical assembly for an intermittent gas assisted plunger lift
well:
Rowlan et al. (2006) describes the plunger lift cycle as three distinct parts:
Shut-in period - Commences with the closing of the flowline motor valve, during which the flow
is ceased and the plunger is allowed to travel (free fall) from the surface to the bottom of the
production tubing. The shut-in time period should ideally be equal to the duration of time taken
for the plunger to fall from the surface to the bumper spring at the base of the tubing. During
this time the casing pressure is allowed to build to an adequate value that will be capable of lifting
both the plunger and accumulated fluids to the surface during the following unloading period.
Unloading period - commences after a predetermined casing pressure has been reached or a
sufficient duration of time has passed after the beginning of the shut-in period. During this period
the motor valve is opened and fluid is allowed to flow from the tubing into the flowline. The
reservoir pressure and pressure built up in the annulus during the shit-in period are used to lift
both the plunger and accumulated liquid to the surface. During this time there is a decrease in
the surface tubing pressure; this causes a differential pressure across the plunger, which in turn,
lifts the plunger and accumulated liquid to the surface.
After-flow period - commences when the plunger reaches the catcher at the surface. During this
period the flow valves are opened which allows the flow of fluid from the tubing into the flowline.
A mechanical plunger catcher or differential pressure is usually used to hold the plunger at the
surface. If the gas velocity is large enough additional liquid may sometimes be produced with the
gas. As the gas velocity decreases, liquid starts to accumulate at the bottom of the tubing. The
after-flow time period should ideally be long enough to allow liquid to accumulate in the tubing,
but not too long that a longer shut-in time period will be needed.
2.7 Design and Optimization of Plunger Lift
The model developed by Foss and Gaul (1965) is based on actual field experiences in the Ventura
Avenue field in California. This model is used to determine critical parameters, such as casing
pressure, gas requirements, and cycle frequency for plunger lift systems. The model is composed
10

of empirical correlations and performance charts established for the minimum-casing-pressure

and gas requirements. The emphasis of the Foss and Gaul (1965) model is on the upward travel
of the plunger. During this period of time, most of the factors are in a state of variation,
interacting with one another. Important among these are:

Tubing pressure decreases substantially from a pressure approximately equal to

maximum casing build pressure to a minimum pressure which is controlled by separator
pressure, a length of flow line, and a relatively low gas flow rate.

Gas flow rate decreases from a relatively high value to an ever decreasing rate as the
plunger nears the surface.

Casing pressure ordinarily decreases from a maximum to a minimum pressure

The velocity of the plunger and liquid changes from zero to approximately 1,000 ft/min
average velocity.

Foss and Gaul (1965) outlined that with a given set of well conditions, it is possible to operate
with a wide variety of average casing pressures but the lowest casing pressure possible is
desirable to achieve the greatest well drawdown. The performance curves that were developed,
showed that the gas requirement per cycle decreased with as casing pressure decreased. In order
to establish the value of the minimum casing pressure, it is essential to know the point at which
a stall out is most likely to occur in the plungers upward travel. It is almost certain that this critical
point will occur when the plunger approaches the surface with the liquid load or when the fluid
is surfacing and is passing through the wellhead since the casing pressure is lowest at these
points. Assuming that the casing head pressure (CHP) is lowest when the plunger approaches the
surface with its liquid load (Foss and Gaul 1965):

= [ + 14.7 + + ( + )] [1 + ]

Equation 1: Minimum Casing Pressure Required

11

Where:
-

Casing pressure just as slug arrives at surface, psia

Pressure required to surface plunger, psi

Wellhead gathering line pressure, psi

Pressure required to lift weight of liquid per barrel, psi/bbl

Liquid frictional pressure loss per barrel, psi/barrel

Barrels of liquid in slug, bbls

Tubing inside diameter, in.

Term for gas friction in tubing

3.0 METHODOLOGY
The methodology used to evaluate and optimize the plunger lift systems will be adapted from
Mohammed (2014). To efficiently evaluate and optimize the plunger lift systems currently
utilized on ten (10) wells in the Main Soldado Field, a wide range of data inputs would be
required. Table 2 below shows the data that would be used and the sources from which they will
be acquired.
Data Inputs

Source

Production rates before and after the installation of the

plunger lift systems
Total well downtime before and after the installation of the
plunger lift systems
Casing and tubing head pressure trends during plunger lift
operation
Inlet gas valves and flowline motor valves cycle times
during plunger lift operation
Injection gas system pressure

Pressure chart recorders on

the respective wells
Daily field reports (Pre-set
cycle times)
Daily field reports

Gas inlet choke sizes

Daily field reports

Static and flowing bottom-hole pressures and temperatures

for the wells under consideration

Recent bottom-hole pressure

(BHP) surveys

Reservoir fluid properties (Water cut, GOR, oAPI)

Lab analyses of fluid samples

Current wellbore schematics of the wells under

consideration

Production well files

Daily field reports

Daily field reports

Table 2: Data that would be used and the sources from which they would be acquired.

12

After this data has been successfully attained and compiled the first step in evaluating the plunger
lift systems would be to compare any increase or decrease in the production rates and total well
downtime before and after the installation of these systems. The casing and tubing pressure
trends in conjunction with the pre-set cycle times on the inlet gas and flowline motor valves
would be used to explain the current operational sequence of the plunger lift systems and
identify any operational discrepancies and their origins. The injection gas pressure together with
the casing head pressures (CHP) and gas inlet choke sizes would be used to calculate the gas
injection rates. These injection rates would then be used with the inlet gas motor valve cycle
times to determine the daily gas usage for the respective wells.
Petroleum Experts software PROSPER would be used to model the inflow performance
relationship (IPR) to determine the absolute open flow potential of each well. The wells in the
Main Soldado Field typically produce at pressures below bubble point therefore the Vogels
model would be used in the simulation software. Fluid properties of the production fluids from
the respective wells together with static and flowing bottom-hole pressures would be used as
the input parameters for PROSPER.
The traditional gas-assisted plunger lift method of production would be proposed to optimize the
current plunger lift operation. This traditional method would be modelled using the Foss and
Gaul model (1965) for plunger lift production. New operating parameters such as gas injection
rates and flowline motor valve cycle times would be calculated and optimized. Production rates
and injection gas required using this method would be calculated and a comparison would be
made with the current production and gas injection rates used for each well. The Foss and Gaul
model (1965) would then be used to calculate the optimum production rates and gas
requirements for five (5) other wells where the introduction of gas assisted plunger lift systems
may potentially increase production while simultaneously reducing paraffinic accumulations.

4.0 PROJECT TIMELINE

Figure 2 on the following page shows the Gantt chart representing the expected timeline for the
completion of the thesis.
13

Figure 2: Gnatt chart showing the proposed timeline for thesis completion

14

5.0 JUSTIFICATION
The production of crude oil from wells completed in the Cruse formation at Petrotrin Trinmar
Operations Main Soldado field has been continuously plagued with wax deposition problems. In
response to this, routine and expensive wireline interventions together with chemical injection
systems had to be utilized in these wells. This contributed to well downtime and a corresponding
decrease in production. After meticulous evaluation, plunger lift systems were recommended as
the most economical method for producing these wells. These systems were installed on a
number of wells where they successfully prevented paraffinic accumulations. However, when
compared to the traditional method of gas-assisted plunger lift, the current plunger lift systems
are inefficient as they are representative of intermittent gas lift with the assistance of a plunger.
This study proposes to evaluate the performance of the current plunger lift systems being utilized
and optimize them to improve their efficiency. This improved efficiency will inherently increase
production rates and reduce the quantity of gas required by the plunger lift systems. An overall
increase in production and reduction in gas requirements can then be translated into a monetary
value. In addition, this study will lay a foundation and methodology for future evaluation, design
and optimization of wells in Petrotrins onshore and offshore fields; that currently use gas
assisted plunger lift systems or require them.

15

6.0 BIBLIOGRAPHY

Beauregard, E., and Paul L. Ferguson. "Introduction to Plunger Lift: Applications, Advantages and
Limitations." Society of Petroleum Engineers, 1982.
Beauregard, E., and S. Morrow. "New and Unusual Applications for Plunger Lift System." Society
of Petroleum Engineers, 1989.
Bello, Oladele Olalekan, Gioia Falcone, Jun Xu, and Stuart L. Scott. "Performance Evaluation of a
Plunger-Assisted Intermittent Gas Lift System." Society of Petroleum Engineers, 2011.
Brown, W. Y. "Prevention and Removal of Paraffin Accumulations." American Petroleum
Institute, 1940.
Chava, Gopi Krishna. 2008. Analyzing pressure and temperature data from smart plungers to
optimize

lift

cycles. Master's

thesis, Texas

A&M

University. Available

electronically

from http : / /hdl .handle .net /1969 .1 /ETD -TAMU -3217.

Chava, Gopi Krishna, Gioia Falcone, and Catalin Teodoriu. "Plunger Lift Modeling toward Efficient
Liquid Unloading in Gas Wells." Society of Petroleum Engineers, 2009.
Foss, D. L., and R. B. Gaul. "Plunger-Life Performance Criteria with Operating Experience-Ventura
Avenue Field." American Petroleum Institute, 1965.
Hassouna, Mohamed. "Plunger Lift Applications: Challenges and Economics." Society of
Petroleum Engineers, 2013.
Lea, James, Orvel Lynn Rowlan, and James N. McCoy. "Measurement and Calculation of Key
Events During the Plunger Lift Cycle." Society of Petroleum Engineers, 2007.

16

Mohammed, Shazim Kaleem. 2014. Evaluation and optimization of wells on plunger lift and
wells with paraffinic accumulations in the Main Soldado field. Masters thesis, The University of
the West Indies St. Augustine, Trinidad and Tobago.
Mower, L. N., J. F. Lea, E. Beauregard, and P. L. Ferguson. "Defining the Characteristics and
Performance of Gas-Lift Plungers." Society of Petroleum Engineers, 1985.
Narvaez, C., and A. A. Ferrer. "Prevention of Paraffin Well Plugging by Plunger-Lift Use." Society
of Petroleum Engineers, 1991.
Oyewole, Peter Olugboyega, and Divyakumar O. Garg. "Plunger Lift Application and Optimization
in San Juan North Basin - Our Journey." Society of Petroleum Engineers, 2007.
Reistle, C. E., Jr. "Paraffin Production Problems." American Petroleum Institute, 1935.
Rowlan, Orvel Lynn, James F. Lea, and James N. McCoy. "Modified Foss and Gaul Model
Accurately Predicts Plunger Rise Velocity." Society of Petroleum Engineers, 2009.
Rowlan, Orvel Lynn, James N. McCoy, and Anthony L. Podio. "Analyzing and Troubleshooting
Plunger-Lifted Wells." Society of Petroleum Engineers, 2006.
Wiggins, Michael L., Sean H. Nguyen, and Sandro Gasbarri. "Optimizing Plunger Lift Operations in
Oil and Gas Wells." Society of Petroleum Engineers, 1999.

17

7.0 APPENDIX

Table 1: Comparisons before and after plunger installation (Hassouna 2013).

Figure 1: Typical Intermittent Gas Assisted Plunger Lift Well (Chacin et al. 1994).

18