Premier Integrated Technologies offers a practical, cost-effective alternative to a standard pumpjack or plunger system with the Dual Stage Plunger System. Our Dual Stage System can save you thousands of dollars per year and can increase production up to 80% over a pumpjack system. Additionally, the Dual Stage increases the scope of traditional plunger lifts to overcome challenges that may be faced.
How Does A Dual Stage System Work?
Installation of a Dual Stage System begins once the well is shut in. The bottom hole assembly is lowered down the wellbore and installed. Once the bottom hole assembly is installed, the bottom plunger is dropped into the well. Next, the Dual Stage Center Stage BHSA tool is lowered by wireline to approximately 60% of the depth of the well, depending on the well’s production.
The bottom plunger moves fluid from the bottom of the well to the Center Stage BHSA tool, where a one-way Pressure relief Check Valve & Packoff holds the liquid above. Once the top plunger is installed, it will move that fluid held from the Center Stage tool to the surface.
The two plungers then travel simultaneously, with the bottom plunger travelling in the bottom section and the top plunger travelling in the upper stage, hence the name Dual Stage Plunger System. This system allows the plungers to move smaller loads more frequently.
The Dual Stage System has the same functions as a conventional single plunger, making it capable of lifting liquids where one plunger would struggle to do so. Two plungers are more efficient than one due to having effectively almost halved the travel depth and liquid load to lift while having the same gas volume and pressure differential to lift it.
A Dual Stage Plunger System can be a viable alternative to most pumpjack systems. But, it can fulfill a variety of other roles as well. Such as:
- Deep, low-pressure wells
- Wells with higher casing pressure than tubing pressure
- Gassy oil wells (wells with a high gas to liquid ratio)
- Older plunger lift systems that have historically produced condensate or oil
- Plunger wells with increased off-times that take multiple hours to build up pressure
- Low rate oil wells
PIT offers well evaluations using available data to determine if your well is a feasible candidate for a Dual Stage System.
Dual Stage Plunger System Study
PIT conducted a study to measure the effectiveness of our Dual Stage System. Utilizing our portable Cloud Controller with built-in production measurement system we were able to conduct a study on over 200 wells that were installed with the Dual Stage. We discovered the following:
- Wells saw an increase in oil production of an average of 50% increase in the oil per day. Reports measured in at up to an 80% increase.
- Decreased lift costs due to reduced well workovers and fewer funds being spent on maintenance and repair, resulting in up to $60,000 in savings per well per year.
- When converting from pumpjack to Dual Stage, wells saw three times as much oil per day.
- The average year one savings per well was $22,500 per well, with an increase in netback of $100,000 per well.
PIT is well known for our plungers. We’ve supplied thousands of plungers to hundreds of companies and are always looking for ways to improve our designs. One of the issues that come up often when dealing with our clients, is how we should handle a well with an SSSV in extreme sour wells. Our 3 ½” Dual Pad Skirted Plunger* is a solution to this issue.
When a Sub Surface Safety Valve (SSSV) is triggered it isolates the well bore. This can happen when there is a system failure or damage to surface production, control, or safety facilities. When an SSSV has finished its life on the well, it can be removed. However, the landing nipple is still in place and is either very expensive or impossible to remove.
How did PIT address these issues? Simple. We created a Dual Pad Skirted Plunger capable of compressing far more than a non-skirted plunger. When compressed, the plunger is able to slip through the nipple. That way there is no need to pull tubing to remove the nipple and no need to spend thousands of dollars in the process.
The flexibility of the Dual Pad Skirted Plunger allows it to significantly increase the efficiency of your well. Not only is it able to collapse to fit through a nipple, it also expands further than a non-skirted plunger. This allows it to create a tighter seal to reduce gas and liquid leaks while traveling through the tubing.
The plunger has to travel regularly through the nipple. This means the plunger is built with durability in mind so that it may withstand the wear and tear that comes from passing through the SSSV nipple.
3 1/2″ Dual Pad Skirted Plunger Case Study
This 3 ½” Dual Pad Skirted Plunger (pictured right) was recently replaced in one of our customer’s wells. It ran on a 13% sour gas well outside of Olds, AB. During that time it removed hundreds of liters of contaminants from the well.
PIT builds our plungers hardy so that they can withstand extremely punishing conditions. This particular plunger made 12 cycles a day through the nipple and the rest of the tubing, expanding and collapsing whenever it was needed.