First Responder Training Course

Welcome to the training course on PCS Ferguson's new two-piece plunger, First Responder. The purpose of this training course is to learn the components, understand the applications, and provide you with all of the tools to strategically sell this new product. We want all of you to be successful right out of the gate, so please complete this training course BEFORE you begin selling First Responder.

This training is confidential and for internal training purposes only. The content is the property of PCS Ferguson.

In-Depth Look at First Responder

First Responder Description

The First Responder is PCS Ferguson's newest plunger that consists of two components. The engineered two-piece plunger design allows the ball and sleeve to fall against the highest flow so that the well can continue production.

This plunger makes more trips with faster fall times, delivering continuous fluid removal with little or no shut-in time. It helps wells achieve a significant increase in daily production.

Applications

  • Very high flowing wells
  • High gas or liquid volume
  • Wells in the beginning of liquid loading

Advantages

  • Calculated fall speeds maximize life of the plunger while reducing wireline expenses
  • Significantly reduces or eliminates shut-in time, which allows optimal production
  • Engineered two-piece design ensures dependable performance
  • Multiple configurations accommodate a wide range of production rates

What does First Responder mean?

First Responder has a two-part meaning:

First refers to the application. Typically it is the first plunger used in the life of the well.

Responder refers to our world-class products and unrivaled customer service. Simply put, we're here to help.

Click to watch how the two-piece plunger works (Yes, it's a competitor's video).

 

When do you generally put a two-piece plunger in a well?

Generally, the two-piece plunger is put in at the beginning of the well's life cycle. Use the image below as a baseline. All wells are different, so there are exceptions to this guideline.

In what applications do you typically use First Responder? Click all that apply.

  • Very high flowing wells
  • Low volume or marginal wells
  • Wells in the beginning of liquid loading

The name, First Responder, refers to this particular plunger being the first one to use in a well's cycle and it refers to our high-quality products and responsive customer service. Is this statement True or False?

  • True
  • False

First Responder Components

Lubricator Cap Specs

2-3/8" Tubing

Lubricator Part Part Number Material
Lube Cap Body LBC-238-FR 1018 WPB
Rod LB-C04-31-FR 17-4 PH SS
Anvil LB-C04-1-FR 4140
Adapter Nipple
(For FB lubes only)
LB-238E-FR  

 

*2-7/8" Lubricator Caps are currently being tested. Spec information will be available soon.

Lubricator Cap Drawing

Rod Drawing

Anvil Drawing

Complete Lubricator Assembly

The drawing above is the complete lubricator assembly. Since the FB lubricators have a female thread on top, the Adapter Nipple (LB-238E-FR) should be installed into the lubricator. PCS lubricators do not need the Adapter Nipple.

Lubricator Considerations

  • Make sure the rod is straight when installing it in the lubricator because the sleeve could catch on the rod (competitors have this problem).
  • If you sell a cap assembly for a competitor's lubricator:
    • Make sure the rod is installed straight

    • Make sure the rod extends past the lowest outlet

       

    • Check for ball blockers

    • Be sure there is the proper amount of preload in the spring

      Ensure threading is engaged far enough on the lubricator

  • Because of the royalties owed to IPS, you'll need to order individual lubricator components, rather than a complete assembly.

Ball Components

2-3/8" Tubing

Ball Material Part Number Weight (lbs)
1-3/8" Zirconia BP-BS238B-ZO 0.228
1-3/8" Stainless Steel BP-BS238B-SS 0.378
1-3/8" Cobalt BP-BS238B-CB 0.437
1-3/8" Tungsten Carbide BP-BS238B-TC 0.722

 

2-7/8" Tubing

Ball Material Part Number Weight (lbs)
1-11/16" Zirconia BP-BS278B-ZO 0.520
1-11/16" Stainless Steel BP-BS278B-SS 0.702
1-11/16" Cobalt BP-BS278B-CB 0.806
1-11/16" Tungsten Carbide BP-BS278B-TC 1.298

 

Ball Drawing

Sleeve Components

Sleeve Material

  • 4140 Steel

Sleeve Size Options

  • 6" Sleeve
  • 9" Sleeve

O.D. Options

  • 2-3/8"
    • 1.900
    • 1.880
  • 2-7/8"
    • 2.335
    • 2.345

6" Sleeve Drawing

9" Sleeve Drawing

Bottom Hole Bumper Spring

The bottom hole bumper spring cushions the fall of the plunger.

Only use a heavy duty bottom hole bumper spring for the ball and sleeve plunger!

Other BHBS's can't handle the impact of this fast-falling plunger.

Plunger Plucker

The plunger plucker is used to retrieve the ball.

What are the sleeve sizes PCS Ferguson offers for First Responder? Click all that apply.

  • 4"
  • 6"
  • 9"
  • 12"

Rank the ball material in weight with the top answer being the lightest and bottom answer being the heaviest.

  • Zirconia
  • Stainless Steel
  • Cobalt
  • Tungsten Carbide

Bottom Hole Bumper Spring

A bottom hole bumper spring is the only type to use for a two-piece plunger.
 

Ball and Sleeve Applications

Ball and Sleeve Combinations for 2-3/8" Tubing

2-3/8" Tubing

Rate (Mcf/d) Ball Recommendation Sleeve Recommendation Ascending Rate (ft/min)
400> 1-3/8" Zirconia 6" Sleeve 600-700
400-600 1-3/8"
Stainless Steel
9" Sleeve 800-900
600-800 1-3/8" Cobalt 9" Sleeve 1000-1100
800-1000 1-3/8"
Tungsten Carbide
9"Sleeve 1100-1200
  • This chart is based on 150 line pressure.
  • Use this information only as a baseline. All wells are different, so results will vary.
  • If you have lower line pressure, you may need a heavier ball and sleeve (less gas restriction).
  • If you have higher line pressure, you may need a lighter ball and sleeve (more gas restriction).

Ball and Sleeve Combination for 2-7/8" Tubing

2-7/8" Tubing

Rate (Mcf/d) Ball Recommendation Sleeve Recommendation

Ascending Rate

(ft/min)

400> 1-11/16" Zirconia 6" Sleeve 500-600
400-600 1-11/16" Zirconia 9" Sleeve 700-800
600-900 1-11/16"
Stainless Steel
9" Sleeve 800-1000
900-1100 1-11/16" Cobalt 9" Sleeve 1000-1300
  • This chart is based on 150 line pressure.
  • Use this information only as a baseline. All wells are different, so results will vary.
  • If you have lower line pressure (less gas restriction), you may need a heavier ball and sleeve.
  • If you have higher line pressure (more gas restriction), you may need a lighter ball and sleeve.

Match the ball and sleeve combinations for a well producing 400-600 Mcf/d.

  • 1-3/8" Stainless Steel Ball
    2-3/8 - 6" Sleeve
  • 1-11/16" Zirconia Ball
    2-7/8 - 9" Sleeve

If you have higher line pressure than 150, how do you adjust the ball and sleeve combination?

  • You may need a heavier ball and sleeve.
  • You may need a lighter ball and sleeve.

How to Safely Remove the Two-Piece Plunger

Steps to safely remove the plunger.

1. Safety first! Make sure you are wearing all company-required PPE. Complete a JSA to identify potential hazards such as slipping or falling. Determine if a ladder or fall protection will be needed to safely remove the lubricator cap for plunger inspection. Safety Note: Only start the plunger removal procedure after you have run a cycle and the plunger has arrived in the lubricator. Never put your head close to a lubricator to listen for a plunger.

2. After the plunger has completed a cycle and has arrived, slowly close the master valve on the wellhead.
   a. If the master valve will not close completely, do not wrench or force it. The master valve may
   need to be inspected by the proper personnel.
   b. If the master valve closes completely, the plunger is probably caught in the lubricator.
   c. Close both the lubricator and manifold valves.

3. Ensure that the lubricator is isolated from all pressure sources and all inlets and outlets are closed.

Steps to safely remove the plunger cont'd.

4. Once the pressure is released, the lubricator cap can be removed. The cap should unscrew fairly easily. If the cap seems tight or isn’t removing easily, there may still be pressure in the lubricator. Shut the ball valve at the inlet side of the separator and open up the blow downs at the separator inlet and at the wellhead.

5. Remove the lubricator cap, rod, and anvil by hand and lay it safely on the ground. The catcher will catch the sleeve.

6.When closing the master valve, the ball should drop onto the valve. Use a plunger plucker to remove the ball from the top of the valve.

*Don't forget to remove the rod before catching the ball and sleeve.

What does it typically mean if the master valve closes completely?

  • The plunger hasn't arrived yet.
  • The plunger is probably caught in the lubricator.

Remove the rod after catching the ball and sleeve. True or false?

  • True
  • False

Troubleshooting the Two-Piece Plunger

Troubleshooting

Scenario One: Ball and sleeve never arrive.

Cause:

  • The ball and sleeve may be too heavy for that particular well.

Solution:

  • Use a retrievable plunger to get the ball and sleeve out of the well.
  • If not able to retrieve the plunger, call for wireline services.
  • Reassess the well and use a different ball and sleeve combination or transition to a
  • different plunger.

 

Scenario Two: Plunger arrives too quickly.

Cause:

  • Ball and sleeve catch during fall.

Solution:

  • Increase / fine-tune after flow.
  • Select a heavier ball or shorter sleeve.

Troubleshooting Cont'd

Scenario Three: Ball ends up on top of sleeve.

Cause:

  • Most likely, the ball is caught in the pumping tee valve.

Solution:

  • Remove the pumping tee set-up.
  • Contact the Engineering department to make a custom ball blocker before installing First Responder components.

Misapplication

The two-piece plunger is commonly misapplied. Here are some red flags to look out for when using the First Responder.

  • If the two-piece plunger is breaking and is destroying equipment, you may be using the wrong plunger.
  • If the wear life is unusually short, you may be using the wrong plunger.
  • If the wireline costs are unusually high, you may be using the wrong plunger.

Tips and Tricks

  • The First Responder does not work in every well, so it’s okay to say no. Only use this plunger in appropriate well conditions.
  • Reevaluate your well every time you need to order a new plunger. Your well conditions are ever-changing, so make sure you’re ordering the best plunger for your well.
    • The ball and sleeve combination originally installed may not be the same combination when replacing due to decline in production.
  • As a proactive measure, monitor a plunger cycle occasionally to make sure everything is operating correctly.
  • Don’t forget to remove the rod before removing the ball and sleeve.
  • If you are dealing with a well that has sand, scale, or paraffin, you may want to transition to a different plunger type.

If the two-piece plunger never arrives, what's typically going on?

  • Most likely, the ball is caught in the pumping tee valve.
  • Most likely, the ball is too heavy for the flow rate, causing it to separate from the sleeve.
  • Most likely, the ball and sleeve caught each other before reaching the BHBS.

First Responder isn't appropriate for all well conditions. Which of the following scenario(s) should you reassess and consider switching to a different type of plunger? Check all that apply.

  • The two-piece plunger is breaking and is destroying equipment.
  • You notice the two-piece plunger's wear life is unusually short.
  • The wireline costs for that well are unusually high.

Plunger Inspection and Maintenance

Preventative Maintenance

Replacement Recommendations

  • PCS Ferguson recommends inspecting the ball and sleeve plunger monthly and replacing the ball and sleeve plunger every 2-3 months.

 

Monthly Maintenance Recommendations

  • Inspect the sleeve for any unusual wear, cracks or deformities.
  • Inspect the ball for any fractures or dents.
  • Monitor production levels regularly to make sure you’re using the optimal ball and sleeve combination.

Benefits of Replacing the Plunger

Regular plunger replacement offers these benefits:

  • Extends the life and productivity of a well.
  • Enables the well to more easily lift and remove liquids.
  • Lowers long-term operating and maintenance costs.
  • Ensures better removal of paraffin, hydrate, and other solids.
  • Decreases the risk and cost of damage to downhole equipment.

How often should you consider replacing the First Responder plunger?

  • PCS Ferguson recommends every month
  • PCS Ferguson recommends every 1-2 months
  • PCS Ferguson recommends every 2-3 months
  • PCS Ferguson recommends every 3-4 months

What are the benefits of replacing the First Responder plunger regularly? Check all that apply.

  • Extends the life and productivity of a well.
  • Enables the well to more easily lift and remove liquids.
  • Lowers long-term operating and maintenance costs.
  • Ensures better removal of paraffin, hydrate, and other solids.
  • Decreases the risk and cost of damage to downhole equipment.

Pricing!

Pricing for 2-3/8" Lubricator Cap Components

2-3/8" Lubricator Cap Components

Component Part Number Price
Lube Cap Body

LBC-238-FR

$250
Rod

LB-C04-31-FR

$250
Anvil

LB-C04-1-FR

$225
Poly Spring LBC-POLY-1 $155

 

*2-7/8" Lubricator Caps are currently being tested, so pricing information will be available soon.

Pricing for Balls

2-3/8" Tubing

Ball Part Number Price

1-3/8" Zirconia

BP-BS238B-ZO

$250

1-3/8"
Stainless Steel
BP-BS238B-SS $100
1-3/8" Cobalt BP-BS238B-CB $150
1-3/8"
Tungsten Carbide
BP-BS238B-TC $230

 

2-7/8" Tubing

Ball Part Number Price
1-11/16" Zirconia

BP-BS278B-ZO

$400

1-11/16"
Stainless Steel

BP-BS278B-SS

$280
1-11/16" Cobalt

BP-BS278B-CB

$330
1-11/16"
Tungsten Carbide

BP-BS278B-TC

$380

 

Pricing for Sleeves

Sleeve O.D. Part Number Price

2-3/8" Sleeve - 6"

1.880

BP-BS238SL-06-88

$350

2-3/8" Sleeve - 6"

1.900

BP-BS238SL-06-90

$350

2-3/8" Sleeve - 9"

1.880

BP-BS238SL-09-88

$400

2-3/8" Sleeve - 9"

1.900

BP-BS238SL-09-90

$400

 

Sleeve O.D. Part Number Price

2-7/8" Sleeve - 6"

2.335

BP-BS278SL-06-35

$480

2-7/8" Sleeve - 6"

2.345

BP-BS278SL-06-45

$480

2-7/8" Sleeve - 9"

2.335

BP-BS278SL-09-35

$520

2-7/8" Sleeve - 9"

2.345

BP-BS278SL-09-45

$520