PLUNGER WITH PLUNGER BALL RETENTION MECHANISM FOR PLUNGER LIFT APPLICATIONS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]This application is a non-provisional patent application claiming the benefit of, and priority to, U.S. Provisional Patent Application No. 63/724,132, filed Nov. 22, 2024, which is incorporated by reference herein in its entirety.

FIELD OF THE DISCLOSURE

[0002]The present disclosure generally relates to a plunger ball retaining mechanism for a plunger assembly used in plunger lift hydrocarbon production.

BACKGROUND

[0003]Wellbores are drilled into a subterranean formation to produce hydrocarbon fluids from a producing portion of the subterranean formation. Most wellbores will initially produce hydrocarbon fluids due to the pressure in the producing portion of the subterranean formation. When hydrocarbon fluid production ceases or slows, artificial lift systems may be used to pressurize the wellbore to aid or force hydrocarbon fluids from the producing portion of the subterranean formation, through the production string, and to a wellhead located above the surface.

[0004]Artificial lift solutions can be employed. One type of artificial lift solution is plunger lift. In plunger lift, a plunger is placed in production tubing that is inside a casing of a wellbore. The gases from the formation or gases injected from a gas-assist plunger lift system below the plunger until a pressure is sufficient to lift the plunger and fluid accumulated above the plunger to the wellhead so as to produce the fluid. The plunger can have a plunger sleeve and a plunger ball. After being lifted to the wellhead, the plunger falls to the bottom of the well. Fluctuations in the wellbore pressure may cause the plunger ball of the plunger to move out of the plunger sleeve, which causes the plunger ball to fall back towards the bottom of the well separately of the sleeve, followed by the slower-falling plunger sleeve. If the plunger sleeve contacts the plunger ball before the plunger ball reaches the bottom of the wellbore, a “dry” cycle, or plunger stroke that does not lift any hydrocarbon production fluid to the surface, can result. Hydrocarbon production is lost during this dry cycle, and the plunger sleeve may travel much faster upwards, thereby potentially causing damage to the wellhead or other surface equipment upon arrival. Accordingly, the hydrocarbon production industry continues to demand improvement in plunger lift technology that increases the reliability of plunger lift production and prevents “dry cycles” triggered by the unintended disengagement of the plunger ball from the plunger sleeve.

SUMMARY

[0005]A plunger ball retention mechanism can include an annular ring and inwardly projecting prongs coupled to the annular ring. The plunger ball retention mechanism can have resilient legs with the inwardly projecting prongs thereon, or the inwardly projecting prongs can be portions of a wave spring, or the annular ring can have alternating band and plate portions where the plate portions are connected to the inwardly projecting prongs, or the plunger ball retention mechanism can have a second annular ring and the inwardly projecting prongs are connected to both the annular ring and the second annular ring.

[0006]A plunger assembly can include a plunger ball, a plunger sleeve including a tubular main body having a central bore extending therethrough, and the plunger ball retention mechanism coupled to the plunger sleeve.

[0007]A plunger lift system can include a wellhead disposed on top of a wellbore and the plunger assembly disposed within the wellbore.

[0008]A method can include producing a hydrocarbon fluid from a wellbore with a plunger lift system comprising the plunger assembly comprising the plunger ball retention mechanism.

[0009]Another method can include retaining, by the plunger ball retention mechanism of the plunger assembly while producing a hydrocarbon fluid from a wellbore, the plunger ball in contact with a plunger ball seat of the plunger sleeve.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]For a more complete understanding of this disclosure, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:

[0011]FIG. 1 illustrates a schematic diagram of a plunger lift system according to an embodiment of the disclosure.

[0012]FIG. 2A illustrates a perspective view of a plunger assembly according to an embodiment of the disclosure.

[0013]FIG. 2B illustrates a side elevational view of the plunger assembly of FIG. 2A.

[0014]FIG. 2C illustrates a side cross-sectional of the plunger assembly of FIGS. 2A to 2B.

[0015]FIG. 2D illustrates a perspective view of a plunger ball retention mechanism of the plunger assembly of FIGS. 2A to 2C.

[0016]FIG. 2E illustrates a side elevational view of the plunger ball retention mechanism of FIG. 2D.

[0017]FIG. 3A illustrates a perspective view of a plunger ball retention mechanism according to another embodiment of the disclosure.

[0018]FIG. 3B illustrates a top view of a ball retention mechanism of FIG. 3A, with the top wall removed.

[0019]FIG. 3C illustrates a side cross-sectional view of a plunger assembly having the plunger ball retention mechanism of FIGS. 3A and 3B.

[0020]FIG. 4A illustrates a perspective view of a plunger ball retention mechanism according to another embodiment of the disclosure.

[0021]FIG. 4B illustrates a perspective view of a sleeve of a plunger assembly according to another embodiment of the disclosure.

[0022]FIG. 4C illustrates a perspective view of a plunger assembly having the plunger ball retention mechanism FIG. 4A on the sleeve of FIG. 4B.

[0023]FIG. 4D illustrates a side cross-sectional view of a plunger assembly having the plunger ball retention mechanism FIG. 4A on the sleeve of FIG. 4B.

[0024]FIG. 5A illustrates a perspective view of a plunger ball retention mechanism according to another embodiment of the disclosure.

[0025]FIG. 5B illustrates a perspective view of a sleeve of a plunger assembly according to another embodiment of the disclosure.

[0026]FIG. 5C illustrates a perspective view of a plunger assembly having the plunger ball retention mechanism FIG. 5A on the sleeve of FIG. 5B.

[0027]FIG. 5D illustrates a side cross-sectional view of a plunger assembly having the plunger ball retention mechanism FIG. 5A on the sleeve of FIG. 5B.

[0028]FIG. 6 illustrates a flowchart of a method of producing hydrocarbon fluids from a wellbore in a plunger lift system according to an embodiment of the disclosure.

DETAILED DESCRIPTION

[0029]Disclosed are a plunger ball retention mechanism, a plunger assembly having the plunger ball retention mechanism, a plunger lift system having the plunger assembly, and methods that utilize the plunger ball retention mechanism.

[0030]The plunger ball retention mechanism has an annular ring and inwardly projecting prongs coupled to (directly connected or connected via other components of the mechanism) an annular ring. Inwardly projecting means projecting radially inwardly toward a longitudinal axis of the plunger ball retention mechanism, a plunger sleeve, a plunger assembly, or a combination thereof. The plunger ball retention mechanism can couple to, or releasably attach to, the plunger sleeve of a plunger assembly. And when the plunger ball retention mechanism is coupled to the plunger sleeve, the inwardly projecting prongs engage and retain a plunger ball within the plunger sleeve. The plunger ball retention mechanism can have resilient legs with the inwardly projecting prongs thereon; alternatively, the inwardly projecting prongs can be portions of a wave spring; alternatively, the annular ring can have alternating band and plate portions where the plate portions are connected to the inwardly projecting prongs; alternatively, the plunger ball retention mechanism can have a second annular ring and the inwardly projecting prongs are connected to both the annular ring and the second annular ring.

[0031]The plunger ball retention mechanism can be placed in a retention groove formed in the outer surface or the inner surface of the tubular main body of the plunger sleeve, so that the inwardly projecting prongs engage and retain the plunger ball within the plunger sleeve. For the plunger ball retention mechanisms placed in a retention groove formed in the outer surface of the plunger sleeve, the inwardly projecting prongs extend through passages formed in the tubular main body of the sleeve and into the central bore of the tubular main body of the plunger sleeve so as to engage and retain the plunger ball within the plunger sleeve. Other embodiments of the plunger ball retention mechanism are contained inside the tubular main body of the plunger sleeve, for example, placed in a retention groove formed in the inner surface of the tubular main body, and have a wave spring contained in an annular ring, where portions of the wave spring are the inwardly projecting prongs that engage an inner wall of the annular ring, which engages and retains the plunger ball within the plunger sleeve.

[0032]Referring to FIG. 1, a schematic diagram of a plunger lift system 100 is shown according to an embodiment of the disclosure. The plunger lift system 100 in FIG. 1 is embodied as a gas-assisted plunger lift (GAPL) system. While FIG. 1 is described with reference to a gas-assisted plunger lift system, the method, systems, and plunger assembly configurations described herein can apply to plunger lift systems that utilize gas provided by the subterranean formation (and do not utilize GAPL) or to plunger lift systems that utilize a combination of GAPL and gas from the subterranean formation.

[0033]The plunger lift system 100 may generally be configured for producing hydrocarbon fluids from a wellbore 150 that extends into a subterranean formation.

[0034]The plunger lift system 100 may include a wellhead 102, a production string 104 extending from the wellhead 102 into the wellbore 150, a separator 106 connected to the wellhead 102, a gas injection compressor 108, a gas injection control valve 110, and a control system 112. The wellhead 102 may generally be disposed on top of the wellbore 150, or more specifically on top of a casing cemented within the wellbore 150. The wellhead 102 may be coupled to the production string 104 and configured to receive produced hydrocarbon fluids therefrom. In some embodiments, the wellhead 102 may include components known in the art with the aid of this disclosure, such as a production tree, stuffing box, one or more seals, a blowout preventer (BOP), or any combination thereof. Embodiments of the plunger lift system 100 that utilize only gas from the formation would not include gas lift equipment described herein (e.g., gas injection compressor, gas injection valve, etc.).

[0035]In some embodiments, the wellhead 102 may be fluidly connected to the separator 106. The wellhead 102 may be configured to deliver such fluids produced from the wellbore 150 to the separator 106. The separator 106 may separate the produced hydrocarbon fluids from the gas that has aided in lifting the hydrocarbon fluids to the wellhead 102. After separation, the separator 106 may subsequently distribute the separated hydrocarbon fluids to a storage vessel and/or pipeline transport.

[0036]The production string 104 may generally be connected to the wellhead 102 and extend from the wellhead 102 into the wellbore 150. The production string 104 may include production tubing 114, a packer assembly 116 comprising one or more packer elements or seals 118, and a lower production tubing 120. The production tubing 114 may be coupled to the wellhead 102, the packer assembly 116 may be coupled to the production tubing 114, and the lower production tubing 120 may be coupled to the packer assembly 116. Collectively, the production string 104 may extend into the wellbore 150 and include a fluid pathway for the produced hydrocarbon fluids to reach the wellhead 102. The production string 104 may also form an annulus 140 between the production string 104 and the wellbore 150. For plunger lift system 100 in FIG. 1, which is embodied as a gas-assist plunger lift system, pressurized gas from the gas injection equipment can be delivered to a zone in the wellbore 150 that is below the plunger via the annulus 140.

[0037]The packer element or seal 118 may be disposed in the annulus 140 and between the packer assembly 116 and the wellbore 150. The packer element or seal 118 may form a fluid tight seal between an upper portion of the annulus 140 located above the packer element or seal 118 and a lower portion of the annulus 140 located below the packer element or seal 118 to contain hydrocarbon fluids within the lower portion of the annulus 140 and force hydrocarbon fluids into the production string 104. In some embodiments, the packer element or seal 118 may be elastomeric and may be selectively expandable to seal the annulus 140.

[0038]The plunger lift system 100 may include a plunger assembly 130, embodiments and aspects of which are described in more detail herein as plunger assemblies 200, 300, 400, and 500. The plunger assembly 130 is generally configured to move upward (lift) and downward (fall) in the production string 104 in response to pressure fluctuations in the wellbore 150.

[0039]The plunger lift system 100, in gas-assist embodiments, may include a gas injection compressor 108. The gas injection compressor 108 may be configured to receive low pressure natural gas (or other gas) from a so-called “sales line” or from a neighboring well and pressurize the gas for use in the plunger lift system 100. The gas injection compressor 108 may be coupled to a gas injection control valve 110 that selectively regulates the pressure and/or flow of the pressurized gas from the gas injection compressor 108 into the wellbore 150, and more specifically into the lower portion of the annulus 140 formed between the production string 104 and the wellbore 150. In some embodiments, the pressurized gas may be injected into the wellbore 150 through a portion of the wellhead 102.

[0040]The plunger lift system 100 may also include a control system 112 that is configured to control the mechanical equipment of the plunger lift system 100. In some embodiments, the control system 112 may include one or more control interfaces. In some embodiments, the control system may be networked with sensors disposed in the plunger lift system 100 and/or the wellbore 150 to facilitate real-time feedback and control of the plunger lift system 100 and/or its individual components (e.g., via Wi-Fi, Bluetooth, NFC, ethernet cables, other wired connections, or combinations thereof).

[0041]During operation of the plunger lift system 100 in FIG. 1, the control system 112 may operate to control the flow of pressurized gas from the gas injection compressor 108, through the gas injection control valve 110, and into the wellbore 150. The pressurized gas can be delivered into the upper portion of the annulus 140 formed between the production string 104 and the casing of the wellbore 150. The pressurized gas may enter the packer assembly 116 from the annulus 140 above the packer element or seal 118, pass through the packer assembly 116, and exit the packer assembly 116 into the lower portion of the annulus 140 below the packer element or seal 118, where the pressurized gas may enter one or more gas injection valves 122 disposed in the lower production tubing 120 of the production string 104.

[0042]The plunger embodiments disclosed herein may be configured to operate in a variety of lift modes, as will be readily understood by those skilled in the art. Such modes may include, but are not limited to, conventional plunger lift, Plunger Assisted Gas Lift (PAGL), Gas Assisted Plunger Lift (GAPL), Plunger Assisted Intermittent Lift, or variations thereof. These methods may encompass the use of continuous or intermittent gas injection, various configurations of injection ports within the tubing string, and the incorporation of packers, mandrels, bull plugs, or similar devices to regulate or direct the gas injection process.

[0043]Referring to FIGS. 2A to 2C, a perspective view, a side elevational view, and a side cross-sectional view of a plunger assembly 200 are shown according to an embodiment of the disclosure. The plunger assembly 200 may include a plunger ball 202, a plunger sleeve 204, and a plunger ball retention mechanism 206. The plunger assembly 200 may be suitable for use in the plunger lift system 100 as an embodiment of plunger assembly 130, and can be configured to be deployed into the production string 104 for producing hydrocarbon fluids from the subterranean.

[0044]The plunger ball 202 may generally include a spherical ball comprising a uniform diameter. It will be appreciated that the plunger ball 202 may be configured in various diameters and/or materials to fit different wellbore 150 configurations, sizes, or production characteristics, and/or desired deployment velocity. The plunger ball 202 may be formed from carbon steels, stainless steels, alloy steels, superalloys, titanium alloys, sintered carbides, or other metallic or ceramic materials. Further, in some embodiments, the plunger ball 202 may include a coating and/or be treated to provide improved abrasion and/or corrosion resistance. The plunger ball 202 may be deployed to the bottom of the wellbore 150 below the plunger sleeve 204. In some embodiments, the plunger ball 202 may be sized and configured to descend to the bottom of the wellbore 150 at a faster rate than the plunger sleeve 204.

[0045]The plunger sleeve 204 may generally include a tubular main body 208 comprising a central bore 210 extending therethrough that establishes fluid communication between a top end 212 and a bottom end 214 of the plunger sleeve 204. The plunger sleeve 204 may include a plurality or series of annular grooves 216 formed in an outer surface 205 of the plunger sleeve 204 and disposed along a longitudinal length of the plunger sleeve 204. The grooves 216 may operate to induce turbulence when the plunger sleeve 204 is deployed into a wellbore 150, which may reduce the slippage of the production liquid from the top of the plunger assembly 200 to the bottom of the plunger assembly 200 when the plunger assembly 200 is in the upward cycle. In some embodiments, each of the grooves 216 may include upper radial surface 218, an inner longitudinal surface 220, and a lower angled surface 222 that collectively form each groove 216.

[0046]In the embodiment shown, the plunger sleeve 204 includes six grooves 216. However, in some embodiments, the plunger sleeve 204 may include at least three grooves 216, at least four grooves 216, at least five grooves 216, at least six grooves 216, at least seven grooves 216, or even more grooves 216 depending on the size and/or configuration of the plunger sleeve 204.

[0047]The plunger sleeve 204 may also include a plunger ball seat 224 configured to receive the plunger ball 202. The plunger ball seat 224 may be formed at the bottom end 214 of the plunger sleeve 204, on an interior of the plunger sleeve 204, such that when the plunger sleeve 204 is deployed, the plunger ball 202 may be received within plunger sleeve 204 and engage the plunger ball seat 224. The plunger ball seat 224 may be formed in the central bore 210 and include an annular, substantially concave seat portion 226 that is complementary to the outer diameter of the plunger ball 202. The plunger ball seat 224 may also include a beveled or radiused entry portion 228 at the bottom end 214 of the central bore 210 that may aid in guiding the plunger ball 202 into engagement with the seat portion 226 of the plunger ball seat 224.

[0048]When the plunger ball 202 is engaged with or seated within the seat portion 226 of the plunger ball seat 224, fluid flow through the central bore 210 of the plunger sleeve 204 may be substantially restricted and/or altogether prevented. In some embodiments, the seat portion 226 may be positioned within the central bore 210 such that a portion of the plunger ball 202 may extend beyond the bottom end 214 of the plunger sleeve 204. However, in some embodiments, the seat portion 226 may be positioned within the central bore 210 and/or the plunger ball seat 224 such that the entirety of the plunger ball 202 is received within the central bore 210 and/or the plunger ball seat 224 such that no portion of the plunger ball 202 extends beyond the bottom end 214 of the plunger sleeve 204.

[0049]Referring to FIGS. 2D to 2E, a perspective view and a side elevational view of the plunger ball retention mechanism 206 of the plunger assembly 200 are shown according to an embodiment of the disclosure. The plunger ball retention mechanism 206 may be installed onto the plunger sleeve 204. The plunger ball retention mechanism 206 may include a main annular ring 230 and a plurality of legs 232 extending longitudinally therefrom. The main annular ring 230 may include a longitudinal notch 234 formed therein to provide the main annular ring 230 with a split-ring or retaining-ring type profile. The notch 234 may also allow the main annular ring 230 to be opened up or expanded in order to install the plunger ball retention mechanism 206 onto the plunger sleeve 204.

[0050]Each of the plurality of legs 232 may extend from the main annular ring 230 in a single direction. When the plunger ball retention mechanism 206 is installed on the plunger sleeve 204, the legs 232 may extend from the main annular ring 230 towards the bottom end 214 of the plunger sleeve 204. In some embodiments, the legs 232 may include beveled, straight edge, or radiused interfaces 236 with the main annular ring 230, which may add structural rigidity to the interfaces 236 and/or provide support to the legs 232. Each leg 232 may also include one or more inwardly projecting prongs 238. The inwardly projecting prongs 238 may be disposed at a distal end of each leg 232 and be formed by a bent, curved, or crimped portion of the leg 232. When the plunger ball retention mechanism 206 is installed on the plunger sleeve 204, the prongs 238 may extend inwardly into the central bore 210 of the plunger sleeve 204 and engage the plunger ball 202 to retain the plunger ball 202 within the plunger sleeve 204. In some embodiments, the interfaces 236 may add structural rigidity to the interfaces 236 and/or provide support to the legs 232 when the prongs 238 engage the plunger ball 202.

[0051]In some embodiments, the plunger ball retention mechanism 206 may include at least two legs 232, at least three legs 232, at least 4 legs, or even more depending the configuration of the plunger assembly 200. It will also be appreciated that the plunger ball retention mechanism 206 may be any of these absolute values, and include any number of legs 232, such as two legs 232, three legs 232, four legs 232, or even more. Further, in some embodiments, the legs 232 may be disposed symmetrically about the main annular ring 230 and/or the plunger ball retention mechanism 206. In other embodiments, the legs 232 may be disposed asymmetrically about the main annular ring 230 and/or the plunger ball retention mechanism 206.

[0052]The plunger ball retention mechanism 206 may be formed from a resilient, metallic material. More specifically, the plunger ball retention mechanism 206 may be formed from a nickel-chromium based alloy such as Inconel®, a nickel-based alloy, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, or magnesium. In some embodiments, the plunger ball retention mechanism 206 may include a coating, such as a gold coating, an aluminum chromium nitride (AlCrN) coating, a titanium aluminum nitride (TiAlN) coating, or any other wear-resistant metallic coating.

[0053]Referring back to FIGS. 2A to 2C, now in conjunction with FIGS. 2D to 2E, the plunger sleeve 204 may also include a retention groove 240 formed in the outer surface 205 of the plunger sleeve 204. The retention groove 240 may be configured to receive the plunger ball retention mechanism 206, such that the plunger ball retention mechanism 206 may be installed onto and retained on the plunger sleeve 204. The retention groove 240 may include a main annular groove 242 and a plurality of leg grooves 244 extending longitudinally therefrom. The retention groove 240 may also include a plunger ball retention passage 246 disposed at a distal end of each of the leg grooves 244. The plunger ball retention passages 246 may be formed in the tubular main body 208 and extend from the outer surface 205 of the tubular main body 208 and through the tubular main body 208 so as to open to the central bore 210. In aspects, the plunger ball retention passages 246 can open to the central bore 210 at a location on the tubular main body 208 that is adjacent to the concave seat portion 226 of the plunger ball seat 224. In aspects, the plunger ball retention passages 246 extend from the distal end of the leg grooves 244 to the central bore 210 adjacent to the concave seat portion 226 of the plunger ball seat 224

[0054]As stated, the main annular ring 230 may include a longitudinal notch 234 formed therein to provide the main annular ring 230 with a split-ring or retaining-ring type profile, which may allow the main annular ring 230 to be opened up or expanded in order to install the plunger ball retention mechanism 206 onto the plunger sleeve 204. When the plunger ball retention mechanism 206 is installed on the plunger sleeve 204, the main annular groove 242 may receive the main annular ring 230, and the leg grooves 244 may receive the legs 232. As such, it will be appreciated that the number of leg grooves 244 may correspond to the number of legs 232.

[0055]The inwardly projecting prongs 238 disposed at the distal end of each leg 232 may be received within the plunger ball retention passages 246 disposed at a distal end of each of the leg grooves 244. The inwardly projecting prongs 238 may extend into at least a portion of the plunger ball seat 224 and/or the central bore 210 of the plunger sleeve 204. As will be discussed later herein, the inwardly projecting prongs 238 may also engage the plunger ball 202 to retain the plunger ball 202 within the plunger ball seat 224 of the plunger sleeve 204.

[0056]In some embodiments, the plunger ball retention mechanism 206 may be received within the retention groove 240 such that no portion of plunger ball retention mechanism 206 extends outwardly beyond an outer diameter of the plunger sleeve 204. In some embodiments, this may protect and/or prevent damage to the plunger ball retention mechanism 206 and/or prevent the plunger ball retention mechanism 206 from becoming dislodged from the plunger sleeve 204 in response to contact with debris, fluids, or an inner wall of the production string 104 during deployment or ascent of the plunger assembly 200 during a lift operation.

[0057]In some embodiments, the plunger sleeve 204 may also include additional features that enhance the performance of the plunger sleeve 204 and/or the plunger assembly 200, such as different of various-shaped grooves 216, helical, spiraled, or rifled grooves 216 or features, and/or recessed or “fish-necked” portions along the outer surface 205 of the plunger sleeve 204 and/or the central bore 210. Such additional features may be based on an inner diameter of the production tubing or production characteristics of the wellbore 150, a length or diameter of the plunger sleeve 204, or a combination thereof. It will therefore be appreciated that the plunger sleeve 204 may be configured in various lengths and diameters to fit different wellbore 150 configurations, sizes, or production characteristics and/or desired deployment velocity. The plunger sleeve 204 may generally be formed from carbon steel, stainless steel, an alloy steel, a superalloy, a titanium alloy, or other metallic or material. Further, in some embodiments, the plunger sleeve 204 may include a coating such as a wear-resistant metallic coating and/or be treated to provide improved abrasion and/or corrosion resistance.

[0058]In operation, the plunger assembly 200 may be deployed into the wellbore 150. The plunger ball 202 may be deployed before the plunger sleeve 204 having the plunger ball retention mechanism 206 thereon, and/or configured to descend into the wellbore 150 at a higher rate as compared to the plunger sleeve 204. When the plunger ball 202 is deployed to the bottom of the wellbore 150, the plunger sleeve 204 may be deployed and come into contact with the plunger ball 202. As the plunger sleeve 204 continues to descend, the plunger ball 202 may enter the plunger ball seat 224, where the plunger ball 202 may contact and exert an outward force on the inwardly projecting prongs 238 that causes the legs 232 to deflect. The plunger ball 202 may thereafter contact and become seated in the concave seat portion 226, where the inwardly projecting prongs 238 may exert a lateral compressive force on the plunger ball 202 that retains the plunger ball 202 in a nesting engagement with the seat portion 226 of the plunger ball seat 224.

[0059]When the plunger ball 202 is nested in the seat portion 226 of the plunger ball seat 224, fluid flow through the central bore 210 of the plunger sleeve 204 may be prevented. In some embodiments, the inwardly projecting prongs 238 may pass over and/or extend below central, antipodal points of the plunger ball 202, which define the largest circular cross-section of the plunger ball 202 and include the plunger ball's center and diameter. Accordingly, the inwardly projecting prongs 238 may extend through the plunger ball retention passages 246 sufficient to define an engagement diameter between opposing inwardly projecting prongs 238 that is smaller than the diameter of the plunger ball 202. In this manner, compressive forces applied by the inwardly projecting prongs 238 may retain the plunger ball 202 in nesting engagement with the seat portion 226 of the plunger ball seat 224 during ascent of the plunger assembly 200 (e.g., upstroke), despite pressure fluctuations in the wellbore 150, thereby preventing “dry” cycles triggered by the unintended disengagement between ball and plunger sleeve in traditional plunger assemblies.

[0060]FIG. 3A illustrates a perspective view of a ball retention mechanism 306 according to another embodiment of the disclosure. The plunger ball retention mechanism 306 has a main annular ring 330. The main annular ring 330 can be molded from a polymeric or elastomeric material, for example. The main annular ring 330 has an inner wall 331, an outer wall 332, a top wall 333, and a bottom wall 334 that form the shape of the main annular ring 330.

[0061]FIG. 3B illustrates a top view of a ball retention mechanism 306 of FIG. 3A, with the top wall 333 removed. As can be seen, the inner wall 331, outer wall 332, and bottom wall 334 (and top wall 333 if it were not removed for illustration purposes) delimit an interior space 335, in which is contained a wave spring 336. The wave spring 336 has alternating outwardly projecting prongs 337 and inwardly projecting prongs 338. That is, inwardly projecting prongs 338 are part of the wave spring 336. During engagement of the plunger ball retention mechanism 306 with a plunger ball 202, the outwardly projecting prongs 337 press against the outer wall 332 of the main annular ring 330, and the inwardly projecting prongs 338 press against the inner wall 331 of the main annular ring 330. The inwardly projecting prongs 338 press against the inner wall 331 so as to engage the inner wall 331 with a plunger ball. In FIG. 3B, the wave spring 336 has six outwardly projecting prongs 337 and six inwardly projecting prongs 338. Alternative embodiments contemplate that more or fewer prongs can be used, such as 2, 3, 4, 5, 6, 7, 8, 9, or 10 of each of the outwardly projecting prongs 337 and the inwardly projecting prongs 338. In aspects, the number of inwardly projecting prongs 338 is equal to the number of outwardly projecting prongs 337.

[0062]The wave spring 336 can be formed from a resilient, metallic material. More specifically, the wave spring 3365 may be formed from a nickel-chromium based alloy such as Inconel®, a nickel-based alloy, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, or magnesium. In some embodiments, the wave spring 336 may include a coating, such as a gold coating, an aluminum chromium nitride (AlCrN) coating, a titanium aluminum nitride (TiAlN) coating, or any other wear-resistant metallic coating.

[0063]FIG. 3C illustrates a side cross-sectional view of a plunger assembly 300 having the plunger ball retention mechanism 306 of FIGS. 3A and 3B. The plunger assembly 300 may be suitable for use in the plunger lift system 100 as an embodiment of plunger assembly 130, and can be configured to be deployed into the production string 104 for producing hydrocarbon fluids from the subterranean.

[0064]The plunger assembly 300 includes the plunger sleeve 204 having a tubular main body 208. Grooves 216 can be seen as formed and previously described. The plunger ball 202 is in the plunger ball seat 224 and held in engagement with the seat portion 226 by the plunger ball retention mechanism 306, so as to block flow into or out of the central bore 210 of the tubular main body 208.

[0065]A retention groove 340 is formed in the inner surface 341 of the plunger ball seat 224 of the plunger sleeve 204. The plunger ball retention mechanism 306 is placed in the retention groove 340. The contour of the retention groove 340 generally matches the contour of the outer wall 332, top wall 333, and bottom wall 334 of the plunger ball retention mechanism 306. The inner wall 331, outer wall 332, top wall 333, bottom wall 334, interior space 335, and wave spring 336 of the plunger ball retention mechanism 306 can be seen. The outwardly projecting prongs 337 of the wave spring 336 push against the outer wall 332 of the main annular ring 330 of the plunger ball retention mechanism 306, which pushes against the retention groove 340, in combination with the inwardly projecting prongs 338 of the wave spring 336 pushing against the inner wall 331 of the main annular ring 330 of the plunger ball retention mechanism 306, cause the inner wall 331 of the main annular ring 330 to engage the plunger ball 202. Engage of the inner wall 331 of the main annular ring 330 with the plunger ball 202 holds the plunger ball 202 in the seat portion 226.

[0066]In operation, the plunger assembly 300 may be deployed as the plunger assembly 130 of FIG. 1 into the wellbore 150. The plunger ball 202 may be deployed before the plunger sleeve 204 having the plunger ball retention mechanism 306 therein, and/or configured to descend into the wellbore 150 at a higher rate as compared to the plunger sleeve 204. When the plunger ball 202 is deployed to the bottom of the wellbore 150, the plunger sleeve 204 may be deployed and come into contact with the plunger ball 202. As the plunger sleeve 204 continues to descend, the plunger ball 202 may enter the plunger ball seat 224, where the plunger ball 202 may contact and exert an outward force on inner wall 331 that inwardly projecting prongs 338 of the wave spring 336 to deflect radially outward. The plunger ball 202 may thereafter contact and become seated in the concave seat portion 226, where the inwardly projecting prongs 338 may exert a lateral compressive force on the inner wall 331 of the main annular ring 330, which exerts a compressive force on the plunger ball 202 and retains the plunger ball 202 in a nesting engagement with the seat portion 226 of the plunger ball seat 224.

[0067]When the plunger ball 202 is nested in the seat portion 226 of the plunger ball seat 224, fluid flow through the central bore 210 of the plunger sleeve 204 may be prevented. In some embodiments, the inner wall 331 of the main annular ring 330 may pass over and/or extend below central, antipodal points of the plunger ball 202, which define the largest circular cross-section of the plunger ball 202 and include the plunger ball's center and diameter. Accordingly, the inner wall 331 defines an engagement diameter that is smaller than the diameter of the plunger ball 202. In this manner, compressive forces applied by the inwardly projecting prongs 338 on the inner wall 331 may retain the plunger ball 202 in nesting engagement with the seat portion 226 of the plunger ball seat 224 during ascent of the plunger assembly 200 (e.g., upstroke), despite pressure fluctuations in the wellbore 150, thereby preventing “dry” cycles triggered by the unintended disengagement between ball and plunger sleeve in traditional plunger assemblies.

[0068]FIG. 4A illustrates a perspective view of a ball retention mechanism 406 according to another embodiment of the disclosure. The plunger ball retention mechanism 406 has an annular ring 430 formed of alternating band portions 431 and plate portions 432. By alternating, it is meant that the sides of each band portion 431 are connected to adjacent plate portions 432 and the sides of each plate portion 432 are connected to adjacent band portions 431. A dimension D1 of each plate portion 432 is greater than a dimension D2 of each band portion 431. In aspects, the thickness of the annular ring 430 is in the range of 1/32 inch to ½ inch (0.079 cm to 1.27 cm). The plunger ball retention mechanism 406 may be formed from a resilient, metallic material. More specifically, the plunger ball retention mechanism 406 may be formed from a nickel-chromium based alloy such as Inconel®, a nickel-based alloy, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, or magnesium. In some embodiments, the plunger ball retention mechanism 406 may include a coating, such as a gold coating, an aluminum chromium nitride (AlCrN) coating, a titanium aluminum nitride (TiAlN) coating, or any other wear-resistant metallic coating.

[0069]Each of the inwardly projecting prongs 438 is connected to one of the plate portions 432, and each plate portion 432 is connected to one inwardly projecting prong 438. Each of the inwardly projecting prongs 438 has a first end 450 and a second end 451 connected to a plate portion 432. The annular ring 430 can include a notch 434, which is a break in the continuity of the annular ring 430, formed therein to provide a split-ring or retaining-ring type profile. The notch 434 may allow the annular ring 430 to be opened up or expanded in order to install or remove the plunger ball retention mechanism 406 onto or from the plunger sleeve 204. Fasteners 433 are shown on the annular ring 430 near the notch 434. The fasteners 433 can be embodied as screws or clips, for example. While the resilient nature of the annular ring 430 can keep the annular ring 430 in the retention groove 240 of the plunger sleeve 204 during operation, fasteners 433 optionally can be used to engage with the plunger sleeve 204 as a secondary means for fastening the annular ring 430 to the plunger sleeve 204 during operation.

[0070]FIG. 4B illustrates a perspective view of the plunger sleeve 204 for use with the plunger ball retention mechanism 406 of FIG. 4A. The plunger sleeve 204 has a tubular main body 208. The retention groove 240 is formed in the outer surface 205 of the tubular main body 208 (the plunger sleeve 204). The depth of the retention groove 240 is equal to or greater than a thickness of the band portions 431 and the plate portions 432 of the annular ring 430 in FIG. 4A. In aspects, the depth of the retention groove 240 is in the range of 1/32 inch to ½ inch (0.079 cm to 1.27 cm). The plunger ball retention passages 246 can be seen formed in the tubular main body 208 of the plunger sleeve 204. In aspects, the retention groove 240 is contoured to receive both band portions 431 and the plate portions 432 of the annular ring 430. The plunger ball seat 224 is inside the plunger sleeve 204.

[0071]FIG. 4C illustrates a perspective view of a plunger assembly 400 having the plunger ball retention mechanism 406 of FIG. 4A on the sleeve 204 of FIG. 4B. The plunger assembly 400 may be suitable for use in the plunger lift system 100 as an embodiment of plunger assembly 130, and can be configured to be deployed into the production string 104 for producing hydrocarbon fluids from the subterranean.

[0072]The annular ring 430 of the plunger ball retention mechanism 406 can be seen in the retention groove 240 of the plunger sleeve 204. Fasteners 433 are shown fastening the plunger ball retention mechanism 406 to the plunger sleeve 204. One of the inwardly projecting prongs 438 can be seen attached to one of the plate portions 432 of the annular ring 430. The inwardly projecting prongs 438 engage the plunger ball 202 in the plunger ball seat 224 of the plunger sleeve 204. One of the band portions 431 can also be seen in the retention groove 240.

[0073]FIG. 4D illustrates a side cross-sectional view of the plunger assembly 400 having the plunger ball retention mechanism 406 of FIG. 4A on the sleeve 204 of FIG. 4B. The inwardly projecting prongs 438 of the annular ring 430 extend through plunger ball retention passages 246 formed in the plunger sleeve 204 (e.g., the tubular main body 208 of the plunger sleeve 204) and into the central bore 210 of the tubular main body 208 of the plunger sleeve 204, so as to engage the plunger ball 202 in the plunger ball seat 224 and against the seat portion 226. It can be seen how the ends 450 and 451 of the inwardly projecting prongs 438 are connected to the plate portions 432, and the apex 452 of the inwardly projecting prongs 438 engages the plunger ball 202.

[0074]In operation, the plunger assembly 400 may be deployed as the plunger assembly 130 of FIG. 1 into the wellbore 150. The plunger ball 202 may be deployed before the plunger sleeve 204 having the plunger ball retention mechanism 406 thereon, and/or configured to descend into the wellbore 150 at a higher rate as compared to the plunger sleeve 204. When the plunger ball 202 is deployed to the bottom of the wellbore 150, the plunger sleeve 204 may be deployed and come into contact with the plunger ball 202. As the plunger sleeve 204 continues to descend, the plunger ball 202 may enter the plunger ball seat 224, where the plunger ball 202 may contact and exert an outward force on the cause the inwardly projecting prongs 438 to deflect or bend radially outward. The plunger ball 202 may thereafter contact and become seated in the concave seat portion 226, where the inwardly projecting prongs 438 may exert a lateral compressive force on the plunger ball 202 and retain the plunger ball 202 in a nesting engagement with the seat portion 226 of the plunger ball seat 224.

[0075]When the plunger ball 202 is nested in the seat portion 226 of the plunger ball seat 224, fluid flow through the central bore 210 of the plunger sleeve 204 may be prevented. In some embodiments, the inwardly projecting prongs 438 may pass over and/or extend below central, antipodal points of the plunger ball 202, which define the largest circular cross-section of the plunger ball 202 and include the plunger ball's center and diameter. Accordingly, the inwardly projecting prongs 438 may extend through the plunger ball retention passages 246 sufficient to define an engagement diameter between opposing inwardly projecting prongs 438 that is smaller than the diameter of the plunger ball 202. In this manner, compressive forces applied by the inwardly projecting prongs 438 may retain the plunger ball 202 in nesting engagement with the seat portion 226 of the plunger ball seat 224 during ascent of the plunger assembly 200 (e.g., upstroke), despite pressure fluctuations in the wellbore 150, thereby preventing “dry” cycles triggered by the unintended disengagement between ball and plunger sleeve in traditional plunger assemblies.

[0076]FIG. 5A illustrates a perspective view of a plunger ball retention mechanism 506 according to another embodiment of the disclosure. The plunger ball retention mechanism 506 has a first annular ring 530, a second annular ring 540, and inwardly projecting prongs 538 between the first annular ring 530 and second annular ring 540. Each of the inwardly projecting prongs 538 has a first end 551 connected to the first annular ring 530 and a second end 552 connected to the second annular ring 540. An apex 550 of each of the inwardly projecting prongs 538 is between the first end 551 and the second end 552. The annular ring 530 can include a notch 534, which is a break in the continuity of the annular ring 530, formed therein to provide a split-ring or retaining-ring type profile. The notch 534 may allow the annular ring 530 to be opened up or expanded in order to install or remove the plunger ball retention mechanism 506 onto or from the plunger sleeve 204. In aspects, the thickness of the annular rings 530 and 540 is the same, and in the range of 1/32 inch to ½ inch (0.079 cm to 1.27 cm). The plunger ball retention mechanism 506 may be formed from a resilient, metallic material. More specifically, the plunger ball retention mechanism 506 may be formed from a nickel-chromium based alloy such as Inconel®, a nickel-based alloy, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, or magnesium. In some embodiments, the plunger ball retention mechanism 506 may include a coating, such as a gold coating, an aluminum chromium nitride (AlCrN) coating, a titanium aluminum nitride (TiAlN) coating, or any other wear-resistant metallic coating.

[0077]FIG. 5B illustrates a perspective view of the plunger sleeve 204 for use with the plunger ball retention mechanism 506 of FIG. 5A. The plunger sleeve 204 has a tubular main body 208. The retention groove 240 is formed in the outer surface 205 of the tubular main body 208 (the plunger sleeve 204). The retention groove 240 is the first groove of two retention grooves, where the second retention groove 243 is also formed in the outer surface 205 of the tubular main body 208 (the plunger sleeve 204). The depth of the retention grooves 240 and 243 is equal to or greater than a thickness of the first annular ring 530 and the second annular ring 540 in FIG. 5A. In aspects, the depth of the retention grooves 240 and 243 is the same and is in the range of 1/32 inch to ½ inch (0.079 cm to 1.27 cm). The plunger ball retention passages 246 can be seen formed in the tubular main body 208 of the plunger sleeve 204 between the retention grooves 240 and 243. The plunger ball seat 224 is inside the plunger sleeve 204.

[0078]FIG. 5C illustrates a perspective view of a plunger assembly 500 having the plunger ball retention mechanism 506 of FIG. 5A on the sleeve 204 of FIG. 5B. The plunger assembly 500 may be suitable for use in the plunger lift system 100 as an embodiment of plunger assembly 130, and can be configured to be deployed into the production string 104 for producing hydrocarbon fluids from the subterranean.

[0079]The annular rings 530 and 540 of the plunger ball retention mechanism 506 can be seen in the retention grooves 240 and 243 of the plunger sleeve 204. The inwardly projecting prongs 538 can be seen attached to the first annular ring 530 and the second annular ring 540. The inwardly projecting prongs 538 engage the plunger ball 202 in the plunger ball seat 224 of the plunger sleeve 204.

[0080]FIG. 5D illustrates a side cross-sectional view of a plunger assembly 500 having the plunger ball retention mechanism 506 of FIG. 5A on the sleeve 204 of FIG. 5B. It can be seen that the inwardly projecting prongs 538 extend through plunger ball retention passages 246 formed in the plunger sleeve 204 and into the central bore 210 of the tubular main body 208 of the plunger sleeve 204, so as to engage the plunger ball 202 in the plunger ball seat 224 and against the seat portion 226. It can be seen how the ends 551 and 552 of the inwardly projecting prongs 538 are connected to the annular rings 530 and 540, and the apex 550 of the inwardly projecting prongs 538 engages the plunger ball 202.

[0081]In operation, the plunger assembly 500 may be deployed as the plunger assembly 130 of FIG. 1 into the wellbore 150. The plunger ball 202 may be deployed before the plunger sleeve 204 having the plunger ball retention mechanism 406 thereon, and/or configured to descend into the wellbore 150 at a higher rate as compared to the plunger sleeve 204. When the plunger ball 202 is deployed to the bottom of the wellbore 150, the plunger sleeve 204 may be deployed and come into contact with the plunger ball 202. As the plunger sleeve 204 continues to descend, the plunger ball 202 may enter the plunger ball seat 224, where the plunger ball 202 may contact and exert an outward force on the cause the inwardly projecting prongs 538 to deflect or bend radially outward. The plunger ball 202 may thereafter contact and become seated in the concave seat portion 226, where the inwardly projecting prongs 538 may exert a lateral compressive force on the plunger ball 202 and retain the plunger ball 202 in a nesting engagement with the seat portion 226 of the plunger ball seat 224.

[0082]When the plunger ball 202 is nested in the seat portion 226 of the plunger ball seat 224, fluid flow through the central bore 210 of the plunger sleeve 204 may be prevented. In some embodiments, the inwardly projecting prongs 538 may pass over and/or extend below central, antipodal points of the plunger ball 202, which define the largest circular cross-section of the plunger ball 202 and include the plunger ball's center and diameter. Accordingly, the inwardly projecting prongs 538 may extend through the plunger ball retention passages 246 sufficient to define an engagement diameter between opposing inwardly projecting prongs 538 that is smaller than the diameter of the plunger ball 202. In this manner, compressive forces applied by the inwardly projecting prongs 538 may retain the plunger ball 202 in nesting engagement with the seat portion 226 of the plunger ball seat 224 during ascent of the plunger assembly 200 (e.g., upstroke), despite pressure fluctuations in the wellbore 150, thereby preventing “dry” cycles triggered by the unintended disengagement between ball and plunger sleeve in traditional plunger assemblies.

[0083]Referring to FIG. 6, a flowchart of a method 600 of producing hydrocarbon fluids from a wellbore 150 in a plunger lift system 100 is shown according to an embodiment of the disclosure.

[0084]The method 600 may begin at block 602 by producing hydrocarbon fluids from the wellbore 150 in the plunger lift system 100 which has a plunger assembly 130 configured according to an embodiment disclosed herein (e.g., plunger assembly 200, 300, 400, or 500). Producing hydrocarbon fluids can include accumulating hydrocarbon fluids (e.g., hydrocarbon liquid, or hydrocarbon gas and liquid) above the plunger assembly 130 such that when a production valve at the wellhead 102 is opened, the plunger assembly 130 and the liquid or mixture of liquid and gas accumulated above the plunger assembly 130 are lifted to the wellhead 102 for production of the fluid mixture (e.g., hydrocarbon gas and hydrocarbon liquid). Additionally, producing hydrocarbon fluids can include injecting a pressurized gas into an annulus 140 of the wellbore 150. In some embodiments, the pressurized gas may be injected into an upper portion of the annulus 140 of the wellbore 150 formed between the production string 104 and the casing of the wellbore 150 and disposed above the packer elements or seals 118. In such cases, the pressurized gas may enter the packer assembly 116 from the annulus 140 above the packer element or seal 118, pass through the packer assembly 116, and exit the packer assembly 116 into the lower portion of the annulus 140 below the packer element or seal 118, where the pressurized gas may enter one or more gas injection valves 122 disposed in the lower production tubing 120 of the production string 104.

[0085]The method 600 may continue at block 604 by retaining the plunger ball 202 within the plunger sleeve 204 by engagement of the plunger ball retention mechanism 206 with the plunger ball 202. In some embodiments, retaining the plunger ball 202 within the plunger sleeve 204 can include retaining, by the plunger ball retention mechanism 206, the plunger ball 202 in contact with the plunger ball seat 224 of the plunger sleeve 204.

[0086]The method 600 can include steps at block 606 and block 608, which can be performed before the steps of block 602 and 604. At block 606, the method can include inserting the plunger ball 202 into the plunger sleeve 204, and engaging or contacting or attaching the plunger ball retention mechanism 206 to the plunger sleeve 204 so as to retain the plunger ball 202 in the plunger assembly 130. At block 608, the method includes positioning the plunger assembly 130 at a bottom of the wellbore 150.

[0087]In aspects, the method 600 can include only steps described at block 602; alternatively, the method 600 can include steps described for blocks 602 and 604; alternatively, the method 600 can includes steps described for blocks 602 and 604 in combination with the steps of block 606, the steps of block 608, or the steps of both blocks 606 and 608. In aspects, any of the foregoing embodiments of the method 600 can include steps relating to use and function of the plunger assembly 130 and plunger lift system 100 described herein.

Additional Description

[0088]It will be appreciated that a plunger lift system, a plunger assembly, a plunger ball retention mechanism, and/or a method may include one or more of the following embodiments:

[0089]Aspect A1. A plunger assembly, comprising: a plunger ball; a plunger sleeve comprising a tubular main body having a central bore extending therethrough; and a plunger ball retention mechanism coupled to the plunger sleeve and comprising a plurality of resilient legs that extend along the tubular main body of the plunger sleeve, wherein each of the plurality of legs includes an inwardly projecting prong that extends into the central bore of the tubular main body of the plunger sleeve and engages the plunger ball to retain the plunger ball within the plunger sleeve.

[0090]Aspect A2. The plunger assembly of any of the preceding Aspects, wherein the plunger ball is formed from carbon steel, stainless steel, a steel alloy, a steel superalloy, titanium, or other metallic material.

[0091]Aspect A3. The plunger assembly of any of the preceding Aspects, wherein the central bore establishes fluid communication between a top end and a bottom end of the plunger sleeve.

[0092]Aspect A4. The plunger assembly of any of the preceding Aspects, wherein the plunger sleeve includes a plurality of annular grooves formed in an outer surface of the tubular main body of the plunger sleeve.

[0093]Aspect A5. The plunger assembly of any of the preceding Aspects, wherein the grooves induce turbulence when the plunger sleeve is deployed into a wellbore.

[0094]Aspect A6. The plunger assembly of any of the preceding Aspects, wherein each of the grooves includes an upper radial surface, an inner longitudinal surface, and a lower angled surface that collectively form each groove.

[0095]Aspect A7. The plunger assembly of any of the preceding Aspects, wherein the plunger sleeve includes at least three grooves, at least four grooves, at least five grooves, at least six grooves, or at least seven grooves.

[0096]Aspect A8. The plunger assembly of any of the preceding Aspects, wherein the plunger sleeve includes a plunger ball seat formed at a lower end of the plunger sleeve and configured to receive the plunger ball therein.

[0097]Aspect A9. The plunger assembly of any of the preceding Aspects, wherein the plunger ball seat is formed in the central bore and includes an annular, substantially concave seat portion that is complementary to an outer diameter of the plunger ball.

[0098]Aspect A10. The plunger assembly of any of the preceding Aspects, wherein fluid flow through the central bore of the plunger sleeve is prevented when the plunger ball is seated within the seat portion of the plunger ball seat.

[0099]Aspect A11. The plunger assembly of any of the preceding Aspects, wherein the plunger ball seat includes a beveled or radiused entry portion at a bottom end of the central bore that is configured to guide the plunger ball into engagement with the seat portion of the plunger ball seat.

[0100]Aspect A12. The plunger assembly of any of the preceding Aspects, wherein the plunger ball retention mechanism includes a main annular ring, wherein the plurality of resilient legs extend longitudinally therefrom.

[0101]Aspect A13. The plunger assembly of any of the preceding Aspects, wherein the main annular ring has diameter equal to a retention groove of the plunger.

[0102]Aspect A14. The plunger assembly of any of the preceding Aspects, wherein the length and thickness of the plurality of resilient legs are engineered to deliver the required retention force.

[0103]Aspect A15. The plunger assembly of any of the preceding aspects, wherein the thickness of the ring is in the range of 1/32 inch to ½ inch (0.079 cm to 1.27 cm).

[0104]Aspect A16. The plunger assembly of any of the preceding aspects, wherein the thickness of the plurality of resilient legs is in the range of 1/32 inch to ½ inch (0.079 cm to 1.27 cm).

[0105]Aspect A17. The plunger assembly of any of the preceding aspects, wherein the length of the plurality of resilient legs is in the range of ½ inch to 3 inch (1.27 cm to 7.62 cm).

[0106]Aspect A18. The plunger assembly of any of the preceding Aspects, wherein the main annular ring has split-ring type profile to be expanded.

[0107]Aspect A19. The plunger assembly of any of the preceding Aspects, wherein the main annular ring includes a longitudinal notch that provides the main annular ring with a split-ring type profile.

[0108]Aspect A20. The plunger assembly of any of the preceding Aspects, wherein the notch allows the main annular ring to be expanded in order to install the plunger ball retention mechanism onto the plunger sleeve.

[0109]Aspect A21. The plunger assembly of any of the preceding Aspects, wherein each of the plurality of resilient legs extends from the main annular ring in a single direction.

[0110]Aspect A22. The plunger assembly of any of the preceding Aspects, wherein the plurality of resilient legs are disposed symmetrically about the main annular ring.

[0111]Aspect A23. The plunger assembly of any of the preceding Aspects, wherein the plurality of resilient legs are disposed asymmetrically about the main annular ring.

[0112]Aspect A24. The plunger assembly of any of the preceding Aspects, wherein the plurality of resilient legs includes beveled or radiused interfaces with the main annular ring.

[0113]Aspect A25. The plunger assembly of any of the preceding Aspects, wherein each of the plurality of resilient legs includes one or more inwardly projecting prongs.

[0114]Aspect A26. The plunger assembly of any of the preceding Aspects, wherein the inwardly projecting prongs are disposed at a distal end of each of the plurality of resilient legs.

[0115]Aspect A27. The plunger assembly of any of the preceding Aspects, wherein the inwardly projecting prongs are formed by a bent, curved, or crimped portion of each of the plurality of resilient legs.

[0116]Aspect A28. The plunger assembly of any of the preceding Aspects, wherein the inwardly projecting prongs extend inwardly into the central bore of the plunger sleeve to engage the plunger ball and retain the plunger ball within the plunger sleeve.

[0117]Aspect A29. The plunger assembly of any of the preceding Aspects, wherein the plunger ball retention mechanism is formed from a resilient, metallic material.

[0118]Aspect A30. The plunger assembly of any of the preceding Aspects, wherein the resilient, metallic material includes a nickel-chromium based alloy, a nickel-based alloy, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, or magnesium.

[0119]Aspect A31. The plunger assembly of any of the preceding Aspects, wherein the plunger ball retention mechanism includes a wear-resistant metallic coating.

[0120]Aspect A32. The plunger assembly of any of the preceding Aspects, wherein the plunger sleeve includes a retention groove formed in an outer surface of the plunger sleeve.

[0121]Aspect A33. The plunger assembly of claim 26, wherein the retention groove is configured to receive the plunger ball retention mechanism, such that the plunger ball retention mechanism is installed into and retained on the plunger sleeve.

[0122]Aspect A34. The plunger assembly of any of the preceding Aspects, wherein the retention groove includes a main annular groove, a plurality of leg grooves extending longitudinally therefrom, and a plunger ball retention passage disposed at a distal end of each of the plurality of leg grooves.

[0123]Aspect A35. The plunger assembly of any of the preceding Aspects, wherein the plunger ball retention passages are formed in the tubular main body and extend from the distal end of the leg grooves into the central bore adjacent to a concave seat portion of a plunger ball seat.

[0124]Aspect A36. The plunger assembly of any of the preceding Aspects, wherein the plunger ball retention mechanism includes an inwardly projecting prong disposed at a distal end of each of the plurality of resilient legs, and wherein the inwardly projecting prongs extend into at least a portion of the central bore of the plunger sleeve.

[0125]Aspect A37. The plunger assembly of any of the preceding Aspects, wherein the inwardly projecting prongs engage the plunger ball to retain the plunger ball within the plunger ball seat of the plunger sleeve.

[0126]Aspect A38. The plunger assembly of any of the preceding Aspects, wherein the inwardly projecting prongs extend below central, antipodal points of the plunger ball to exert a compressive force on the plunger ball to retain the plunger ball in nesting engagement with the seat portion of the plunger ball seat.

[0127]Aspect A39. A plunger lift system, comprising: a plunger assembly disposed within the wellbore, the plunger assembly comprising: a plunger ball; a plunger sleeve comprising a tubular main body having a central bore extending therethrough; and a plunger ball retention mechanism coupled to the plunger sleeve and comprising a plurality of resilient legs that extend along the tubular main body of the plunger sleeve, wherein each of the plurality of legs includes a prong that extends into the central bore of the tubular main body of the plunger sleeve and engages the plunger ball to retain the plunger ball within the plunger sleeve.

[0128]Aspect A40. The plunger lift system of any of the preceding Aspects, wherein the plunger ball is formed from carbon steel, stainless steel, a steel alloy, a steel superalloy, titanium, or other metallic material.

[0129]Aspect A41. The plunger lift system of any of the preceding Aspects, wherein the central bore establishes fluid communication between a top end and a bottom end of the plunger sleeve.

[0130]Aspect A42. The plunger lift system of any of the preceding Aspects, wherein the plunger sleeve includes a plurality of annular grooves formed in an outer surface of the tubular main body of the plunger sleeve.

[0131]Aspect A43. The plunger lift system of any of the preceding Aspects, wherein the grooves induce turbulence when the plunger sleeve is deployed into a wellbore.

[0132]Aspect A44. The plunger lift system of any of the preceding Aspects, wherein each of the grooves includes an upper radial surface, an inner longitudinal surface, and a lower angled surface that collectively form each groove.

[0133]Aspect A45. The plunger lift system of any of the preceding Aspects, wherein the plunger sleeve includes at least three grooves, at least four grooves, at least five grooves, at least six grooves, or at least seven grooves.

[0134]Aspect A46. The plunger lift system of any of the preceding Aspects, wherein the plunger sleeve includes a plunger ball seat formed at a lower end of the plunger sleeve and configured to receive the plunger ball therein.

[0135]Aspect A47. The plunger lift system of any of the preceding Aspects, wherein the plunger ball seat is formed in the central bore and includes an annular, substantially concave seat portion that is complementary to an outer diameter of the plunger ball.

[0136]Aspect A48. The plunger lift system of any of the preceding Aspects, wherein fluid flow through the central bore of the plunger sleeve is prevented when the plunger ball is seated within the seat portion of the plunger ball seat.

[0137]Aspect A49. The plunger lift system of any of the preceding Aspects, wherein the plunger ball seat includes a beveled or radiused entry portion at a bottom end of the central bore that is configured to guide the plunger ball into engagement with the seat portion of the plunger ball seat.

[0138]Aspect A50. The plunger lift system of any of the preceding Aspects, wherein the plunger ball retention mechanism includes a main annular ring, wherein the plurality of resilient legs extend longitudinally therefrom.

[0139]Aspect A51. The plunger lift system of any of the preceding Aspects, wherein the main annular ring includes a longitudinal notch that provides the main annular ring with a split-ring type profile.

[0140]Aspect A52. The plunger lift system of any of the preceding Aspects, wherein the notch allows the main annular ring to be expanded in order to install the plunger ball retention mechanism onto the plunger sleeve.

[0141]Aspect A53. The plunger lift system of any of the preceding Aspects, wherein each of the plurality of resilient legs extends from the main annular ring in a single direction.

[0142]Aspect A54. The plunger lift system of any of the preceding Aspects, wherein the plurality of resilient legs are disposed symmetrically about the main annular ring.

[0143]Aspect A55. The plunger lift system of any of the preceding Aspects, wherein the plurality of resilient legs are disposed asymmetrically about the main annular ring.

[0144]Aspect A56. The plunger lift system of any of the preceding Aspects, wherein the plurality of resilient legs includes beveled or radiused interfaces with the main annular ring.

[0145]Aspect A57. The plunger lift system of any of the preceding Aspects, wherein each of the plurality of resilient legs includes one or more inwardly projecting prongs.

[0146]Aspect A58. The plunger lift system of any of the preceding Aspects, wherein the inwardly projecting prongs are disposed at a distal end of each of the plurality of resilient legs.

[0147]Aspect A59. The plunger lift system of any of the preceding Aspects, wherein the inwardly projecting prongs are formed by a bent, curved, or crimped portion of each of the plurality of resilient legs.

[0148]Aspect A60. The plunger lift system of any of the preceding Aspects, wherein the inwardly projecting prongs extend inwardly into the central bore of the plunger sleeve to engage the plunger ball and retain the plunger ball within the plunger sleeve.

[0149]Aspect A61. The plunger lift system of any of the preceding Aspects, wherein the plunger ball retention mechanism is formed from a resilient, metallic material.

[0150]Aspect A62. The plunger lift system of any of the preceding Aspects, wherein the resilient, metallic material includes a nickel-chromium based alloy, a nickel-based alloy, nickel, titanium, tungsten, stainless steel, spring steel, steel, aluminum, zinc, or magnesium.

[0151]Aspect A63. The plunger lift system of any of the preceding Aspects, wherein the plunger ball retention mechanism includes a wear-resistant metallic coating.

[0152]Aspect A64. The plunger lift system of any of the preceding Aspects, wherein the plunger sleeve includes a retention groove formed in an outer surface of the plunger sleeve.

[0153]Aspect A65. The plunger lift system of any of the preceding Aspects, wherein the retention groove is configured to receive the plunger ball retention mechanism, such that the plunger ball retention mechanism is installed into and retained on the plunger sleeve.

[0154]Aspect A66. The plunger lift system of any of the preceding Aspects, wherein the retention groove includes a main annular groove, a plurality of leg grooves extending longitudinally therefrom, and a plunger ball retention passage disposed at a distal end of each of the plurality of leg grooves.

[0155]Aspect A67. The plunger lift system of any of the preceding Aspects, wherein the plunger ball retention passages are formed in the tubular main body and extend from the distal end of the leg grooves into the central bore adjacent to a concave seat portion of a plunger ball seat.

[0156]Aspect A68. The plunger lift system of any of the preceding Aspects, wherein the plunger ball retention mechanism includes an inwardly projecting prong disposed at a distal end of each of the plurality of resilient legs, and wherein the inwardly projecting prongs extend into at least a portion of the central bore of the plunger sleeve.

[0157]Aspect A69. The plunger lift system of any of the preceding Aspects, wherein the inwardly projecting prongs engage the plunger ball to retain the plunger ball within the plunger ball seat of the plunger sleeve.

[0158]Aspect A70. The plunger lift system of any of the preceding Aspects, wherein the inwardly projecting prongs extend below central, antipodal points of the plunger ball to exert a compressive force on the plunger ball to retain the plunger ball in nesting engagement with the seat portion of the plunger ball seat.

[0159]Aspect A71. A method of producing hydrocarbon fluids from a wellbore in a plunger lift system, comprising: positioning a plunger ball of a plunger assembly at a bottom of the wellbore; deploying a plunger sleeve of the plunger assembly towards the bottom of the wellbore, until the plunger sleeve receives the plunger ball and a plunger ball retention mechanism of the plunger assembly engages the plunger ball; and retaining the plunger ball within the plunger sleeve by engagement of the plunger ball retention mechanism with the plunger ball in response to a fluctuation of pressure in the wellbore during an ascent of the plunger assembly within the wellbore.

[0160]Aspect A72. The method of any of the preceding Aspects, wherein retaining the plunger ball within the plunger sleeve by engagement of the plunger ball retention mechanism with the plunger ball includes the plunger ball retention mechanism retaining the plunger ball in contact with a plunger ball seat of the plunger sleeve.

[0161]Aspect A73. The method of any of the preceding Aspects, wherein the plunger ball seat is formed in a central bore of the plunger sleeve and includes an annular, substantially concave seat portion that is complementary to an outer diameter of the plunger ball.

[0162]Aspect A74. The method of any of the preceding Aspects, wherein fluid flow through the central bore of the plunger sleeve is prevented when the plunger ball is seated within the seat portion of the plunger ball seat.

[0163]Aspect A75. The method of any of the preceding Aspects, wherein the plunger ball retention mechanism includes a main annular ring and a plurality of resilient legs extending longitudinally therefrom.

[0164]Aspect A76. The method of any of the preceding Aspects, wherein each of the plurality of resilient legs extends from the main annular ring in a single direction.

[0165]Aspect A77. The method of any of the preceding Aspects, wherein each of the plurality of resilient legs includes one or more inwardly projecting prongs.

[0166]Aspect A78. The method of any of the preceding Aspects, wherein the inwardly projecting prongs are formed by a bent, curved, or crimped portion of each of the plurality of resilient legs.

[0167]Aspect A79. The method of any of the preceding Aspects, wherein the inwardly projecting prongs extend inwardly through a plurality of plunger ball retention passages and into a central bore of the plunger sleeve so as to engage the plunger ball and retain the plunger ball within the plunger sleeve. In aspects, the prongs retain the plunger ball within the plunger ball seat of the plunger sleeve.

[0168]Aspect A80. The method of any of the preceding Aspects, wherein the inwardly projecting prongs extend below central, antipodal points of the plunger ball to exert a compressive force on the plunger ball to retain the plunger ball in nesting engagement with a seat portion of the plunger ball seat.

[0169]Aspect A81. A method can include producing hydrocarbon fluids from a wellbore with a plunger lift system, wherein the plunger lift system includes a plunger assembly configured according to an embodiment disclosed herein; and retaining the plunger ball within the plunger sleeve by engagement of the plunger ball retention mechanism with the plunger ball. The plunger assembly can include the plunger assembly of any of the above Aspects. The retaining step can be performed during producing, for example, when the plunger assembly falls from the wellhead to the bottom of the well and when the plunger assembly is lifted from the bottom of the well to the wellhead.

[0170]Aspect A82 is the method of any of the preceding Aspects, wherein retaining the plunger ball within the plunger sleeve by engagement of the plunger ball retention mechanism with the plunger ball includes the plunger ball retention mechanism retaining the plunger ball in contact with a plunger ball seat of the plunger sleeve.

[0171]Aspect A83 is the method of any of the preceding Aspects, wherein the plunger ball retention mechanism includes a main annular ring and a plurality of resilient legs extending longitudinally therefrom.

[0172]Aspect A84 is the method of any of the preceding Aspects, wherein each of the plurality of resilient legs extends from the main annular ring in a single direction.

[0173]Aspect A85 is the method of any of the preceding Aspects, wherein each of the plurality of resilient legs includes one or more inwardly projecting prongs.

[0174]Aspect A86 is the method of any of the preceding Aspects, wherein the inwardly projecting prongs are formed by a bent, curved, or crimped portion of each of the plurality of resilient legs.

[0175]Aspect A87 is the method of any of the preceding Aspects, wherein the inwardly projecting prongs extend inwardly into a central bore of the plunger sleeve through a plurality of plunger ball retention passages to engage the plunger ball and retain the plunger ball within a plunger ball seat of the plunger sleeve.

[0176]Aspect A88 is the method of any of the preceding Aspects, wherein the inwardly projecting prongs extend below central, antipodal points of the plunger ball to exert a compressive force on the plunger ball to retain the plunger ball in nesting engagement with a complementary seat portion of the plunger ball seat.

[0177]Aspect B1. A plunger assembly, comprising: a plunger ball; a plunger sleeve comprising a tubular main body having a central bore extending therethrough; and a plunger ball retention mechanism coupled to the plunger sleeve, wherein the plunger ball retention mechanism includes an annular ring and inwardly projecting prongs coupled to the annular ring, wherein the inwardly projecting prongs engage the plunger ball to retain the plunger ball within the plunger sleeve.

[0178]Aspect B2. The plunger assembly of any of the preceding Aspects, wherein the plunger sleeve includes a retention groove formed in an outer surface or an inner surface of the plunger sleeve, wherein the retention groove receives the plunger ball retention mechanism such that the plunger ball retention mechanism is installed into the retention groove and retained on the outer surface or the inner surface of the plunger sleeve while the inwardly projecting prongs extend into the central bore of the tubular main body.

[0179]Aspect B3. The plunger assembly of any of the preceding Aspects, wherein plunger ball retention passages are formed in the plunger sleeve and are located adjacent to a concave seat portion of a plunger ball seat, wherein the inwardly projecting prongs extend below central, antipodal points of the plunger ball to exert a compressive force on the plunger ball to retain the plunger ball in nesting engagement with the concave seat portion of the plunger ball seat.

[0180]Aspect B4. The plunger assembly of any of the preceding Aspects, wherein the plunger ball retention mechanism further includes a plurality of resilient legs extending longitudinally from the annular ring, wherein each of the plurality of resilient legs extends from the annular ring in a single direction, wherein the inwardly projecting prongs are disposed at a distal end of the plurality of resilient legs, wherein the inwardly projecting prongs extend through plunger ball retention passages formed in the plunger sleeve and into the central bore of the tubular main body of the plunger sleeve.

[0181]Aspect B5. The plunger assembly of any of the preceding Aspects, wherein the annular ring includes an outer wall, an inner wall, a top wall, and a bottom wall that delimit an interior space, wherein the inwardly projecting prongs are part of a wave spring that is contained in the interior space of the annular ring.

[0182]Aspect B6. The plunger assembly of any of the preceding Aspects, wherein the annular ring includes alternating band portions and plate portions, wherein the inwardly projecting prongs are connected to the plate portions, wherein the inwardly projecting prongs extend through plunger ball retention passages formed in the plunger sleeve and into the central bore of the tubular main body of the plunger sleeve.

[0183]Aspect B7. The plunger assembly of any of the preceding Aspects, wherein the plunger ball retention mechanism includes further includes a second annular ring, wherein each of the inwardly projecting prongs has a first end connected to the annular ring and a second end connected to the second annular ring, wherein an apex of each of the inwardly projecting prongs is between the first end and the second end, wherein the inwardly projecting prongs extend through plunger ball retention passages formed in the plunger sleeve and into the central bore of the tubular main body of the plunger sleeve.

[0184]Aspect B8. A plunger lift system, comprising: a wellhead disposed on top of a wellbore; and a plunger assembly disposed within the wellbore, the plunger assembly comprising: a plunger ball; a plunger sleeve comprising a tubular main body having a central bore extending therethrough; and a plunger ball retention mechanism coupled to the plunger sleeve, wherein the plunger ball retention mechanism includes an annular ring and inwardly projecting prongs coupled to the annular ring, wherein the inwardly projecting prongs engage the plunger ball to retain the plunger ball within the plunger sleeve.

[0185]Aspect B9. The plunger lift system of Aspect B8, wherein the plunger sleeve includes a retention groove formed in an outer surface or an inner surface of the plunger sleeve, wherein the retention groove receives the plunger ball retention mechanism such that the plunger ball retention mechanism is installed into the retention groove and retained on the outer surface or the inner surface of the plunger sleeve while the inwardly projecting prongs extend into the central bore of the tubular main body.

[0186]Aspect B10. The plunger lift system of any of the preceding Aspects, wherein plunger ball retention passages are formed in the plunger sleeve and are located adjacent to a concave seat portion of a plunger ball seat, wherein the inwardly projecting prongs extend below central, antipodal points of the plunger ball to exert a compressive force on the plunger ball to retain the plunger ball in nesting engagement with the concave seat portion of the plunger ball seat.

[0187]Aspect B11. The plunger lift system of any of the preceding Aspects, wherein the plunger ball retention mechanism further includes a plurality of resilient legs extending longitudinally from the annular ring, wherein each of the plurality of resilient legs extends from the annular ring in a single direction, wherein the inwardly projecting prongs are disposed at a distal end of the plurality of resilient legs, wherein the inwardly projecting prongs extend through plunger ball retention passages formed in the plunger sleeve and into the central bore of the tubular main body of the plunger sleeve.

[0188]Aspect B12. The plunger lift system of any of the preceding Aspects, wherein the annular ring includes an outer wall, an inner wall, a top wall, and a bottom wall that delimit an interior space, wherein the inwardly projecting prongs are part of a wave spring that is contained in the interior space of the annular ring.

[0189]Aspect B13. The plunger lift system of any of the preceding Aspects, wherein the annular ring includes alternating band portions and plate portions, wherein the inwardly projecting prongs are connected to the plate portions, wherein the inwardly projecting prongs extend through plunger ball retention passages formed in the plunger sleeve and into the central bore of the tubular main body of the plunger sleeve.

[0190]Aspect B14. The plunger lift system of any of the preceding Aspects, wherein the plunger ball retention mechanism further includes a second annular ring, wherein each of the inwardly projecting prongs has a first end connected to the annular ring and a second end connected to the second annular ring, wherein an apex of each of the inwardly projecting prongs is between the first end and the second end, wherein the inwardly projecting prongs extend through plunger ball retention passages formed in the plunger sleeve and into the central bore of the tubular main body of the plunger sleeve.

[0191]Aspect B15. A plunger ball retention mechanism comprising: an annular ring; and inwardly projecting prongs coupled to the annular ring.

[0192]Aspect B16. The plunger ball retention mechanism of Aspect B15, further comprising: a plurality of resilient legs extending longitudinally from the annular ring, wherein each of the plurality of resilient legs extends from the annular ring in a single direction, wherein the inwardly projecting prongs are disposed at a distal end of the plurality of resilient legs.

[0193]Aspect B17. The plunger ball retention mechanism of any of the preceding Aspects, wherein the annular ring includes an outer wall, an inner wall, a top wall, and a bottom wall that delimit an interior space, wherein the inwardly projecting prongs are part of a wave spring that is contained in the interior space of the annular ring.

[0194]Aspect B18. The plunger ball retention mechanism of any of the preceding Aspects, wherein the annular ring includes alternating band portions and plate portions, wherein the inwardly projecting prongs are connected to the plate portions.

[0195]Aspect B19. The plunger ball retention mechanism of any of the preceding Aspects, further comprising a second annular ring, wherein a first end of each of the inwardly projecting prongs is connected to the annular ring, wherein a second end of each of the inwardly projecting prongs is connected to the second annular ring.

[0196]Aspect B20. A method comprising: producing a hydrocarbon fluid from a wellbore with a plunger lift system comprising the plunger assembly of any of the preceding Aspects; or retaining, by the plunger ball retention mechanism of the plunger assembly of any of the preceding Aspects while producing a hydrocarbon fluid from a wellbore, the plunger ball in contact with a plunger ball seat of the plunger sleeve.

[0197]Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the disclosure. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.