IP Library › Granted Patent US 12,442,279
Granted Patent B2
US 12,442,279 · App. 18/240,001 · Granted Oct 14, 2025

Multi-stage plunger hydrocarbon lifting

Inventors: Amr Mohamed Zahran (Al Khobar, SA); Syed Muhammad Bin Syed Taha (Dhahran, SA); Mohamed Sayed (Dammam, SA); Gustavo Alvarez (Dhahran, SA); Bagus Wahyu Setiadi (Dhahran, SA)
Assignee: Saudi Arabian Oil Company
E21B43/121E21B34/06F04B47/12
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Quick Facts
Patent No.
US 12,442,279
App. No.
18/240,001
Granted
Oct 14, 2025
Kind
B2
Abstract

A method includes lifting a first plunger within a production string disposed within a wellbore. The production string divides the production string into multiple stages. The plunger landing assemblies include a first landing assembly and an intermediate landing assembly. The lifting includes lifting the first plunger in a first stage to lift production fluid accumulated uphole of the first plunger. The method also includes continuing to lift the first plunger until the first plunger strikes the intermediate one of the plurality of landing assemblies, allowing the production fluid to flow past the second one of the plurality of landing assemblies into a second stage. The method also includes securing the first plunger and lifting, with the production fluid accumulated uphole of a second plunger residing in the second stage, the second plunger to lift the production fluid toward the wellhead.

Claims (54)

1. A method, comprising:

lifting a first plunger within a production string disposed within a wellbore formed in a subterranean zone, the production string extending from a wellhead and comprising a plurality of plunger landing assemblies residing in the production string and dividing the production string into a plurality of stages, each stage comprising a portion of the production string between two consecutive plunger landing assemblies or a plunger landing assembly and the wellhead, the plurality of plunger landing assemblies comprising a first landing assembly and an intermediate landing assembly residing between the first landing assembly and the wellhead, wherein the lifting comprises lifting the first plunger in a first stage of the plurality of stages to lift production fluid accumulated uphole of the first plunger;

continuing to lift the first plunger until the first plunger strikes the intermediate one of the plurality of landing assemblies, allowing the production fluid to flow past the second one of the plurality of landing assemblies into a second stage of the plurality of stages;

securing, with a controllable catcher, the first plunger to retain the first plunger and prevent the first plunger from traveling in a downhole direction; and

lifting, with the production fluid accumulated uphole of a second plunger residing in the second stage, the second plunger to lift the production fluid toward the wellhead.

2. The method of claim 1 , wherein the production string comprises one or more sensors at or near the catcher, the catcher controllable as a function of sensor feedback from the one or more sensors, and the securing comprises securing, as a function of the sensor feedback, the first plunger.

3. The method of claim 1 , further comprising releasing the first plunger, allowing the first plunger to fall and land on the first landing assembly for fluid to accumulate on the first plunger.

4. The method of claim 1 , wherein the first plunger comprises a bypass plunger defining a fluid pathway extending through the plunger, allowing the production fluid to flow uphole through the first plunger as the first plunger falls in the production string within the first stage.

5. The method of claim 4 , wherein the first plunger comprises a bypass valve configured to close when the first plunger lands on the first landing assembly, blocking the fluid pathway, and open when the first plunger reaches the intermediate landing assembly.

6. The method of claim 1 , wherein the second stage is defined between the intermediate landing assembly and the wellhead, and the lifting comprises lifting the production fluid to the terranean surface of the wellbore through the wellhead.

7. A method, comprising:

receiving, by a system comprising one or more computers in one or more locations, first sensor feedback from one or more sensors attached to a production string disposed within a wellbore; and

transmitting, by the system and as a function of the first sensor feedback, instructions to a controller to activate the controller, the controller configured to actuate, as a function of the instructions, an actuator or pump fluidly coupled to a downhole catcher to actuate the downhole catcher and catch a first plunger with the downhole catcher to prevent the first plunger from traveling in a downhole direction, wherein the production string comprises a plurality of plunger landing assemblies residing in the production string and dividing the production string into a plurality of stages, each stage comprising a portion of the production string between two consecutive plunger landing assemblies or a plunger landing assembly and the wellhead, the plurality of plunger landing assemblies comprising a first landing assembly and an intermediate landing assembly residing between the first landing assembly and the wellhead, the downhole catcher residing downhole of the intermediate landing assembly in a first stage of the plurality of stages.

8. The method of claim 7 , wherein the first sensor feedback comprises motion feedback.

9. A wellbore assembly, comprising:

a production string configured to be disposed within a wellbore formed in a subterranean zone, the production string configured to be fluidly coupled to a wellhead residing at a terranean surface of the wellbore;

a plurality of plunger landing assemblies residing in the production string and dividing the production string into a plurality of stages, each stage comprising a portion of the production string between two consecutive plunger landing assemblies or a plunger landing assembly and the wellhead, the plurality of plunger landing assemblies comprising a first landing assembly and an intermediate landing assembly residing between the first landing assembly and the wellhead,

a plurality of plungers, each plunger configured to reside in the production string in a respective one of the plurality of stages; and

a catcher configured to reside downhole of the intermediate landing assembly and configured to catch a first plunger of the plurality of plungers after the first plunger has been lifted to push production fluid uphole past a second plunger resting on the intermediate landing assembly, the catcher configured to retain the first plunger of the plurality of plungers to prevent the first plunger of the plurality of plungers from traveling in a downhole direction.

10. The wellbore assembly of claim 9 , wherein the plurality of stages comprises a first stage and a second stage uphole of and adjacent the first stage, the first stage defined between the first landing assembly and the intermediate landing assembly, the catcher and the first plunger residing in the first stage.

11. The wellbore assembly of claim 9 , wherein the first plunger is a bypass plunger defining a fluid pathway extending through the plunger, allowing the production fluid to flow uphole through the first plunger as the first plunger falls in the production string within the first stage.

12. The wellbore assembly of claim 11 , wherein the first plunger comprises a bypass valve configured to close when the first plunger lands on the first landing assembly, blocking the fluid pathway, and open when the first plunger reaches the intermediate landing assembly.

13. The wellbore assembly of claim 9 , wherein the production string defines a fluid pathway extending from the first stage to the second stage to allow the production fluid to flow from the first state to the second stage as the first plunger of the plurality of plungers is lifted.

14. A method, comprising:

lifting a first plunger within a production string disposed within a wellbore formed in a subterranean zone, the production string extending from a wellhead and comprising a plurality of plunger landing assemblies residing in the production string and dividing the production string into a plurality of stages, each stage comprising a portion of the production string between two consecutive plunger landing assemblies or a plunger landing assembly and the wellhead, the plurality of plunger landing assemblies comprising a first landing assembly and an intermediate landing assembly residing between the first landing assembly and the wellhead, wherein the lifting comprises lifting the first plunger in a first stage of the plurality of stages to lift production fluid accumulated uphole of the first plunger;

continuing to lift the first plunger until the first plunger strikes the intermediate one of the plurality of landing assemblies, allowing the production fluid to flow past the second one of the plurality of landing assemblies into a second stage of the plurality of stages;

securing, with a catcher, the first plunger; and

lifting, with the production fluid accumulated uphole of a second plunger residing in the second stage, the second plunger to lift the production fluid toward the wellhead;

wherein the production string comprises one or more sensors at or near the catcher, the catcher controllable as a function of sensor feedback from the one or more sensors, and the securing comprises securing, as a function of the sensor feedback, the first plunger; and

wherein the catcher is fluidly coupled to an actuator or pump through a hydraulic line, the actuator or pump disposed at or near a terranean surface of the wellbore and coupled to a controller electrically coupled to the sensors, and the securing comprises actuating, by the controller, the actuator or pump as a function of the sensor feedback to move the catcher by moving hydraulic fluid through the hydraulic line.

15. A method, comprising:

lifting a first plunger within a production string disposed within a wellbore formed in a subterranean zone, the production string extending from a wellhead and comprising a plurality of plunger landing assemblies residing in the production string and dividing the production string into a plurality of stages, each stage comprising a portion of the production string between two consecutive plunger landing assemblies or a plunger landing assembly and the wellhead, the plurality of plunger landing assemblies comprising a first landing assembly and an intermediate landing assembly residing between the first landing assembly and the wellhead, wherein the lifting comprises lifting the first plunger in a first stage of the plurality of stages to lift production fluid accumulated uphole of the first plunger;

continuing to lift the first plunger until the first plunger strikes the intermediate one of the plurality of landing assemblies, allowing the production fluid to flow past the second one of the plurality of landing assemblies into a second stage of the plurality of stages;

securing, with a catcher, the first plunger; and

lifting, with the production fluid accumulated uphole of a second plunger residing in the second stage, the second plunger to lift the production fluid toward the wellhead;

wherein the production string comprises a retrievable tool residing downhole of and adjacent the intermediate landing assembly, the retrievable tool comprising an outwardly projecting pocket defining a fluid pathway extending from the first stage to the second stage, and wherein continuing to lift the first plunger comprises lifting the first plunger to push, with the first plunger, the production fluid along the fluid pathway into the second stage.

16. A method, comprising:

receiving, by a system comprising one or more computers in one or more locations, first sensor feedback from one or more sensors attached to a production string disposed within a wellbore; and

transmitting, by the system and as a function of the first sensor feedback, instructions to a controller to activate the controller, the controller configured to actuate, as a function of the instructions, an actuator or pump fluidly coupled to a downhole catcher to actuate the downhole catcher and catch a first plunger with the downhole catcher, wherein the production string comprises a plurality of plunger landing assemblies residing in the production string and dividing the production string into a plurality of stages, each stage comprising a portion of the production string between two consecutive plunger landing assemblies or a plunger landing assembly and the wellhead, the plurality of plunger landing assemblies comprising a first landing assembly and an intermediate landing assembly residing between the first landing assembly and the wellhead, the downhole catcher residing downhole of the intermediate landing assembly in a first stage of the plurality of stages;

further comprising transmitting, by the system and as a function of a second sensor feedback, instructions to a controller to activate the controller, the controller configured to actuate, as a function of the instructions, the actuator or pump to actuate the catcher and release the first plunger after production fluid uphole of the first plunger has been flowed from the first stage to the second stage.

17. The method of claim 16 , wherein the second sensor feedback comprises one of 25 . pressure feedback, temperature feedback, or motion feedback.

18. A method, comprising:

receiving, by a system comprising one or more computers in one or more locations, first sensor feedback from one or more sensors attached to a production string disposed within a wellbore; and

transmitting, by the system and as a function of the first sensor feedback, instructions to a controller to activate the controller, the controller configured to actuate, as a function of the instructions, an actuator or pump fluidly coupled to a downhole catcher to actuate the downhole catcher and catch a first plunger with the downhole catcher, wherein the production string comprises a plurality of plunger landing assemblies residing in the production string and dividing the production string into a plurality of stages, each stage comprising a portion of the production string between two consecutive plunger landing assemblies or a plunger landing assembly and the wellhead, the plurality of plunger landing assemblies comprising a first landing assembly and an intermediate landing assembly residing between the first landing assembly and the wellhead, the downhole catcher residing downhole of the intermediate landing assembly in a first stage of the plurality of stages;

wherein the controller is configured to actuate a pump coupled to a hydraulic line, and the transmitting comprises transmitting instructions to the controller to cause the controller to actuate the pump to move hydraulic fluid along the hydraulic line to move the downhole catcher.

19. A wellbore assembly, comprising:

a production string configured to be disposed within a wellbore formed in a subterranean zone, the production string configured to be fluidly coupled to a wellhead residing at a terranean surface of the wellbore;

a plurality of plunger landing assemblies residing in the production string and dividing the production string into a plurality of stages, each stage comprising a portion of the production string between two consecutive plunger landing assemblies or a plunger landing assembly and the wellhead, the plurality of plunger landing assemblies comprising a first landing assembly and an intermediate landing assembly residing between the first landing assembly and the wellhead,

a plurality of plungers, each plunger configured to reside in the production string in a respective one of the plurality of stages; and

a catcher configured to reside downhole of the intermediate landing assembly and configured to catch a first plunger of the plurality of plungers after the first plunger has been lifted to push production fluid uphole past a second plunger resting on the intermediate landing assembly,

wherein the plurality of stages comprises a first stage and a second stage uphole of and adjacent the first stage, the first stage defined between the first landing assembly and the intermediate landing assembly, the catcher and the first plunger residing in the first stage,

further comprising a retrievable tool residing in the first stage downhole of and adjacent the intermediate landing assembly, the retrievable tool comprising an outwardly projecting pocket defining a fluid pathway extending from the first stage to the second stage, the first plunger configured to be along the first stage to push the production fluid uphole along the fluid pathway into the second stage to accumulate on the second plunger.

20. The wellbore assembly of claim 19 , wherein the retrievable tool comprises one or more sensors and the catcher, the catcher controllable as a function of sensor feedback from the one or more sensors.

21. The wellbore assembly of claim 20 , wherein the catcher is fluidly coupled to an actuator or pump through a hydraulic line, the actuator or pump disposed at or near a terranean surface of the wellbore and coupled to a controller electrically coupled to the sensors, and the securing comprises actuating, by the controller, the actuator or pump as a function of the sensor feedback to move the catcher by moving hydraulic fluid through the hydraulic line.

Assignments (2)
CORRECTIVE ASSIGNMENT TO CORRECT THE CONVEYING PARTY DATA FROM GUSTAVO ARIEL ALVAREZ TO GUSTAVO ALVAREZ PREVIOUSLY RECORDED ON REEL 65582 FRAME 285. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Recorded Mar 8, 2024
From: ZAHRAN, AMR MOHAMED; TAHA, SYED MUHAMMAD BIN SYED; SAYED, MOHAMED; ALVAREZ, GUSTAVO; SETIADI, BAGUS WAHYU
To: SAUDI ARABIAN OIL COMPANY
Reel/Frame 066771/0458 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 16, 2023
From: ZAHRAN, AMR MOHAMED; TAHA, SYED MUHAMMAD BIN SYED; SAYED, MOHAMED; ALVAREZ, GUSTAVO ARIEL; SETIADI, BAGUS WAHYU
To: SAUDI ARABIAN OIL COMPANY
Reel/Frame 065582/0285 →
Continuity (1)
Related Publication 20250075600A1 · Mar 6, 2025
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