PETROLEUM SOCIETY

CANADIAN INSTITUTE OF MINING, METALLURGY & PETROLEUM PAPER 2007-159

Plunger Lift Analysis,

A.L. PODIO
University of Texas at Austin

This paper is to be presented at the Petroleum Society’s 8th Canadian International Petroleum Conference (58th Annual Technical
Meeting), Calgary, Alberta, Canada, June 12 – 14, 2007. Discussion of this paper is invited and may be presented at the meeting if
filed in writing with the technical program chairman prior to the conclusion of the meeting. This paper and any discussion filed will
be considered for publication in Petroleum Society journals. Publication rights are reserved. This is a pre-print and subject to
correction.

Abstract Introduction
A new portable monitoring system has taken the guesswork Plunger lift is a low cost method for lifting liquids (water,
out of plunger lift analysis, troubleshooting and optimization. condensate and/or oil) from primarily liquid loaded gas wells
The plunger generates an acoustic pulse as it falls through each and is used infrequently to produce oil wells. The operating
tubing collar recess when the well is shut-in. Each acoustic cost of plunger lift system is low compared to other artificial lift
pulse travels through the gas in the tubing and is detected at the methods, because the reservoir supplies the energy required to
surface. The pulses are converted to an electrical signal by a lift the liquids. During plunger lift operations the motor
microphone and pressure transducer. The signals are digitized, controlled valve is opened and at a later time shut-in. During
stored and processed in a computer to determine plunger shut-in the gas flow down the flowline is stopped when the
position, plunger fall velocity, and plunger arrival at the liquid surface valve is closed, allowing time to elapse for the plunger
level in the tubing. The problem of not knowing the plunger to fall down to the bottom of the tubing. After a pre-determined
location during the operation cycle has been overcome with this amount of time elapses the controller commands the motor flow
new technology by allowing the operator to see the plunger valve to open and the tubing pressure begins to drop toward the
location at any time during the cycle. Having a detailed flowline pressure. Differential force acting on the plunger
analysis of the operation of the well makes optimization of results from the drop in surface tubing pressure and the high
plunger lift production achievable with a minimum of effort and reservoir pressure below the plunger. The differential force
avoids the usual waste of time due to trial and error lifts the plunger and a portion of the liquid above the plunger to
procedures. Example data collected from various plunger lifted the surface. The open and shut-in operational cycle of the
wells are presented in this paper to show how to identify plunger lift system is repeated throughout the day to produce
operational problems such as holes in the tubing, stuck
liquids and gas from the well.
plungers and plungers not getting to bottom

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 Without acquiring a fluid level shot in plunger lift wells, an elapse, the motor valve is closed, starting the next plunger
acoustic fluid level instrument can be used to continuously cycle.
record at a fast sampling rate the acoustic signal produced as the The new portable monitoring system can be used to begin
plunger travels up and down the tubing and to monitor the acquisition of data at any time during the cycle. At least ONE
variation of pressures during the plunger cycles. The acquired COMPLETE CYCLE must be acquired to be able to do a
acoustic and pressure data can be processed to determine the 1) complete analysis of the plunger lift system. One complete
depth to the plunger 2) fall velocity of the plunger 3) time for cycle consists of one valve opening plus one valve closing or
the plunger to fall to the liquid 4) time for the plunger to fall to one valve closing plus one valve opening. If the operator is
the bottom of the tubing 5) the volume and rate of gas flowing only interested in determining the plunger fall velocity, then
into the well 6) the appropriate cycle times for optimum data acquisition must start just before the Shut-in period begins
operation. As the data is collected and analyzed at the well, the and continue until after the beginning of the Unloading period.
goal for the plunger lift analyst should be to answer the WELL Acquisition of data over several cycles may be required to
PERFORMANCE QUESTIONS listed in Table 1. The plunger analyze a well that behaves erratically; in order to identify the
lift well can be produced more efficiently if the well problem and to correctly analyze the operation of the plunger
performance questions are answered. Analysis of the collected lift installation.
data is used to optimize and troubleshoot the operation of
plunger lifted wells. Setup of Acquisition Hardware
The following sections of this paper describe the procedure
Over a long time period the electrical signals can be digitized
used to acquire the data for plunger lift analysis. Example data
and stored by software in a computer. The acoustic and
showing various operational problems encountered during
pressure signals signal are recorded with special software at the
operation off plunger lift systems will be presented.
optimum resolution of the analog to digital converters. The
computer offers unattended operation of the equipment in that
Plunger Lift Operation Cycle the computer can be programmed to acquire data without
The plunger lift cycle can be divided into three distinct parts1: monitoring by an operator. As the data is acquired the
1-The Shut-in period begins when the flowline motor valve processing speed of the laptop computer allows instant analysis.
closes, the flow is shut-in and the plunger falls down the tubing. The acoustic, tubing and casing signals are acquired at a
The plunger falls from the surface through the gas in the tubing default sampling rate of 30 measurements per second and data
until the plunger hits the accumulated liquid at the bottom of the is displayed in real-time sample-by-sample basis. For high-
tubing. The plunger then falls through any accumulated liquid pressure wells or fast falling plungers, faster sampling rates of
at the bottom of the tubing. The shut-in time period should be 60 or 120 samples per second may be needed to follow bumper
long enough for the plunger should fall to the bottom of the springs and by-pass types of plungers.
tubing and rest on a plunger catcher or bumper spring. During The most common data acquisition hardware for plunger lift
shut-in, the casing pressure must build to sufficient pressure to includes an acoustic gas gun with microphone and pressure
be high enough to lift the accumulated fluids and the plunger to transducer connected to the tubing through a ½” or larger, fully
the surface during the next time period when the valve opens. opening valve, connected on the lubricator and a second
2-The Unloading period begins after a predetermined pressure transducer connected to the casing. It should be noted
amount of time has elapsed from the start of the shut-in period. that if a needle valve is present on the well at the point of gun
Based on meeting some type required of operational criteria a connection, it should be replaced in order to record the best
valve controller opens the motor valve between the tubing and quality acoustic signal. A full opening ball valve should be
the flowline. The pressure from the reservoir and the pressure used to connect the gas gun to the lubricator. The gas gun
from the gas stored in the casing annulus are used to lift the should be cocked manually or by charging the gas chamber to a
accumulated liquid and plunger to the surface. During the pressure greater than the maximum expected tubing head
unloading period the surface tubing pressure drops to a value pressure so that during the unloading and afterflow cycles the
close to the line pressure and the differential pressure across the well fluids will not enter the volume chamber and contaminate
plunger lifts the plunger and the liquid slug above the plunger to the gun mechanism. Other types of gas guns may require the
the surface. gas gun chamber to be charged to a pressure greater than the
3-The Afterflow period begins when the plunger arrives at maximum expected well pressure in order to keep the internal
the surface. The flow valves are open as the well produces gas gun mechanisms closed. If high well head pressures are
up the tubing and down the flow line. The plunger is held at encountered when liquid is being unloaded at the surface and
surface by either the differential pressure caused by the flow of the gas gun valve opens, then the internal mechanism of the gun
gas past the plunger or a mechanical plunger catcher. may be contaminated from well fluids and cleaning of the gun
Sometimes additional liquid will also be produced with the gas, may be required upon completion of the test.
if the gas velocity in the tubing is high enough to lift liquid to The gun’s microphone is connected to the portable
the surface. As the gas rate decreases, liquids are not carried to monitoring system via a coaxial cable and the microphone is
surface because the gas velocity becomes too low2 and the used to monitor the acoustic noise throughout the cycle. The
liquid will accumulate at the bottom of the tubing. If the plunger generates noise during the shut-in time period and
afterflow period is too long, the liquid accumulation at the during the rest of the cycle noise is generated by flowing gas
bottom of the tubing will cause the pressure at the bottom of the and flowing liquid.
well to build-up and further reduce the flow from the formation.
The after-flow time period should be long enough to bring Identifying Key Events During Data
liquid into the tubing, but not to long that longer shut-in time
period is required to bring the plunger and liquid to the surface. Acquisition
After meeting specific control criteria or a predetermined time The elapsed time for a plunger lift cycle is often longer than
one hour; usually a plunger lift data set consists of more than
500,000 data points. After acquiring a large quantity of data it

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may be difficult to identify a key event. Identifying key events tubing gas at the beginning of the plunger fall. The figure on
that occur during the plunger cycle will aid in the analysis of the the right shows a gradual increase in tubing pressure and a
data; the process of identifying a key event is called sudden drop in pressure when the plunger’s fall begins; this
“annotating”. To aid in the analysis of the plunger lift cycle it is trace is representative of plunger installations where the gas
recommended to annotate the key event while acquiring data. pressure holds the plunger at the surface during the afterflow
When a specific event occurs during the plunger lift cycle time period. The figure on the right shows a sudden drop in
software allows the time of the event to be identified; events tubing pressure when the plunger was released from the catcher.
such as the exact time when the control valve opens or closes, The tubing pressure will also suddenly increase when the
the plunger starts to fall or gets stuck in the tubing, etc. Usually plunger suddenly stops in a tight spot in the tubing or stops on a
annotating is done while acquiring the data but annotating can dry bumper spring. As the plunger falls through a tubing collar
be also done after the data acquisition is complete. Figure 1 a pressure wave is generated as each tubing collar recess
shows the tubing, casing pressures and acoustic signal for one temporally carries a portion of the plunger weight. When the
plunger lift cycle where key events are identified and annotated tubing temporally holds the weight of the plunger, then the
on the figure. A key event such as the time when the plunger pressure above the plunger rapidly increases. This acoustic
reaches the liquid at the bottom of the tubing is generally pulse, which is generated at the tubing collar recess, travels
characterized by the disappearance of the tubing collars signals through the gas to the surface and is detected by the microphone
generated as the plunger passes through the tubing and by a and also by the tubing pressure transducer. These acoustic
large amplitude pulse followed by a change in the noise level. pulses are normally obtained when a plunger falls down the
The events that are related to the opening and closing of the tubing in a well that produces a limited amount of liquid so that
control valve are identified by rapid change in the pressure. A the tubing interior is relatively dry. Figure 4 shows a portion of
key event of the time when the plunger reaches the bottom of the acoustic and pressure records during 0.2 minutes during the
the tubing is generally characterized by a further reduction in shut-in time period. The record shows that a 0.1-psi amplitude
the acoustic noise level, plus a slight increase in the tubing pressure wave and an acoustic signal are generated as the
pressure. Figure 2 illustrates key events during the Unloading plunger fell past the 112th tubing collar recess at a depth of 3444
and Afterflow period. These include the arrival of the liquid feet. These signals created by the plunger falling past each
and plunger to the surface and are generally apparent both on tubing collar recess are monitored at the surface so that the
the pressure and the acoustic signals, characterized by rapid plunger travel is followed on a continuous basis. Periodic firing
changes in amplitude and slope of the traces. Liquid arrival at of the gas gun is not required to determine the position of the
the surface is characterized by a sudden increase of the tubing plunger by echo ranging. The method of acoustically recording
pressure and the detection of significant noise amplitude on the plunger generated pressure waves from the tubing collar recess
acoustic signal. The arrival of the plunger at the surface can be has been defined as “passive” monitoring of the plunger
identified as the point of peak tubing pressure while the motor position during the fall. The schematic for the instrumentation
valve is open. If liquid is above the plunger, the pressure spike set up is shown in Figure 5, with pressure sensors connected to
always occurs and once the plunger arrives in the lubricator the both the tubing and casing. For passive monitoring, high
tubing pressure rapidly drops as the gas is released into the frequency (30Hz or greater) data acquisition is used to record
surface flow line. If there is no liquid above the plunger, there the signals from both tubing and casing pressure sensors, plus
may be a short duration slight increase in tubing pressure and a the acoustic signal from the microphone.
sharp noise on the acoustic data. The point where the tubing When the plunger enters the liquid the fall is slower than in
pressure begins to decline corresponds to the beginning of the gas, the tubing recess acoustic pulses are generally difficult to
afterflow period when gas is flowing through the open valve. identify when transmitted through the liquid. Usually a
Unexpected occasional events should be identified with a decrease in the acoustic noise level indicates that the plunger is
comment from the operator. Identifying specific key events that submerged in the tubing liquid. The field acquired acoustic and
occur during the plunger lift cycle will help in the analysis of tubing pressure data in Figure 6 shows tubing collar recess
the collected data. echoes both in the gas above the liquid and lower frequency
echoes from the collar recesses below the liquid level. Usually
Monitoring Plunger Location when the tubing pressure is high (greater than 2700 kPa) it is
possible to see acoustic pulses as the plunger falls through the
The digital fluid level instrument monitors and digitally
liquid. When the plunger finally rests on bottom on the bumper
records the acoustic and pressure signals from inside the tubing
spring the noise level drops again and a small increase in tubing
as a function of time. It has the sensitivity to acquire tiny
pressure is observed, and the time when the plunger reached
signals from the gas gun microphone detecting pressure changes
bottom may be determined with certainty.
created by the plunger falling in the tubing. Usually an acoustic
Monitoring of tubing and casing pressure simultaneously
pulse is generated and tubing pressure fluctuation occurs when
with the acoustic signals can precisely identify timing of
the plunger falls through a tubing collar recess. The tubing
various key events during the operation of the plunger. The
carries the weight of the plunger when the plunger is resting at
variation of pressure during the cycle is then used to calculate
the bottom or mechanically held at the surface by a catcher, but
volumetric flow of gas from the reservoir into the well and from
during the remaining time of the cycle the weight of the plunger
the well to the flow line. The objective of these calculations is
is applied to the gas or fluid in the tubing. A difference in
to present an analysis of the performance of the plunger system
pressure exists across the plunger; this pressure difference is
in terms of gas and liquid production per cycle in order to
approximately equal to the weight of the plunger divided by the
optimize the operation of the system.
tubing area plus or minus other minor factors. This difference
in pressure above and below the plunger is usually in the range
of 14 to 20 kPa (2 to 3 psi) in pressure. Figure 3 shows the Analysis
beginning of the shut-in period where a sudden drop in tubing The process to analyze the collected plunger lift data
pressure is caused by the weight of plunger suddenly acting on includes four steps: 1) Select the Plunger cycle to analyze, 2)

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Identify Key events in the selected cycle, 3) Determine plunger indicates the plunger rising in the tubing). After some of the
fall velocity, 4) Determine the gas gravity. collar recesses are counted, the plunger fall velocity past each
1) The purpose of this step is to select one complete cycle from collar is determined and the speed and depth of the plunger as a
the total sequence of data that was recorded. A time period is function of time is computed. How fast the plunger falls to the
selected to identify the beginning and end of a complete plunger bottom during the shut-in period in shown at the bottom of the
cycle from the collected set of data. The cycle may start at the figure; the average fall velocity through gas is 51.3 m/min (–
beginning of shut-in or at the start of the flow period and 168.3 ft/min) and the average fall velocity through the liquid is
continue until the following cycle, which are valve-opens to 11.89 m/min (–39.0 ft/min). In the lower right corner, the table
valve-opens or valve-closes to valve-closes. displays the time, plunger velocity and depth values that
2) Key events are identified during the selected cycle. During correspond to the movement of the plunger past ten previously
the Shut-in time period identify within the plunger cycle the identified collars.
times when the following two key events take place:
1. Plunger hits Liquid Plunger Fall Velocity and Depth Graph
2. Plunger on Bottom
Figure 8 is used for quality control of the analysis process
During the Unloading and Afterflow Period identify within the
since it represents the position of the plunger and its
plunger cycle the times when the following two key events take
instantaneous velocity to the depth where collars have been
place:
counted.
1. Liquid Arrives to surface
The general trend of the plunger fall velocity is to
2. Plunger arrives to surface
consistently slow down as time (plunger depth) increases.
3) Determine plunger location during the shut-in time period by
When liquid is present in the bottom of the tubing trapping the
identifying and counting tubing collar signals as the plunger
gas in the tubing, it is normal for the plunger fall to initially
falls past each tubing collar recess. Identification of these
start fast and gradually slow down as the plunger gets deeper
signals is used to determine the plunger position and fall
into the well. Significant deviations from this trend would be
velocity vs. time.
an indication that the identification of the collar signals should
4) The gas gravity is required to compute the volume of gas in
be reviewed/verified OR that there may be a problem with the
the tubing and casing, plus the pressure at the bottom of the
operation of the well. An operational problem may exist in the
tubing and casing. Gas properties may be input or determined
well if the plunger falls at a constant speed or slows down and
by processing the acoustic signal of the plunger fall. After steps
speeds up during its fall.
1-4 are completed, then a complete analysis of the plunger lift
Figure 8 shows, at the top, that collar #2 has been selected
system can be performed.
(by manually locating the vertical dotted line using the software
buttons) where the plunger is only 19.63 m (64.4 ft) from the
Plunger Fall surface showing that the fall velocity is –77.7 m/min (–255
In the record for the shut-in period, each tubing collar echo ft/min) at that point. When the plunger hit the liquid the fall
is identified and counted to determine how fast the plunger falls velocity had decreased to 41.3 m/min (–135.4 ft/min). The
and determine if it falls to the bottom. The location in time of elapsed time for the plunger to fall from the surface to the liquid
the tubing collar recess echoes determines the speed and depth level in the tubing was 45.2 minutes. This time also
of the plunger. If the acoustic signals generated by the plunger corresponds to the plunger being at a depth of 2229 m (7313.2
are clearly visible on the acoustic trace, then software is used to ft), based on the average tubing joint length determined for the
automatically identify and record the time of occurrence of each well. The plunger fell through the gaseous liquid column in the
acoustic collar recess pulse and count all the tubing joints that bottom of the tubing at a rate of 11.9 m/min (–39 ft/min) and
the plunger has traversed. Using the plunger depth and the fell from 2229 to 2369 ft (7313.2 to 7773 ft) in 11.8 minutes.
elapsed time then the plunger fall velocity is computed and a Plungers fall much slower in a gaseous liquid in the bottom of
graph of the position of the plunger and plunger velocity vs. tubing than in gas.
time is generated. Plunger fall velocity that deviates from the general trend
Figure 7 displays the acoustic record beginning at a time of (gradually slowing down with depth) is easily identified by
approximately 8.9 minutes after data acquisition began. The examination of the plunger fall trace. The corresponding collar
graph at the lower left is a representation of the acoustic signal reflections can be examined in more detail on the acoustic trace
recorded from the start of the shut-in period [A] until the marker by double clicking a point of interest on the graph. A detailed
[1] when the plunger hit the liquid near the bottom of the discussion3 of the various methods that may be used for
tubing. Note that in the lower left window the vertical white monitoring the plunger position during the shut-in periods is
band is the 1-minute interval of the acoustic trace plotted at the found in the paper: SPE 80891.
top of the figure. The signal at 9.361 minutes in the upper trace
corresponds to the time when the plunger fell past 44th the Gas Properties
tubing collar recess at a depth of 1416.8 feet. The user may
The specific gravity of the produced gas must be determined
manually identify all the pulses that correspond to the plunger
to accurately calculate the pressure distribution in the tubing
falling past the tubing collars or the collars may be
and casing and calculate the volumetric rates of gas inflow from
automatically selected after the software has been “trained” to
the reservoir. Properties of gas sampled at the sales line or even
properly identify these signals. The times are marked with a
at the separator, generally are not necessarily representative of
line when the plunger fell past collar 44 (labeled C44 at 9.361
the properties of the gas within the annulus or the tubing. The
minutes) and when the plunger reached the next tubing collar
best estimate of the gas gravity will be obtained from
(labeled C45 at 9.514 minutes). Using the well’s average joint
measurements while tracking the plunger fall. At a certain
length of 9.81 m/joint (32.2 feet/joint), the fall velocity of the
pressure and temperature the acoustic velocity in a gas is
plunger is computed to be 63.78 m/min (–209.24 ft/min).
directly related to its specific gravity. This relationship is used
(Negative sign indicates falling down the tubing and positive
compute the gas gravity when the gas acoustic velocity has been

4
determined. Shooting the liquid level in the tubing during the to a depth of 2097 m (6880 ft) from the surface and is located
shut-in period makes a direct estimate of acoustic velocity. about 97 m (318 ft) from the top of the gaseous liquid at the
Most often it is not necessary to shoot a fluid level, since bottom of the tubing.
acoustic velocity in the tubing gas can be computed by
analyzing the signals generated as the plunger falls past the Following are definitions of the various quantities displayed:
tubing collars. Surface Pressure Tubing: This is the tubing head pressure
The acoustic velocity of the tubing gas can be computed by measured at the specific time selected during the cycle.
analyzing in more detail the acoustic signals generated by the Surface Pressure Casing: This is the casing head pressure
plunger as it falls past the tubing collars. An acoustic pulse that measured at the specific time selected during the cycle.
is generated when the plunger goes past a collar propagates via Tubing Pressure Buildup: psi/min: This is the rate of change
the gas in the tubing above the plunger to the wellhead (where it in tubing head pressure as a function of time when the motor
is detected by the microphone) and then is reflected back down valve is closed, expressed in psi per minute.
through the gas until it reaches the top of the plunger and is %Liquid: Is the computed percentage liquid in the gaseous
reflected back to the surface where the microphone detects it as liquid column at the bottom of the tubing calculated based on
a first echo. Since the acoustic velocity in the gas is in the range the tubing pressure buildup5.
of 427 m/sec (1400 ft/sec) for low pressure methane gas and the Gaseous Liquid Level: is the depth to the top of the gaseous
plunger velocity is much slower, in the order of 60-300 m/min liquid column at the bottom of the tubing.
(1 to 5 m/sec) [200-1000 ft/min (3.3 to 16 ft/sec)], the plunger Liquid Level (Gas Free): is the measured depth to the top of
has not fallen a significant distance by the time the acoustic an equivalent gas-free column of liquid in the tubing.
pulse catches up with the plunger and is reflected back to the Gas Flow: displays the instantaneous gas flow rate in
surface. This reflection process is repeated several times before Mscf/D, or cumulative volumes in Mscf, calculated from
the plunger reaches the next collar. Figure 7 shows that collar material balances in the annulus and the tubing at the time
C44’s echo occurs at 9.361 minutes and its repeat echo (marked corresponding to the displayed plunger position. The following
with the vertical dashed line) occurs 2.21 seconds later. The instantaneous flow rates are displayed: 1) Formation: gas rate of
depth to collar C44 is 432 m (416.8 ft) and the repeat echo flow from the formation, 2) Casing: gas rate of flow from the
traveled from the microphone to the top of the plunger and back casing, 3) Tubing effect: gas rate of flow from the tubing, 4)
to the microphone in 0.0368 minutes. For this round trip travel Flow Line: gas rate of flow from the well into the flowline
time the acoustic velocity calculates to be 391 m/sec (1282.1 The user can select to display cumulative produced gas
ft/sec) and the corresponding gas specific gravity calculates to volumes values by clicking on the units field and selecting the
be 0.724. values of cumulative per plunger cycle or cumulative per day.
In some cases, due to the noise level in the wellbore or other Assuming all of the liquid accumulated at the bottom of the
plunger characteristics, it may not be possible to identify the tubing, prior to unloading, is produced to the surface, then 1)
multiple reflection signals. The user then should retrieve the gas Liquid Production STB/Cyc: displays the total liquid produced
gravity that was computed from the acoustic velocity when a per plunger cycle, and 2) Liquid Production STB/D: displays
conventional fluid level survey was done in the tubing during the total liquid produced per day assuming that each cycle
the shut-in period and enter this value in the calculation form. produces the same volume of liquid.
Liquid at Bottom of Tubing: displays the volume of liquid
Cycle Analysis at the bottom of the tubing as a function of time in Bbls or
height of gas-free liquid.
The analysis begins either at the beginning of the Shut-in period
Tubing Intake Pressure: this is the pressure in the annulus
(motor valve closes) or at the start of the Unloading period
calculated at the depth of the tubing intake (depth to bumper
(motor valve opens). Figure 9 provides a complete analysis of
spring).
the plunger cycle and a detailed summary of the pressures and
PBHP: This is the calculated producing bottom-hole
volumes flowing into and out of the well as a function of the
pressure at the datum depth. The PBHP changes throughout the
plunger position. The average producing bottom hole pressure
plunger lift cycle.
is calculated and is compared to the static bottom-hole pressure.
Reservoir Pressure (SBHP): This is the shut-in BHP as
Vogel's IPR relationship is used to determine the well's inflow
entered in the well data file.
performance efficiency and the maximum obtainable gas and
The information on this schematic diagram is a complete
liquid flow rates.
representation of the well's operating conditions at times
On the right of Figure 9 the wellbore schematic shows the
selected by the user during the complete plunger cycle.
position of the plunger as well as the position of the tubing
The top left-hand side of the Cycle Analysis Tab shows the
intake in relation to the formation depth. The Plunger Lift
current oil, water and gas daily flow data from the most recent
Operational Cycle is displayed at the top left side of the
production test as entered in the well data file. This information
wellbore diagram. This indicates the section of the plunger lift
is used in subsequent calculations of well performance and
cycle that is being displayed depending on the previous
should be as recent and as accurate as possible.
analysis: 1) Shut-in, 2) Unloading, or 3) Afterflow.
The Potential is the maximum daily production if the
At the lower left is a slider control that is used to step
producing pressure (PBHP) were reduced to zero. It is
through the complete plunger cycle. The display of the position
computed using the selected IPR Method for representing the
of the plunger changes when selecting a particular time during
well’s performance: (Productivity Index or Vogel IPR).
the cycle using the slider, the software displays the measured
PBHP/SBHP-This is the ratio of the current producing bottom-
and computed values dependent on elapsed time. Clicking on
hole pressure to the shut-in bottom-hole pressure. A value of
the Auto-Step button animates the figure and results with the
1.0 corresponds to a shut-in well. A value of zero corresponds
plunger moving up and down the tubing at equal time steps
to a well producing at open flow or maximum production rate.
through out the cycle. Figure 9 shows the instantaneous
Producing Efficiency - Expresses the current well test flow rate
conditions during the Shut-in cycle when the plunger has fallen
as a percentage of the calculated potential maximum flow rate.

5
It is very important that the well data be accurate, because the the difference between the tubing and casing pressure indicates
program calculates bottom hole pressure and calculates the that liquid had entered the tubing at the end of the afterflow
plunger’s performance analysis using all these values. time period. At an elapsed time of approximately 28 minutes
At the bottom left of the window is a time line on the horizontal axis the vertical dashed line shows the time
corresponding to the plunger cycle that has been analyzed. The where all the liquid being held in the tubing had been pushed
timeline shows the sequence of operational cycles, the time from the tubing and the only difference in casing minus tubing
(hh:mm:ss) when the plunger cycle started and when it ended as pressure is due to the weight of the falling plunger. Another
well as the start time of each operation. The duration (mm:ss) indication that all of the liquid was pushed from the tubing is
of each operational cycle is also displayed. The slider bar the tubing and casing pressure equalize at approximately 55
allows the operator to move through the plunger cycle to minutes when the plunger landed on the dry bumper spring at
display the position of the plunger and view the variation of the bottom.
flow and pressure variables. The Step Increment is defaulted to Figure 12 displays how pressure equalizes between tubing
60 seconds/step but may be changed by the user to a more and casing in a typical stair step fashion when a standing valve
convenient value by entering a different time step in seconds. is installed in a plunger lifted well to prevent liquid from being
pushed out of the tubing. Notice how the tubing pressure
Analysis Plots suddenly increases when the standing valve opens and gas
enters the tubing and then remains constant while the standing
The software provides the user the ability to plot a large number
valve is closed and no gas is entering the tubing. The tubing
of diagnostic graphs to aid in further analysis of the plunger
pressure increases in approximate 2.7 kPa (0.4 psi) steps as the
cycle or to identify problems that may not be apparent from the
standing valve opens and closes at the end of the shut-in time
routine analysis. Two variables may be plotted as a function of
period. The pressure difference between the casing pressure
elapsed time on the horizontal axis. The values discussed in the
and the tubing pressure remain constant, indicating that all of
Cycle Analysis section that change as the user steps through the
the liquid is being held in the tubing by the standing valve.
plunger cycle can be plotted and compared to each other. In
Measurement of this stair-step action of the tubing pressure is a
Figure 10 the numeric values of the two variables are displayed
simple means to verify that the standing valve installed in a well
in the boxes at the lower right, for the time corresponding to the
is functioning properly.
position of the vertical dashed line indicator which is positioned
Figure 13 shows the effect of a hole in the tubing on the
with the Left and Right buttons or directly positioned by
plunger fall velocity. The plunger falls at a nearly constant
pointing and clicking on the point of interest on the signal trace.
velocity of 66 m/min (217 ft/min) from the surface to the hole.
Plots can be viewed in greater detail by using the zoom feature
Once the plunger falls past the hole at 1540 m (5051 ft) from
to change the elapsed time range of the horizontal axis. The
the surface, then the trapped gas between the plunger and the
analysis plots display the data at a default step increment of 60
liquid at the bottom of the tubing result in the plunger gradually
seconds. If a more detailed investigation is required an
slowing down to a fall velocity of 61 m/min (200 ft/min). In
increment of 5-15 seconds is usually best for the display of the
this well a 0.05 cm (1/8 in) diameter hole in the tubing was
plunger lift data.
located in the 156th tubing joint from the surface. During the
Figure 10 displays the cumulative production from the
unloading period of the cycle the presence of a hole was causing
formation and the instantaneous gas flow rate down the flow
the plunger to not arrive at the surface 80% of the time.
line computed from the measured pressures, gas properties, and
Figure 14 shows the tubing pressure behavior when the
height of the gas free liquid in the tubing, plus the wellbore
plunger falls past a hole in the tubing, where the hole is above
configuration. Gas flow from the formation occurs during the
the liquid in the bottom of the tubing. In this example the
entire cycle whether the flowline valve is open or closed and the
tubing and casing pressure at the surface and at the hole are
increase in cumulative volume from the formation is steeper at
equalized due to a hole through the tubing. When the plunger
the low flowing bottom hole pressure after the plunger arrival
began the fall the gas pressure in the tubing below the plunger
shown by the vertical dashed line indicator line. Generally
was increased by the weight of the falling plunger and the
there are two peak instantaneous gas flow rates down the flow
increase in pressure below the plunger forced pressure out of
line, one peak occurs at the beginning of the unloading period
the hole slightly raising the casing pressure. When the plunger
when the flow line valve is first opened and a second peak gas
falls past the hole then the higher gas pressure from casing
flow rate occurs at the beginning of the afterflow period
equalizes back into the tubing, thereby equalizing the tubing
immediately after the plunger arrives at the surface. These two
and casing pressure at the hole. The plunger falls past the hole
peak rates are typical of the flow regime occurring at the time
at a depth of 549 m (1800 ft) from the surface and the point
when the flow line valve is open. The initial high gas flow rate
where tubing pressure begins increasing is used to identify the
is due to gas stored in the tubing above the plunger and the
depth of the hole. When trouble-shooting tubing for a possible
second high gas flow rate is due to gas accumulated behind the
hole; the tubing must have some liquid in the bottom to trap the
plunger which lifted the plunger and liquid to the surface.
gas between the plunger and the liquid, only then can the tubing
pressure increase can occur when the plunger falls past the hole.
Operational Problem Examples Figure 15 shows the plunger suddenly stopping as it was
Figure 11 shows a common problem in plunger lifted wells. As falling to bottom during the shut-in period of the cycle. In this
the pressure builds during the shut-in period, the liquid in the example the plunger had fallen 569 (1866 ft) from the surface
tubing is often pushed out and the plunger hits dry tubing when and the sharp 20 kPa (3 psi) increase in the tubing pressure at
arriving at the bottom. Hitting dry is a problem because the this depth indicates that the plunger is stuck in the tubing and
gaseous liquid normally slows the plunger fall; hitting dry can the tubing gas pressure is no longer depressed by the weight of
result in damage to the plunger, bumper spring and downhole the plunger. Three minutes after the plunger began the fall the
assembly. To alleviate this condition a standing valve is used to operator identified that the plunger was stuck and began
hold the liquid in the tubing during the shut-in time period. At corrective measured to unstick the plunger.
the start of the shut-in period (leftmost dashed vertical marker)

6
 Figure 16 shows the impact of reduced gas production due plunger lift production achievable with a minimum of effort and
to having the shut-in time set for too long of a period. The avoids the usual waste of time due to trial and error procedures.
initial 68 minute shut-in time period of the plunger cycle is
displayed. Long shut-in time resulted in fewer cycles per day NOMENCLATURE
and in large liquid loads during the unloading cycle with an
average plunger rise velocity of 177 m/min (580 ft/min). The BPD = Barrels per Day
initial afterflow period lasted 70 minutes and during shut-in the STB/Cyc = Stock Tank Barrels per Cycle
plunger fell to the liquid level in 30 minutes and the plunger MscfD = 1000 Standard Cubic Feet per Day
rested on the bumper spring for almost 30 minutes. Based on PBHP = Producing Bottom Hole Pressure
the plunger resting on bottom for too long of a time period, SBHP = Static Bottom Hole Pressure
Figure 17 shows that the shut-in period was decreased from 68
minutes to 33 minutes. The shorter shut-in time period resulted REFERENCES
in an increase in gas production from 4750 to 6820 m3/d (168
1. Phillips, Dan and Listiak, Scott, “How to Optimize
to 241 MscfD) and condensate production increased from 1 to
Production from Plunger Lift Systems,” World Oil,
1.3 m3/d (6 to 8 BPD). The shorter shut-in time period also April 1998 presented at the Southwestern Petroleum
resulted in an increase in the plunger rise velocity close to 305 Short Course, Lubbock, Texas, 1997.
m/min (1000 ft/min); afterflow time should be lengthened to 2. Turner, R.G., Hubbard, M.G. and Dukler, A.E.:
reduce system pressure, to bring more liquid into the tubing and “Analysis and Prediction of Minimum Flow Rate for
decrease the plunger unloading speed. the Continuous Removal of Liquids from Gas
Wells,” SPE 2109, presented at SPE Gas
Conclusions Technology Symposium, Omaha, Nebraska,
Troubleshooting plunger lift operational problems become September 12-13, 1968.
much easier when the plunger depth and fall velocity are 3. Rowlan, O.L., McCoy, J.N., and Podio, A.L,
known. ”Determining How Different Plunger Manufacture
1. Plunger fall velocity can be accurately measured Features Affect Plunger Fall Velocity” SPE 80891,
with an acoustic instrument, presentation at the SPE Production and Operations
2. Minimum shut-in time for the plunger lift Symposium held in Oklahoma City, Oklahoma,
U.S.A., 23–25 March 2003
installation can be determined.
4. Phillips, Dan and Listiak, Scott, “How to Optimize
3. Plunger fall measurements will ensure that the
Production from Plunger Lift Systems,” World Oil,
plunger will fall through the fluid at the bottom of
April 1998 presented at the Southwestern Petroleum
the tubing and be resting on the bumper spring by Short Course, Lubbock, Texas, 1997.
the end of the shut-in period. 5. McCoy, James N., Podio, Augusto, L. and
4. If a plunger becomes stuck is easily identified and Huddleston, Ken L., “Acoustic Determination of
corrective measured can be taken to fix the Producing Bottomhole Pressure,” SPE 14254,
problem. presented at the 1985 SPE Annual Technical
5. Holes in the tubing are identified by observing Conference and Exhibition, Las Vegas, Nevada,
changes in the plunger fall velocity and in the September 22-25, 1985.
tubing pressure.
Monitoring the complete plunger cycle with a new portable
monitoring system is a fairly simple task. By accurately
Table 1
Plunger Lift Survey Answers Well Performance Questions:
measuring the plunger fall velocity and depth to the liquid level, 1. Where is the plunger? On bottom? In or above
then the minimum shut-in time for the plunger lift installation liquid? Surface?
can be determined. The plunger fall measurements ensure that 2. What is the depth to the top of the liquid in the
the plunger will reach the bottom of the tubing by the end of the tubing?
shut-in period. Maximum production from the plunger lift 3. What are the producing and static BHP’s?
installation will be obtained by having the shortest possible 4. Is liquid in the casing annulus above the tubing
shut-in time. intake?
The new portable monitoring system minimizes the need for 5. What are the casing and tubing pressures during the
using a wire line. A plunger can be dropped and tracked to the operational cycle?
seat nipple or collar stop. The tubing collar recesses can be 6. Does tubing gas/liquid pressure push liquid out of
counted to be sure the plunger has arrived at the bottom. The tubing?
operator will save time by quickly identifying holes and 7. What is the maximum production rate available from
eliminating the need to drop standing valve and pressure test the the well?
tubing. The new portable monitoring system increases safety of 8. What is the gas flow rate? From Formation? Annulus?
plunger lift operations by knowing where the plunger is in the Flowline?
tubing. If a plunger is not going to bottom and the well is 9. What is the gas gravity?
pressured up, then the plunger could surface dry at a very high
10. Are there restrictions to plunger fall in the tubing?
velocity. Plunger arrival at high velocity can cause equipment
damage and could result in exceeding the mechanical integrity
limits of the lubricator. Development of a new portable
monitoring system has taken the guesswork out of plunger lift
analysis, troubleshooting and optimization. Having a detailed
analysis of the operation of the well makes optimization of

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Figure 1 - Annotating Key Events during a Plunger Cycle

Fig. 2 Description of Key Events during the Unloading and Afterflow Period

8
Figure 3 – Change in Pressure Due to Weight of Plunger Acting on Tubing Gas

th
Figure 4 – Acoustic Signal from 112 Tubing Collar Recess

9
Figure 5– Passive Data Acquisition Configuration

Figure 6 – Tubing Collar Recess Echoes Above and Below Liquid Level

10
Figure 7 – Determining Plunger Fall Velocity and Depth

Figure 8 – Plunger Fall Velocity and Depth

Figure 9 – Cycle Analysis

11
Figure 10 – Cumulative Gas Produced from Formation and Gas Flow Rate into Flow Line

12
Figure 11 – During Shut-in Liquid Pushed out of the Tubing

Figure 12 – Plunger Falls Past Hole in Tubing during Shut-in Period

13
Figure 13 – During Shut-in Fall Velocity Decreases when Plunger Passes Hole in Tubing

Figure 14 – Tubing Pressure Change Increases when Plunger Passes Hole in Tubing

14
Figure 15 – Tubing Pressure Suddenly Increases when Plunger becomes Stuck on Tubing

Figure 16 – Shut-in time Period too Long

Figure 17 – Shut-in Time Period Adjusted to Minimum Time

15