Segmented Plunger Piston Assembly for Gas Well Liquid Removal
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Solution Overview
Problem
Conventional plunger lift systems face challenges such as the risk of wells being easily 'killed' due to shut-in procedures, frequent replacement of free pistons, and the risk of pistons getting hung up in the production string, leading to inefficiencies and high costs in gas well operations.
Innovation Solution
A plunger piston assembly with a sealing sleeve, intermediate sleeve, and plug configuration that allows for a divided and nested arrangement, enabling the piston to descend through the production string without shutting in the well, reducing wear, and facilitating efficient liquid removal without frequent replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional plunger lift systems are used, then liquid removal from wellbore is achieved, but the well must be shut-in which increases the risk of well closure and reduces operational efficiency
Solution Approach 1:
The plunger piston assembly is divided into separate components: a sealing sleeve with a first seal, an intermediate sleeve with a second seal, and a plug. These segments can be dropped independently through the production string, allowing liquid removal without requiring well shut-in, thus maintaining productivity while reducing the risk of well closure.
Solution Approach 2:
The system transitions from a static well shut-in procedure to a dynamic component deployment process. The segmented plunger piston assembly allows the well to remain open during operation while still achieving liquid removal, converting a static risk state into a dynamic operational state that maintains productivity.
2Productivity
If conventional free pistons are used, then liquid lifting is achieved, but frequent replacement is required due to wear and hanging up
Solution Approach 1:
By segmenting the plunger piston into a sealing sleeve, intermediate sleeve, and plug, each component can be optimized independently for durability. The seals are positioned to minimize wear, and the modular design allows individual components to be replaced without replacing the entire assembly, extending overall service life while maintaining liquid removal efficiency.
Solution Approach 2:
The intermediate sleeve acts as a mediator between the sealing sleeve and the plug, providing a transition zone that reduces wear on the seals. This intermediary component protects the critical sealing surfaces from direct contact with abrasive wellbore conditions, thereby extending the operational life of the plunger piston assembly.
3Productivity
If conventional plunger pistons are used, then liquid removal is achieved, but the pistons may get hung up in the production string
Solution Approach 1:
The segmented design with separate sealing sleeve, intermediate sleeve, and plug reduces the likelihood of hang-up by minimizing continuous contact points between the plunger assembly and the production string. Each segment can move independently, reducing the probability that the entire assembly will become stuck, while still maintaining effective liquid removal capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the operational efficiency and longevity of the plunger lift system by reducing the risk of well closure, minimizing piston wear, and lowering replacement costs, while maintaining effective liquid removal from gas wells.
Implementation Method 1
a sealing sleeve having a central axis, an upper end, a lower end, and a throughbore extending axially from the upper end of the sealing sleeve to the lower end of the sealing sleeve
Implementation Method 2
The plunger piston assembly is configured to descend at least partially through the production string
Implementation Method 3
When the pressure below the piston, due to the influx of gas, is sufficient, the piston is pushed upward through the production string
Implementation Method 4
The upper end of the intermediate sleeve is configured to be removably seated in the receptacle of the sealing sleeve
Data Source
AI summary
A plunger piston assembly for a plunger lift system used to remove fluids from a subterranean wellbore includes a sealing sleeve having a central axis, an upper end, a lower end, and a throughbore extending axially from the upper end of the sealing sleeve to the lower end of the sealing sleeve. The throughbore of the sealing sleeve defines a receptacle extending axially from the lower end of the sealing sleeve. In addition, the plunger piston assembly includes an intermediate sleeve having a central axis, an upper end, a lower end, and a throughbore extending axially from the upper end of the intermediate sleeve to the lower end of the intermediate sleeve. The throughbore of the intermediate sleeve defines a receptacle extending axially from the lower end of the intermediate sleeve. The upper end of the intermediate sleeve is configured to be removably seated in the receptacle of the sealing sleeve. Further, the plunger piston assembly includes a plug configured to be removably seated in the in the receptacle of the intermediate sleeve.