The Energy Flows Through Us

PLUNGER LIFT SYSTEMS

INTERNATIONAL LIFT SYSTEMS
Lufkin Industries: The Leader in Artificial Lift Oilfield Equipment & Services
Founded in 1902, Lufkin Industries, Inc. (NASDAQ:
LUFK) is a vertically integrated company that designs,
engineers, manufactures, sells, installs and services
high-quality and high-value-added oilfield equipment
and power transmission products across the globe.
Additionally, the Company operates a gray and
ductile iron foundry producing up to 300 tons per
day of captive and commercial castings for the heavy
equipment, valve and machine tool markets.
Lufkins Oilfield Division is a leading global provider of
artificial lift equipment and services to the upstream
sector of the oil and gas industry. The divisions
product lines consist of Beam and Hydraulic Pumping
Units, Gas Lift, Plunger Lift, Completion Components
and Automation.
Lufkins International Lift Systems (ILS) product
line manufactures and supports a complete
portfolio of plunger lift products, which includes
lubricators, plungers, bottom hole assemblies
and controllers. In addition to plunger lift,
Lufkin ILS offers a complete line of gas lift,
waterflood, chemical injection, packoff and
insert string equipment.
Lufkins well-established position in the major
oil producing areas of the world has enabled
the Company to maintain its presence in all
major markets.
 QUALIT Y

Because of our
confidence in the
quality process,
Lufkin is able to
make this promise:

We will provide
you with timely
delivery of quality Meet i ng and E xc eedi ng Qu al i ty
products and Standar ds
services that meet As part of Lufkins effort to ensure quality within our products, we regularly review
our processes and procedures to maintain current quality standards. We utilize
or exceed all our experience in sales, operations, engineering and manufacturing to ensure
every product we manufacture delivers high performance-based quality results.
requirements. Additionally, we keep up with the latest regulatory compliance across our global
enterprise to ensure our product quality meets your needs, regardless of location.

M anuf act uring Accredit at ions :

We manufacture to the leading standards and specifications in the industry.

Please refer to www.lufkin.com/quality for a complete list of accreditations and

standards that we maintain.

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Plunger Lift Systems
HEALTH, S AFET Y AND ENVIRONMENT

U nparalleled HSE C o m m i t m ent

Safety is an integral part of the planning and execution of every job. HSE is an inseparable component within our manufacturing
and quality programs to insure efficient operations. Committed management along with a conscientious, well-trained workforce
combine to make our organization a safe and efficient workplace.

Lufkins in-house and industry-wide HSE program

participation further solidifies our commitment.
Our HSE program and organizational involvement
includes:

HALO (Hazard Awareness through Line

Observation) Lufkins Behavior Based Safety
(BBS) program

Job Safety Analysis (JSA) and Standard

Operating Procedure (SOP) development using
Process Picture Mapping (PPM) techniques

Active Membership and Participation in:

NSC (National Safety Council)
ASSE (American Society of Safety
Engineers)
ACGIH (American Council of
Governmental Industrial Hygienists)
COPS (California Oil Producers)
STEPS (South Texas Exploration and
Production Safety) network
ISNetworld
PEC/Premier
SafeLand
SafeGulf

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Plunger Lift Systems
 OPERATING PRINCIPLES

What is Plunger Lift?

Solar Panel
Lubricator
Plunger Lift is an artificial lift method that uses the wells own
Controller energy (gas and/or pressure) to lift accumulated fluids from the
tubing and annulus.
Catcher Sensor Motor Valve
The system operates through a series of shut-in periods and flow
periods, intermitting the well. Intermitting alone is very inefficient
due to the fluid fall back during the flow cycle. The rule of thumb
for intermitting is approximately 10% of the fluid slug is lost for
every 1,000 ft of lift. A plunger utilizes an interface seal between
a fluid in the tubing and stored gas in the annulus. The head gas is
blown down creating differential pressure across the plunger, which
brings both the plunger and accumulated fluid to the surface.
Wellhead
Seal efficiency is critical for effective plunger operation. The amount
of fluid and gas being produced must be taken into account when
selecting the plunger type. The more fluid being produced the better
the seal efficiency must be.

The Benefits of Plunger Lift are:

Low capital cost.

No rig required to install.

No fuel cost.

Low maintenance.

Stabilized well production.

Minimal well downtime.

Plunger Can be moved to other wells.

Bottom Hole
Bumper Spring

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Plunger Lift Systems
Candidate Well Indicators

Wells with unstable production (liquid loading).

Wells being intermitted, swabbed or vented.
Gas locked pumping wells.
Wells with large differential between the casing and tubing flowing pressure.
Wells with liquid to gas ratios (LGR) less than 150 bbl/mmcfd.

Typical Maximum
Operating Depth 8,000 ft TVD* 21,000 ft TVD*
Operating Volume 1-5 BPD 200 BPD
Operating Temperature 120F 500F
Wellbore Deviation N/A 35 deg Conventional 70 deg Bypass
Corrosion Handling Excellent
Gas Handling Excellent
Solids Handling Poor to Fair
2-3/8" = 400 SCF / BBL /1,000 ft Lift
GLR Required
2-7/8" = 600 SCF / BBL / 1,000 ft Lift
Service Wellhead Catcher or Wireline
Prime Mover Type Wells Natural Energy
* TVD - True Vertical Depth BPD - Barrels per Day SCF - Standard Cubic Feet BBL - Barrels

Mechanical considerations that may lead to problems:

Well Surface Equipment

Sand Tank and separator capacities
Scale Bottle necks, chokes
Temperature Flow line limitations (pressure
increases when plunger is flowing/
Tubing arriving)
Continuous ID (packers, anchors, Orifice plate sizing
crimps, rod cut, scale, soap buildup)
Compression
Packer or tubingless completions
Centralized or single wellhead
End of Tubing (EOT) compression
Wellhead Suction pressure control
Continuous ID (valves, tees, landing Wells fight for line space correct
threads, hanger, wrong wellhead size) compressor size, synchronization
Unnecessary valves or tees High line pressure delays
Piping not plumb By-pass valve configuration
Not using flanged master valves for safety

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Plunger Lift Systems
Plunger Lif t Sy s t em Applications

Conventional Plunger Lift

As the well is shut-in and the plunger falls to the bottom, pressure
begins building up in the casing. Additional time should be given in
the beginning to account for any extra accumulation of fluid in the
tubing. The rule of thumb for initial fall time is 200 ft/min (depth to
the spring / 200 = minimum fall time required).

When pressure is enough to lift the plunger and the liquids to surface
are at a reasonable velocity (rise velocity of approximately 650 - 750
ft/min) against the surface pressure, the surface valve will open.

The motor valve at the surface will open and the plunger and fluid
slug will begin to rise.

The gas in the annulus expands into the tubing to provide the lifting
pressure. At this point, the well is now producing during the rise
time to add to the energy required to lift the plunger and fluid slug.
This is referred to as the On Cycle.

The plunger arrives in the lubricator and is held in place by the flow
of fluid and gas and pressure below. The well is now allowed to flow
for a set period of time. This is referred to as After Flow or Delay
Time.

After Flow is critical to the plunger cycle for two reasons. One, the
well is now allowed to flow at the maximum rate for the operator
to sell gas. Two, the well is able to bring more fluid in from the
formation so that the plunger has fluid to bring to the surface on the
next cycle. If no fluid is available, the plunger will run dry and the
risk of plunger and/or surface equipment failure increases.

As the gas flow starts to drop and the gas velocities in the tubing
decrease, the liquid begins to accumulate in the bottom of the well.
The casing pressure begins to rise, indicating a pressure drop in the
tubing. If the flow is allowed to continue too long, a fluid slug will
accumulate that will require a high casing pressure buildup to lift it.
This could cause the plunger to not arrive on the next cycle.

The motor valve closes and the plunger begins to fall. The plunger
hits bottom (stops on the bumper spring) and the cycle begins again.

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Plunger Lift Systems
 PRODUCT S

Conventional
Threaded

Bowen The lubricator is the main component of any plunger

Flanged lift system. It is what accepts the plunger as it travels to
the surface. All flow from the well is diverted through
it to the flowline. The spring housed in the top of the
lubricator is designed to help cushion the force of the
plunger as it arrives into the lubricator. The dual outlet
configuration allows for optimal flow of gas and fluids
during the plunger lift cycle.

Feat ures & B enefit s

The top cap has an API ACME #6 thread vs.
a standard 8 rd thread. This provides a much
safer connection when high impacts are seen
at the surface.
The main lubricator is 3,000 psi WP. All
lubricators are hydrostatically tested to 5,000
psi as per ASTM testing standards. 5,000 psi,
sour service and flanged configurations are
also available.
The catch assembly is a dog style catch
rather than a ball or pin style. This helps ensure
that the plunger is caught every time with the
plunger as high up in the lubricator as possible
for easy and safe removal for inspection.
Standard lubricator strings are made of 17-4
Stainless Steel to be able to handle low levels
of sour service.
Available in 1-1/2", 2-1/16", 2-3/8", 2-7/8" and
3-1/2" sizes.

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Plunger Lift Systems
L ubricat or s

Spe c i fi c at i o ns
Dimensions: Approximate length is 38 inches (97cm.) OAL. Length of
Cross is 22 to 27 inches (depends on design). (56 cm. to
68 cm.)
Weight: 36 to 71 Lbs. (16 to 33 Kg)
Note: (Variations in weight occur with options used.)
Materials: Lubricator cross, top and cap are 4130 & 4140 steel
meeting design specifications.
Threads: Cross Pins are 8 rd EUE. Top Cap is Acme #6 Thread. Flow
outlets are 11-1/2V NPT and the Needle valve is 1/2" NPT.
Hardness: RC 20 to RC 27. Variation is due to window in
specifications. Equipment can be manufactured to exact
Brinnel or Rockwell hardness to comply with customer
specifications.
Flow Outlets: Forged Steel weld type flow outlets with 3,000 psi WP.
These are tested to 5,000 psi when they have been welded
to cross yielding a lubricator working pressure of 3,000 psi
per ASTM testing standards.
Pressures: Completed Lubricators are individually hydrostatically
tested to 5,000 psi yielding a working pressure of 3,000
psi per ASTM testing standards.
Surface: Surfaces exposed to the elements and UV exposure are
both primed and painted to protect from the elements.
Optional coatings are available and quoted per your
requirements.
Sealing Elements: The top and cross are sealed by O-rings as is the catch
assembly. Viton seals are available in both 70 and 90
durometer to meet customer specifications.

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Plunger Lift Systems
 PRODUCT S

Plunger Offerings
The plunger is the heart of the system. It creates a mechanical seal between the fluid in the tubing and the gas pressure in the
annulus, which allows for fluid to be carried to surface. The seal is critical to the efficiency of the system.

A plunger style is selected based on the amount of fluid being lifted and the gas pressure available. The more fluid produced
the better the seal efficiency needs to be.

Lufkin carries a wide variety of plungers to work in conjunction with common tubing sizes.

P roduc t s
Continuous flow or Bypass plunger
Bullet plunger
Pad plunger
Brush plunger
Spiral plunger
Tornado plunger
Turbo Flow plunger
Recoil plunger
Staged plunger lift systems

Opti ons
Sour gas service available
All standard mandrels 4140 HR-HT at a
26 Rc
All standard plungers available with
recoil sub
Pad plunger pads are 17-4 ss
investment casting to a 38 Rc
Tubing sizes:
1-1/2"
2-1/16"
2-3/8"
2-7/8"
3-1/2

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Plunger Lift Systems
Plunger s

Continuous Flow or Bypass Plunger Lift Systems

A Continuous Flow or Bypass plunger system improves production by allowing

continuous well operation while removing liquid build-up. The system is designed to
fall against the natural flow of the well and sweep accumulated fluid from the tubing
walls rather than fluid built up at the end of the tubing string. As a result, the system is
dependent on gas rate vs. built up pressure energy.

These plunger styles operate using a valve mechanism. When the plunger falls to the
bottom of the well the bumper spring closes the valve to allow the plunger to drive back
to the surface. Once arriving in the lubricator, the valve is actuated back open and is
ready to start back down the well to begin the next cycle. This style plunger is available
in padded and tornado body styles.

Complementary equipment includes the pneumatic catcher (auto-catch) to manage the

plunger drop cycles.

Feat ure s & B enefi ts

Combats declining gas flows, increasing liquid production, and high operating
costs associated with problem wells.
Requires little or no shut-in time.
Maximizes flow rates.
Works well with on-site compression.
Eliminates line pressure spikes.
Maintains a low flowing bottom hole pressure.
Valve design helps ensure the plunger falls to the bottom against the flow with
minimal off times.
Special detent grooves on the valve rod prevents the valve from closing
prematurely (against fluid slugs or high gas rate) during the fall cycle and that
the valve stays closed during the up cycle.

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Plunger Lift Systems
Plunger s

Bullet Plunger

The Bullet plunger is a quick falling style of Bypass plunger that allows the plunger
to fall at a much higher speed than a regular Conventional plunger. This is due to the
bypass area through the plunger.

Lufkins new locking mechanism allows the internal shifting rod to be locked in both
the open and closed position. This greatly reduces the chance for the shifting rod to
be opened or closed prematurely due to fluid weight above the plunger or from gas or
fluid flow from below the plunger.

Complementary equipment includes the pneumatic catcher (auto-catch) to manage

the plunger drop cycles.

Feat ure s & B enefi ts

Fall speeds between 700 900 ft/min allow the plunger to reach the
spring in less than half the time of a Conventional plunger.
Locking mechanism ensures the plunger reaches the spring before shifting
closed and reaches the surface without prematurely opening and losing
fluid load.
Tornado body design provides exceptional seal efficiency to help maximize
production.
Internal shifting rod eliminates the need to have additional items inside of
the lubricator.

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Plunger Lift Systems
 PRODUCT S

Pad Plunger

Triple Lufkin Pad plungers are extremely durable and

can be used in nearly all types of situations.
Pads are available in single, dual and triple pad
configurations. The spring-loaded pads are able
to expand and contract to keep a consistent
seal with the tubing walls providing minimal
Dual
slippage of gas and fluid. The pads are made
from interlocking 17-4 heat-treated stainless
steel castings. The mandrels are designed,
engineered and manufactured in our Houston
facility by highly experienced machinist. 4140
hot rolled, heat-treated steel and 302 stainless
steel make up the pad springs.

Feat ures & B enefit s

High efficiency due to metal-to-metal
Single seal (Friction Seal).
Spring-loaded pads can collapse to run
past anomaly.
Works best in lower GLR wells.
Best suited to low-pressure wells.
Excellent wear-ability due to the
expansion of the pads as they wear.
Can run single, double, or triple pad
depending on depth of well and amount
of fluid production.

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Plunger Lift Systems
Plunger s

Brush Plunger

The Lufkin Brush plunger has a flexible, Combo

over-sized, brush spirally wound onto a
solid mandrel filling the tubing to create an
excellent seal even when tubing irregularities
are present. The flexibility of the brush allows
the plunger to travel without damage to the Standard
tubing, clearing both liquid and sand from the
wellbore.

Lufkin Brush plungers are ideal for carrying

small amounts of solids and not damaging
internally coated tubing strings.

Feat ure s & B enefi ts

High efficiency seal (wet seal).
Short
Good for wells that produce small
amounts of solids.
Can be used in irregular tubing IDs due
to the flex of the brush.
Good to 250F bottom hole temperature.

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Plunger Lift Systems
Plunger s

Tornado Plunger

The Tornado plunger is an impressively adaptable plunger. It

effectively removes formation sand, frac sand and paraffin. The
specially designed undercut grooves enhance gas turbulence,
increasing the seal efficiency. The plunger is available with
a rifled nose and heel, which further increases efficiency by
generating a vortex of gas and fluid. The Tornado is made
of hardened alloy steel increasing its life and durability. It is
available for sour service.

Fe at ure s & B enefi ts

Under cut grooves enhance the turbulent seal and
greatly reduces slippage compared to regular bar
stock or sand plungers.
Improved production for low LGR wells compared to
pad plungers due to reduced frictional drag.
Rifling provides more uniform wear in deviated wells.

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Plunger Lift Systems
 PRODUCT S

Bumper Springs
Tubing Stop
Combo
The bottom hole assembly of a plunger system
Collar will typically comprise of two components.
Stop The bumper spring, which is used to absorb
Combo the shock of the plunger falling from surface,
and a hold down component. The hold down
component is meant to keep the spring in place
so it cannot travel up and down in the tubing
string. This can be either seated in a nipple or
2 Cup landed inside of a tubing collar or the tubing
Combo itself with either a collar stop, tubing stop or
cup assembly. The spring can also be designed to
float in the lower tubing section.

Feat ures & B enefit s

All springs come standard with 17-4
Floating stainless steel springs.
Entire spring assembly is available in
Tubing stainless steel.
Can be free fall set from surface using a
Stop
cup seat hold down.
Ball & Seat option for trapping fluid.
Wireline retrievable.
Springs are shot peened to remove any
possible stress fractures.
Sour service equipment available.

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Plunger Lift Systems
 PRODUCT S

LIFTManager Controller

The LIFTManager plunger lift controller is user-friendly with multi- Feat ures & B enefit s:
option functionality. The basic unit is very easy to operate and comes Easily installs with standard two-bolt
configured with the control method(s) specified by the user. The system valve bracket.
can be set up to be as simple as intermittent control or as sophisticated Four lines of display allows for quick
as an auto adjusting differential pressure control. collection of historical data.
Travel time history
Modes of Operation: Pressure history
Intermittent Basic Time Control Current measures pressure(s)
Time control (on/off) Auto adjust feature Calculates longest, shortest and
average off time
Pressure control (2 pressures) On/Off/Afterflow
Valve and plunger count (intermit
Differential Pressure Control Hi/Lo option
mode)
Auto adjust feature Secondary pressure control High/Low external pressure switch
for on cycle
Hi/Lo option shutdown supported.
Single or dual valve option Controller program easily upgraded for
Tank wait option individual or all control modes.
Basic time control with dual valve option
can be used for intermittent gas lift /
plunger lift assist applications.
User-friendly keypad.
Battery operated with solar
charger option.

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Plunger Lift Systems
 WELL OPTIMIZATION DESIGN DATA SHEET
Contact Name: ___________________________________ Date: ______________________

Company Name: __________________________________ Phone: _____________________

Field Name: ______________________________________ Location: ___________________
Casing Size O.D./I.D. ____________________________/ ____________________________ in
DOWNHOLE

Tubing O.D./I.D. _________________________________/ ____________________________ in

DATA

Master Valve Size ______________________ in End of Tubing Depth__________________ ft

Package Depth _________________________ ft Top Nipple Depth ____________________ ft
Top Nipple I.D. ________________________ in Top Nipple Type ______________________
Sliding Sleeve Depth __________________________________________________________ ft
Sliding Sleeve Type and Size ___________________________________________________ in
At least 6 months of data or graphical history is preferred
PRODUCTION

Current Daily Gas Rate _____________________________________________________ mcfd

DATA

Gas Rate After Blow Down Or Shut In _________________________________________ mcfd

Current Daily Water Rate ___________________________________________________ bwpd
Current Daily Condensate Rate ______________________________________________ bopd
Current Water Cut ____________________________________________________________%
Separator/Flow Line Back Pressure _____________________________________________ psi
SURFACE PRESSURE

Available Pressure At Surface (for injection) _______________________________________ psi

Maximum Injection Gas Available _____________________________________________ mcfd
DATA

Tubing Head Pressure _______________________________________________________ psi

Flowing Casing Pressure _____________________________________________________ psi
1 Hr Shut In Casing Head Pressure _____________________________________________ psi
1 Hr Shut In Tubing Head Pressure _____________________________________________ psi
RESERVOIR

Zone _______________________________________________________________________
DATA

Top Of Perforations ___________________________________________________________ ft

Bottom Of Perforations ________________________________________________________ ft
Midpoint of Perforations _______________________________________________________ ft
Productivity Index (PI) __________________________________________________________
Estimated Current Reservoir Pressure ___________________________________________ psi
Reservoir Temperature _______________________________________________________ F
Gas Gravity _______________________________________________________________S.G.
Condensate / Oil Gravity __________________________________________________Deg API
Water Gravity _____________________________________________________________S.G.
N2 _________________________________ % H2S _______________________________%
CO2 ________________________________ %
Please e-mail to ils@lufkin.com or fax form to 281-445-1134