4th Annual Appalachian Basin Gas Well Deliquification Workshop Marietta College, Marietta, Ohio June...

4th Annual Appalachian BasinGas Well Deliquification Workshop

Marietta College, Marietta, Ohio

June 3 – 5, 2013

Mark Scantlebury, P. Eng., BASc

President and CEO

Extreme Telematics Corp.

Applications for Magnetic Sensing in Plunger Lift

Overview

• Background

• Problems With Plunger Arrival Sensors

• Solving The Problems

• Other Benefits

• Other Applications

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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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

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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The Problems

• There are several problem with current designs

– False Detections

– Missed Arrivals

– Noisy Switch Closure

– Short Switch Closure

– High Power Draw

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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The Problems

• Why Sensors Have 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.

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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The Problems

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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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

Venturi Viper™(titanium)

Viper™(stainless steel)

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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The Problems

• Noisy Switch Closure

– Accepted as the norm

– Bouncing plungers

– Inconsistent movement

– System noise

– Plunger geometry

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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The Problems

• Short Switch Closure

– Short Plungers

– Fast Plungers

– Output not active long enough

– Missed using polling architecture

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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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

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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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

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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The Solution

• Noise Immunity

– Can’t prevent all noise

– Filter it out using a long term average

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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The Solution

• Detection

– Continuously monitor the changes in the signal

– Low amplitude or short duration changes ignored

– Eliminates false detections

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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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

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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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

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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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

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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The Solution

• Repeatability/Reliability

– Easier to manufacture

– Better tolerances

– No moving parts to wear

– Factory calibration

– Self calibrating

– Large spread between thresholds

– Self test

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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The Solution

• Upgradable Software

– Embedded firmware

– New images loaded on demand

– Feedback from the field

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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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

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Data Capture Tools

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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What’s Next

• Now that a new standard has been set, there are many more uses for this type of technology

– Enhanced Detection Algorithms

– Sensing Plunger Velocity

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Enhanced Detection Algorithms

• Gather Data From the Field

• Solve Additional Problems

– Interference from lightning

– Interference from other systems

– Different Plunger Types

• Continuous Improvement

– 100% detection is achievable

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Plunger Data

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Plunger Data

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Plunger Data

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Plunger Data

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Fast Plungers

• Fast Plungers are the #1 problem in Plunger Lift

• Costly to Replace Cracked Lubricator

• Incident Reports, Injury, or Death

• Desire to Detect and Correct Fast Plungers Before They Cause Problems

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Conventional Wisdom

• Why Not Use 2 Sensors?

• Too Reliant on Sensor Output

– Different Sensitivity

– Different Clocks

• Error in Position

• Need Additional Hardware

• Have to be Spaced out 10s -100s of meters to Reduce Error

• Not Practical

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Magnetic Domain

• Look at the Magnetic Domain Instead of Switch Output

• More Information Available in Waveforms

• Not Simple to Detect Velocity

• Captured Data from Cyclops is Invaluable

• Thousands of Test Runs During Development

• Variations in Plunger Types, Velocity, Position

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Sample Data

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Sample Data

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Sensing Plunger Velocity

• There are Some Challenges with these Waveforms

– Different for Each Plunger Type

– Variance in Sensitivity

– Differences Due to Position

• There Does Appear to Be Hope

– Deviation Correlated to Velocity

– Enough Similarities to be Usable

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Sensing Plunger Velocity

• ETC has Filed Patent Pending Algorithms for Detecting Plunger Velocity

• Use Combination of Deformation from Baseline, Waveform Timings, and Amplitude.

• Avoids Errors Associated with Using Multiple Independent Devices

• Well Head Mounted Velocity Sensor

• Practical Solution for Every Well

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Sasquatch IS

• First Plunger Velocity Sensor

• Well Head Mounted

• Same Rugged Design as Cyclops IS

• Reliable Detection up to 750 m/min

• Discrete or Modbus Interface

• Will Help Prevent Lubricator Breaches

• Field Trial Summer 2013

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Other Applications

• Monitoring Earth’s Magnetic Field

– Looking for a Change

– Rotating Equipment

– Sliding Metal

– Movement in Relation to Earth

• Lots of Other Applications

• Possibilities are Endless

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Questions?

June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Copyright

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June 3 – 5, 2013 2013 Appalachian Basin Gas Well Deliquification Workshop, Marietta, Ohio

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Disclaimer

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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.

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