What's new in artificial lift: Part 1—twenty new systems are described for sucker rod and progressing-cavity pumping, plunger lift and gas lift

World Oil, April, 2006 by James F. Lea, Herald W. Winkler, Robert E. Snyder

Plunger control/data acquisition. The Auto-Cycle * plus ACP SCADA Client * is a full-featured PC-based control/data acquisition system of Ferguson Beauregard (FB), Tyler, Texas, with an intuitive Microsoft Windows graphical user interface. Operators can manage well-head production anytime via a PC connection to the company's LAN/WAN. The multi-user system enables pumpers to group wells and liquid tanks by route. The "Go-Mobile" feature downloads route data to the mobile computer. As the pumper travels, additional information is recorded manually for non-automated processes using the Walk-up SCADA feature. In the office, adjustments and manual data are synchronized and stored in a SQL data base. Analysis features include trending and schematic trace. The latter enables polling the well repeatedly for real-time visualization of its performance and also stores data. All production data is available for query and reporting via third-party applications, including Crystal Reports.

The ACP SCADA Client is integrated with the RTU5000 * controller. It is pre-programmed with FB's patented Auto-Cycle plunger-lift control algorithm. Auto-Cycle makes adjustments to after-flow and shut-in time based on plunger travel velocity. Various control strategies include plunger-lift control for up to four-valve operation, gas injection and Plunger Enhanced Chamber Lift (PECL). Product features include low power for remote installations; CSA certification for Class 1, Division 2; programmable flash for local/remote upgrades; and dual protocol support for telemetry (native FB/Net2 and industry-standard Modbus). Telemetry options include landline modem, cellular, radio and satellite.

Valve production method. The most attractive feature of this Ferguson Beauregard controller, in addition to increased production, is the simplicity of the method and that it is used in conjunction with plunger lift for the same costs. This controller utilizes an algorithm that allows production from both tubing and casing, as opposed to the tubing only.

The algorithm has the ability to self-adjust control parameters dependent on present well conditions and control production from the tubing, the casing, and both tubing and casing. The larger cross-sectional diameter of the casing provides a larger flow area for increased production. In the 3-Valve Production Method, production is from the tubing, both the tubing and casing, and casing only during a plunger cycle. Wells in the Texas Panhandle, Kansas and Oklahoma regions have shown about two-fold increases in production.

Bypass plungers. Plungers are finding their way in newer applications and more diversified conditions as a result of continued improvements in design and applications. The Bypass Plungers by FB are a direct outcome of this. They can be broken into two categories, "continuous flow" and "short shut-in flow" plungers. Continuous flow plungers are used in wells where it is imperative that the plunger returns to bottom quickly. This is made possible by having a larger bypass area. These wells may be flowing around their critical flowrate, and do not need to be shut-in to build up pressure; and they may be producing moderate to considerable liquids. The bypass is open when the plunger is falling, and closes upon hitting the bumper spring. Upon reaching surface, the bypass mechanism opens a passage for fluid to flow through, and the plunger falls back when flowrate drops.