Applications for Magnetic Sensing in Plunger Lift · 2013-02-24 · Gas Well Deliquification...

Gas Well Deliquification Workshop

Sheraton Hotel, Denver, Colorado

February 17 – 20, 2013

Mark Scantlebury, P. Eng., BASc.

President and CTO

Extreme Telematics Corp.

Applications for Magnetic Sensing in Plunger Lift

Agenda

• Background

• Problems With Current Solutions

• Modern Solutions

• Where Do We Go Next?

Feb. 17 – 20, 2013 2013 Gas Well Deliquification Workshop

Denver, Colorado

2


Denver, Colorado

3

Background

Magnetic Sensing Has Been in Plunger Lift for Years

• Mechanical movement of a magnet as plunger arrives

• Coil Based Designs that Induce Current

• Riddled with problems

• One of the least expensive parts of the system can be

the most critical

• Leads to poor system performance to compensate for

bad sensors

The Problems

There are several problem with current designs

• False Detections

• Missed Arrivals

• Noisy Switch Closure

• Short Switch Closure

• High Power Draw


Denver, Colorado

4

The Problems

False Detections

• Poor Noise Immunity – Interference from other

devices, electrical noise, or temperature

fluctuations.

• Designed with Too High of Sensitivity – Small

movements seen as plunger arrival

• Manufacturing Defects – Not all coils created

equally.


Denver, Colorado

5

The Problems


Denver, Colorado

6

The Problems

Missed Arrivals

• Plunger travels too slowly

past the sensor

• Plunger does not travel all

the way past the sensor

• Sensitivity is not high

enough

• Non-ferrous or alloy

plungers are invisible


Denver, Colorado

7

Venturi Viper™

(titanium)

Viper™

(stainless steel)

Photos courtesy of

The Problems

Noisy Switch Closure

• Accepted as the

norm

• Bouncing plungers

• Inconsistent

movement

• System noise

• Plunger geometry


Denver, Colorado

8

The Problems

Short Switch

Closure

• Short Plungers

• Fast Plungers

• Output not

active long

enough

• Missed using

polling

architecture


Denver, Colorado

9

The Problems

High Power Draw

• Fast moving plungers cause high current

• Large current consumption while switch is

closed

• Would prefer a more consistent power draw


Denver, Colorado

10

The Solution

A microprocessor based design

that implements a magnetic field

sensor.

• Noise Immunity

• Enhanced Detection Algorithms

• Adjustable Sensitivity

• Flexible Mounting Location

• More Repeatability/Reliability

• Upgradable Software

• Real Time Debugging

Feb. 17 – 20, 2013

2013 Gas Well Deliquification Workshop

Denver, Colorado

11

The Solution

Noise

Immunity

• Can’t

prevent all

noise

• Filter it out

using a long

term

average


Denver, Colorado

12

The Solution

Detection

• Continuously

monitor the

changes in the

signal

• Low amplitude or

short duration

changes ignored

• Eliminates false

detections


Denver, Colorado

13

The Solution

Enhanced Detection

Algorithms

• Determine a long

term

average/baseline

• Look for patterns

• Distinguish

between slow or

rapid change

• Adjust for

different plunger

types

Feb. 17 – 20, 2013

2013 Gas Well Deliquification Workshop

Denver, Colorado

14

The Solution

Adjustable Sensitivity

• Use a switch or some other input device

• Changed by operator/installer at any time

• Sets a threshold for detection of different plunger

types

• Allows balance between false detects and missed

arrivals


Denver, Colorado

15

The Solution

Flexible Mounting Location

• Plunger does not need to pass by sensor

• Not dependent on speed

• Sense through thicker lubricators

• Mount on flow tee, master valve, or casing

• Sense movement of other lubricator parts when

using non-ferrous plungers


Denver, Colorado

16

The Solution

Repeatability/Reliability

• Easier to manufacture

• Better tolerances

• No moving parts to wear

• Factory calibration

• Self calibrating

• Large spread between

thresholds

• Self test


Denver, Colorado

17

The Solution

Upgradable Software

• Embedded firmware

• New images loaded on

demand

• Feedback from the field


Denver, Colorado

18

The Solution

Real Time Debugging

• Not limited to a switch

interface

• Real time stream data

• Graph in real time

• Log to file

• Understand field data better

• Identify problems or limitations

• Truly an electronic “eye” on

your well


Denver, Colorado

19


Denver, Colorado

20

What’s Next

Now that a new standard has been set, there are

many more uses for this type of technology

• Enhanced detection algorithms

• Velocity Information

• Uses outside of plunger lift


Denver, Colorado

21

What’s Next

Enhanced Algorithms

• Feedback from the field

• New plunger type data

• Different types of installs

• Continuous improvement

• 100% detection is achievable


Denver, Colorado

22

Plunger Data


Denver, Colorado

23

Plunger Data


Denver, Colorado

24

Plunger Data


Denver, Colorado

25

Plunger Data


Denver, Colorado

26

What’s Next

Velocity Information

• Enhanced waveform analysis

• Fast plungers are dangerous

• Early detection of problems

• Smart plungers not practical

• Additional information after incident

• Legislated in the future


Denver, Colorado

27

What’s Next

Other Applications

• Not limited to plunger lift

• Looks for a change in magnetic field

• Other moving metal detection

• Rotating or sliding equipment


Denver, Colorado

28

Questions?


Denver, Colorado

29


Denver, Colorado

30

Copyright

Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Gas Well Deliquification Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to:

– Display the presentation at the Workshop.

– Place it on the www.alrdc.com web site, with access to the site to be as directed by the Workshop Steering Committee.

– Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee.

Other use of this presentation is prohibited without the expressed written permission of the author(s). The owner company(ies) and/or author(s) may publish this material in other journals or magazines if they refer to the Gas Well Deliquification Workshop where it was first presented.


Denver, Colorado

31

Disclaimer

The following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Gas Well Deliquification Web Site.

The Artificial Lift Research and Development Council and its officers and trustees, and the Gas Well Deliquification Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Gas Well Deliquification Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained.

The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials.

The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose.

Applications for Magnetic Sensing in Plunger Lift · 2013-02-24 · Gas Well Deliquification...

Documents

Transcript of Applications for Magnetic Sensing in Plunger Lift · 2013-02-24 · Gas Well Deliquification...