Multi-Well Plunger Lift Controller User Manual - · PDF fileMulti-Well™ Plunger Lift Controller User Manual Table of Contents 1 The 8000 Series ™ and Multi-Well brands are trademarked

Multi-Well™ Plunger Lift Controller User Manual

1Table of Contents

The 8000 Series™ and Multi-Well™ brands are trademarked by PCS Ferguson.

These documents and materials are copyrighted by PCS Ferguson.

© 2017 All rights reserved.

For information contact:

PCS Ferguson 3771 Eureka Way Frederick, CO 80516

Phone: 720-407-3550

Fax: 720-407-3540

Email: [email protected]

Website: www.pcsferguson.com


2 Table of Contents

1 Table of Contents

1 Understanding Plunger Lift Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.1.1 Plunger Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.1.2 Plunger Cycle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.1.3 Production on Site (provided by the site owner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1.2 Plunger Lift Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.2.1 Basic Modes of the Plunger Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1.2.2 Conditional Modes of the Plunger Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1.3 Optimization Programs, Production Methods, and Set Points . . . . . . . . . . . . . . . . . . . . . 131.3.1 Constant factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1.3.2 Variable factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1.4 Time Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.4.1 Time Set Points and the Basic Plunger Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

1.4.2 Pressure Set Points and the Time Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

1.4.3 Other Conditional Modes and Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

1.5 Pressure Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.6 Automatic Adjustment for Plunger Arrival . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171.6.1 Time Method with the AutoCycle Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

1.6.2 Plunger Arrival Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

1.6.3 Plunger Arrival Counts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

1.6.4 Automatic Time Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

1.6.5 AutoCycle Pressure Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

1.6.6 Automatic Adjustment of Pressure Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

2 Understanding Multi-Well Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272.1 Centralized Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.2 Synchronized Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.3 Basic Example of a Multi-Well System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.4 Master and Slave Well Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.5 Production Order in a Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Understanding Well Site Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . .32


3Table of Contents

3.1 On Site Communication with an 8000 Series Controller . . . . . . . . . . . . . . . . . . . . . . . . 32

3.2 Off Site Communication with an 8000 Series Controller . . . . . . . . . . . . . . . . . . . . . . . . 33

3.3 Well Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333.3.1 Well System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

3.3.2 Wireless Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

3.3.3 Wired Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

3.4 Security Access Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4 Configuring Automation of Multiple Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . .384.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.2 Configuration Task List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5 Preparing Plunger Lift Slaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.2 Task List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.3 Set the Well Identity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.4 Configure the Onboard Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.5 Set Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.6 Set the Slave’s Response if Master is Unavailable [Optional] . . . . . . . . . . . . . . . . . . . . . 50

6 Preparing a Remote IO Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.2 Task List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.3 Prepare the Remote IO Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.4 Reset the Modbus address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.5 View Data from the 8200 Remote IO Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7 Configuring the Multi-Well Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .557.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.2 Configuration Task List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.3 Reset the Modbus address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.4 Use the PC Clock to Set the Multi-Well Master’s Clock . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.5 Add Wells and Assign Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.6 Use the EFM Clock to Set the Multi-Well Master’s Clock [Optional] . . . . . . . . . . . . . . . . 60

7.7 Backup the Configuration Data [Optional] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61


4 Table of Contents

8 Enabling and Configuring the Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . .628.1 Configuration Task List for Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

8.2 Enable Onboard Inputs/Outputs on the Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

8.3 Configure Onboard Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

8.4 Configure Onboard Digital Inputs for Plunger Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8.5 Verification of the Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9 Configuring a Radio [Optional] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

10 Configuring Plunger Lift Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7110.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

10.2 Configure the Time Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

10.3 Configure a Pressures Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7310.3.1 Setup the Casing-Line Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

10.3.2 Setup the Tubing-Line Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

10.3.3 Setup the Casing-Tubing Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

10.3.4 Setup the Casing-Line/Tubing-Line Method (Multi-Well only) . . . . . . . . . . . . . . . . . . . . . . . . . . .78

10.4 Configuring the Time Method with AutoCycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8010.4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

10.4.2 Configuring the AutoCycle Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

10.4.3 Monitoring the AutoCycle Program Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

10.4.4 Modifying How AutoCycle Applies Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

11 Set Points for Plunger Lift Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8711.1 Control Production Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

11.1.1 Fall Time (All production methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

11.1.2 Close Time (All production methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

11.1.3 A Open Time (All production methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

11.1.4 Sales Time (All production methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

11.1.5 Delay Close Time (Pressure methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

11.1.6 Mandatory Shut-In Time (All production methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

11.1.7 Casing Peak Pressure Time (Pressure methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

11.1.8 High Line Pressure Shut-In Delay (All production methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

11.1.9 B Open Time (All production methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

11.1.10 B Delay Time (All production methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

11.1.11 Differential Open Pressure (Pressure methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92


5Table of Contents

11.1.12 Secondary Tubing-Line Pressure (Multi-Well C-L/T-L Pressure Method) . . . . . . . . . . . . . . . . .92

11.1.13 Secondary Pressure Mode (Multi-Well C-L/T-L Pressure Method) . . . . . . . . . . . . . . . . . . . . . .92

11.1.14 Load Factor (Fluid Slug) (Pressure methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

11.1.15 Casing Drop Pressure (Pressure Methods). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

11.1.16 Low Line Pressure Substitute (C-L, T-L, C-L / T-L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

11.2 Adjust Open Pressure Value (T-L or C-L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9511.2.1 Multiplier (T-L or C-L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

11.2.2 Threshold (T-L or C-L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

11.3 Adjust for Plunger Misses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611.3.1 Mode (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

11.3.2 Incremental Pressure (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

11.3.3 Increment Pressure, T-L (Multi-Well Only: C-L/T-L Pressures Method) . . . . . . . . . . . . . . . . . . . .97

11.3.4 Plunger misses before increment (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

11.4 Control Exit of SALES Mode (Pressure Methods Only) . . . . . . . . . . . . . . . . . . . . . . . . . 9711.4.1 D.I.P. Close Pressure (Pressure Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

11.4.2 Gas Low Flow Close Rate (Pressure Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

11.4.3 Critical Flow Constant (Pressure Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

11.5 Control Shut-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9911.5.1 Low Line Pressure (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

11.5.2 High Line Pressure (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

11.6 Specify Shut-in Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10011.6.1 Low Casing Pressure (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

11.6.2 High Casing Pressure (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

11.6.3 Low Tubing Pressure (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

11.6.4 High Tubing Pressure (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

11.6.5 High Surface Casing Pressure (All Production Methods) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

11.7 Control the Valve Timer for the Separator Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10111.7.1 Open timer, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

11.7.2 Open duration, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

12 Set Points for the AutoCycle Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10212.1 Overview of Arrival Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

12.1.1 Reset Defaults Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

12.2 Early Window Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10312.2.1 Enable Early Arrival Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

12.2.2 Hr Min Sec in the Early Window area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103


6 Table of Contents

12.2.3 Initial Count in the Early Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

12.2.4 Current Count in the Early Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

12.3 Fast Window Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10412.3.1 (Fast Plunger Time) (Hr Min Sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

12.3.2 Initial in the Fast Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

12.3.3 Current in the Fast Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

12.3.4 Hist (Read Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

12.3.5 Deduct from Off-Time in Fast Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

12.3.6 Add to Afterflow in Fast Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

12.4 Good Window Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10512.4.1 No Label (Hr Min Sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

12.4.2 Initial in the Good Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

12.4.3 Current in the Good Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

12.4.4 (History Read Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

12.4.5 Current Afterflow in the Good Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

12.4.6 Current Off-Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

12.4.7 Min Off-Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

12.4.8 Min Afterflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

12.4.9 Max Afterflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

12.5 Slow Window Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10812.5.1 Current On-Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

12.5.2 Initial in the Slow Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

12.5.3 Current in the Slow Window area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

12.5.4 (History Read-Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

12.5.5 Deduct from Afterflow in Slow Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

12.5.6 Add to Off-Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

12.6 No Plunger Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10912.6.1 Initial in the No Plunger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

12.6.2 Current in the No Plunger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

12.6.3 (History Read-Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

12.6.4 Add to Off-Time in the No Plunger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

12.6.5 Max Off-Time in the No Plunger Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

12.7 Pressure Overrides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11012.7.1 Open Tubing Valve (Production Valve) If Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

12.7.2 Close Tubing Valve (Production Valve) If Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

12.7.3 Plunger Open Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111


7Table of Contents

12.7.4 Plunger Close Adjustments Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

12.7.5 Safety Shut-Down (PSIG) Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

12.8 Controls for Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11212.8.1 Options for controlling adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

12.9 Activity History (Read-only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

13 8000 Series Walk Up Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11413.1 Basic Key Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

13.2 The Multi-Well™ Application Keypad Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

13.3 The AutoCycle™ Program Keypad Commands (Single-Well only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

14 Monitoring Tank Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12014.1 Understanding the Tank Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

14.1.1 System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

14.1.2 Tank Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

14.1.3 Alarms and Shut-Ins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

14.1.4 Polling Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

14.1.5 The Tank Configuration File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

14.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

14.3 Task List for Tank Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

14.4 Configure Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12414.4.1 Importing an OleumTech or iLevel Tank configuration file . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

14.4.2 Configuring Tanks in the WellVision Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

14.5 Tank System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

14.6 Monitoring Levels in the Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12714.6.1 Review Current Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

14.6.2 Review Tank Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

14.6.3 Respond to Tank Level Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

15 Viewing Graphs of Well Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13215.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

15.2 General Task List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

15.3 View a Basic Well Trending Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

15.4 View a Summary of Data within a Timeframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

15.5 View Details and Calculations within a Timeframe . . . . . . . . . . . . . . . . . . . . . . . . . . 136


8 Table of Contents

Appendix A: Multiwell IO Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Appendix B: Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142


9

Revision HistoryDate Description Version

6/1/2017 Initial Release 1.0


10 Understanding Plunger Lift Operations


Over time, a well’s gas production declines but a plunger lift system can increase a well’s productivity and life span. The natural pressure that lifts the gas from the well to the surface declines. Liquids collect in the wellbore or tubing and reduce the gas flow. If the liquids remain in the well, they eventually stop the gas flow. A plunger system lifts the liquids out of the well. Deliquification optimizes gas production and increases the life span of the well.

This chapter describes basic components of a plunger lift system, plunger lift functions, and your role in the operations.

NOTE For more information about configuring a well program, see the “Configuring Automation of Multiple Wells” section of this document.

1.1 Components The well system components of plunger lift operations are:

1 .1 .1 Plunger Components

• Plunger that acts as a well-bore swab

• Lubricator that catches the plunger when it surfaces and provides access for maintenance

• Arrival sensor that indicates when the plunger has surfaced

• Bottom hole bumper spring that cushions the plunger’s fall

1 .1 .2 Plunger Cycle Control

• Motor valve, a pneumatic valve, that controls gas flow

• Production Valve , a solenoid valve, that controls the motor valve

• Controller that uses a Well Program to control the Production Valve

• User interface such as the WellVision™ application, the WellTrekker™ application, or the Walk Up Display to direct the controller

• Analog and digital devices that provide data inputs the controller monitors

– Sales line pressure sensor

– Tubing pressure sensor

– Casing pressure sensor

– Other devices

• [Optional] Tank Valve a solenoid valve for a vent that can relieve backpressure on the Sales Line and assist the plunger cycle


11Understanding Plunger Lift Operations

1 .1 .3 Production on Site (provided by the site owner)

• Sales line

• Separator that separates gas, oil, and water

• Tank that stores the liquids removed by the plunger

Figure 1.1 The basic components of the Plunger Lift System in place



1.2 Plunger Lift CycleThe plunger system lifts the liquids using pressure from the gas flow. The plunger moves between the bottom hole bumper spring and the lubricator at the top of the well. The Motor Valve controls physical flow of the gas. The Production Valve controls when the Motor Valve is open and closed. When the Production Valve is closed, the gas flow is off. The plunger falls down the well, through the liquid, and to the bottom hole bumper spring. When the Production Valve is open, the gas flow is on. The natural pressure from the gas flow lifts the plunger. The liquids move ahead of the plunger, out of the well, and into a separator or directly into the tanks. The separator directs gas into the Sales line, oil to an oil tank, and water to a water tank.

The controller uses a Well Program to direct the components through the plunger cycle. The plunger cycle has modes. The Well Program specifies the modes used during the cycle. Using the Well Program, the controller optimizes production in response to the well conditions. The Well Program has production methods to simplify configuration of optimization. The user chooses a production method and enters set points to create a Well Program.

The following paragraphs describe the modes and production methods that the Well Program uses to optimize production.

1 .2 .1 Basic Modes of the Plunger Cycle

The plunger cycle has basic modes: FALL, CLOSE, A OPEN, and SALES. During FALL mode, the plunger returns to the bottom of the well. During CLOSE mode, the pressures build in the well. The well is not producing gas. During A OPEN mode, the plunger rises to the top with the liquids. After the plunger arrives, the Well Program uses SALES mode to produce gas.

The modes that the Well Program uses depend on the arrival of the plunger, on the production method, and set points. An arrival sensor detects the surfacing of the plunger. The controller monitors this sensor and other input devices. The controller compares the data inputs with the set points specified by the user in the Well Program. In the basic scenario for the Time method, after the plunger arrives, the controller directs the Well Program into SALES mode.

Each mode has primary set points and a group of secondary set points. The basic set points are periods of time or pressure values. Additional set points are values used in a calculation. The production method determines which set points the Well Program uses to exit and enter modes. For a basic example, the primary set points for the Time Method are Fall Time, Close Time, A Open Time, and Sales Time.

1 .2 .2 Conditional Modes of the Plunger Cycle

The controller and Well Program can respond automatically to well conditions. The well conditions affect the arrival of the plunger. A Well Program has a group of secondary set points that specify conditional modes: Line Delay, Mandatory Shut-In, B Open, and B Delay. These set points allow the plunger lift system to respond to the conditions of the well. The production method specifies which set points the controller uses to respond to well conditions.

To optimize production in response to well conditions, the Well Program has modes for using delay, shut-in, and the Tank Valve. Not all well systems have a Tank Valve, but a Well Program can use it to optimize production.



For an example of a delay, the basic mode, A OPEN, is a fixed time, A Open Time. However, well conditions can slow the arrival of the plunger. If the Well Program specifies the set point, Delay Close, the controller can allow production beyond the time set for A OPEN mode. The plunger does not arrive but gas continues to flow and the plunger continues to rise.

To close production in response to conditions, the system has a MANDATORY SHUT-IN mode. The primary set point for this mode is a time setting. However, the controller can use a pressure setting on the Casing to enter this mode. For example, if the plunger does not arrive during the time specified for the set point, A Open, the controller counts down the time interval specified by the set point and detects that the pressure on the casing is lower. After that time, the Well Program enters Mandatory Shut-in mode and production stops so that pressure can build to raise the plunger on the next plunger cycle.

1.3 Optimization Programs, Production Methods, and Set PointsThe user can specify a Well Program in the WellVision application. Using the information unique to the well, the user chooses a production method and specifies the set points. The controller uses this Well Program to evaluate the data inputs and direct operations.

The Well Program can include the following factors to adjust production. These factors apply to every production method.

1 .3 .1 Constant factors

• Tubing depth

• Tubing diameter

• Plunger type or style

1 .3 .2 Variable factors

• Sales line pressure

• Production ratio of gas-to-liquid

Some set points are common to all of the methods. These set points close the well to protect the gas lines from damage or can respond to possible damage.

For example, to monitor backpressure and protect the sales line, each method includes the following set points for that line:

• High Line Shut-in Pressure: The maximum pressure that the program allows on the line before automatically closing. To prevent shut-in due to spikes in pressure, the user can specify a delay time.

• High Line Pressure Shut-in Delay time: A period of time the controller samples the pressure. The controller uses the samples to decide if a high reading is temporary or steady. If temporary, production can continue. If steady, the program closes the well.

• Low Line Shut-in Pressure: The minimum pressure the program allows on the line before automatically closing the well.



NOTE Always enter values for these set points to protect the Sales Line. These settings can prevent ruptures or close the well in the case of a rupture. Also, set the Notifications tool to send a text or an email in response to alarms. For more information about the Notifications tool, see “Monitoring Well Performance“ in the Help Files.

The user can choose from several production methods. Each method employs specific primary set points and a group of associated set points. These set points allow the user to customize movement between the modes in response to well conditions.

The user can disable any set point by entering zero or a value too high to occur. (Zero time is 00:00:00; zero pressure is 0; high time is 99:59:59; and high pressure depends on the gauge).

The WellVision and WellTrekker applications offer the following production methods to optimize a well with the Plunger Lift System:

• Time method

• Time method with AutoCycle

• Casing pressure minus Tubing pressure

• Casing pressure minus Line pressure

• Tubing pressure minus Line pressure

• Casing pressure minus Line pressure or Tubing pressure minus Line pressure

The following paragraphs describe the methods and their set points.

1.4 Time MethodUsing the Time method, the controller manages the well using set points of time. The times for FALL, A OPEN, CLOSE, and SALES modes repeat for every plunger cycle. The Well Program offers additional set points to respond to well conditions. The following sections describe how the controller and the Well Program work together through the basic and conditional modes of the plunger cycle.

NOTE For more information, see the “Set Points for Plunger Lift Operations” section of this document.

1 .4 .1 Time Set Points and the Basic Plunger Cycle

A basic Well Program, that uses the time method, moves through the following modes using plunger arrival and time countdowns.

The controller closes the Production Valve and the Well Program enters the FALL mode. During FALL mode, the plunger drops. The controller counts down the time specified for Fall Time. The Well Program enters CLOSE mode. The controller counts down the time specified for Close Time. During the CLOSE mode, pressure builds in the well. The Controller monitors the data coming from the pressure sensors. However, the Well Program using a Time method does not use pressure readings to change modes. The controller continues to monitor pressures and the Well Program can use pressure settings to override the time settings.



After the Close Time expires, the Well Program enters A OPEN mode and opens the Production Valve. The controller counts down the time set in A Open Time. This setting should match the time the plunger usually takes to come up the wellbore and remove the liquids. The arrival sensor detects the surfacing of the plunger. The controller directs the Well Program to enter SALES mode. The controller counts down the time set in Sales Time. After the Sales Time expires, the controller directs the Well Program to enter FALL mode and closes the Production Valve. The process repeats. If the Sales Time is zero (00.00.00), the Well Program enters FALL mode. The user can turn off any set point for time with a value of zero (00.00.00).

1 .4 .2 Pressure Set Points and the Time Method

If the user specifies the set points for high and low line pressure, the Well Program responds to the pressure settings by entering DELAY CLOSE mode. The sequence of the modes depends on when the controller detected the High Line Shut-In pressure and the results of the sampling during the time set in High Line Pressure Shut-in Delay.

If the pressure sampling reveals the pressure spiked and then fell, the Well Program returns to the previous mode. The controller continues to count down the time set for that mode during the delay. The delay does not change the duration of A OPEN mode or SALES mode.

Well conditions change and the changes affect the plunger arrival. To respond to variations in the plunger’s arrival, the user can specify additional set points in the Well Program.

1 .4 .3 Other Conditional Modes and Set Points

The plunger might not surface as expected during A OPEN mode. The flow might be too low to raise the plunger or excessive backpressure might be the issue. To raise the plunger, the program must close the Production Valve for a time to build pressure or the system must relieve excessive backpressure through a Tank Valve.

Respond to no plunger by closing Production ValveTo close the Production Valve, the Well Program offers a set point, Mandatory Shut-in Time. After the A Open time expires, the controller checks for data from the arrival sensor. If the controller cannot verify arrival and the program provides a Mandatory Shut-In time, the controller directs the program into MANDATORY mode and counts down the time. After the time expires, the Well Program enters FALL mode.

Respond to no plunger by opening Tank ValveIf the system has a Tank Valve, the controller can direct the valve to open and vent the backpressure. With the backpressure relieved, the flow might raise the plunger and the sensor can detect the arrival.

To add this response to the program, the user specifies a B Open Time. After the plunger arrives and the time expires, the Well Program enters B DELAY mode. The program uses the B Delay Time before entering SALES mode. The controller counts down the Sales Time. The program enters FALL mode. The cycle repeats.



If the flow cannot raise the plunger with the backpressure released, then the program enters MANDATORY SHUT-IN mode. The controller counts down the Mandatory Shut-In time. When the controller detects the required pressure, the program enters OPEN mode. The cycle repeats.

NOTE For more information about using the Time Method, see the “Configuring Automation of Multiple Wells” section of this document. For more information about set points, see the “Set Points for Plunger Lift Operations” section of this document.

1.5 Pressure MethodsA well analysis might indicate that pressures instead of time would optimize production more effectively. The user can choose a production method that uses pressure differentials. The WellVision and WellTrekker applications offer the following calculations as methods.

• Casing pressure minus Tubing pressure

• Casing pressure minus Line pressure

• Tubing pressure minus Line pressure

• Dual Pressure Differential: Casing pressure minus Line/Tubing minus Line pressure

For each of these methods, the user specifies a differential in pressure based on the well’s conditions. The primary set point is Differential Open Pressure. The set point answers the question: “At what pressure difference, does the user want the Well Program to enter A OPEN mode?” Time still plays a role as the controller counts down Fall Time before evaluating the pressure differential. After the Fall Time expires, the controller evaluates the pressures. If the difference meets pressure criteria specified by the set points shown as a delta p (∆p), then the Well Program enters A OPEN mode.

Basis for differential Well opens if: Well exampleCasing pressure – Line pressure

Difference in pressure is greater than (>) the setting

Most well configurations

Tubing pressure – Line pressure

Difference in pressure is greater than (>) the setting

Well with a packer and no annular pressure

Casing Pressure – Tubing pressure

Difference in pressure is less than (<) the setting

Well with slow building casing pressures

Casing pressure – Line pressure or Tubing pressure – Line pressure (Multi-well only)

If both conditions are met or either one of them are met.

Wells that users want to respond to two differentials

Table 1.2 Production Methods and Pressure Differential

NOTE For more information about the pressure methods, see the Configuring Automation for Multiple Wells section of this document.



1.6 Automatic Adjustment for Plunger ArrivalThe Time Method with the AutoCycle program provides automatic adjustments using the plunger arrival and number of arrivals. Using the AutoCycle program, a Well Program uses initial settings, monitors the arrival of the plunger, and adjusts time or pressure settings. These adjustments fine-tune the production cycle for optimum plunger speed, liquid removal, and well performance.

For this method, the controller monitors and records data about the arrival of the plunger. The Well Program uses the AutoCycle program to respond with adjustments immediately.

1 .6 .1 Time Method with the AutoCycle Program

The AutoCycle program uses the plunger speed to optimize production. The user provides values for a set of arrival times. These values depend on the specific well. The arrival times indicate to the AutoCycle program the speed of the plunger. Given the depth of the well and the arrival time, the AutoCycle program calculates the speed by dividing the depth by the arrival time.

Maintaining an appropriate speed is critical to the production and safety of the well. Plungers that arrive too fast can damage wellhead components at the surface. This damage might lead to failure. Plungers that arrive too slowly might indicate that pressures are falling. The pressure might be too low to raise the plunger. To optimize production, the AutoCycle program uses a set of arrival windows. Each window type has a set of counters and a set of adjustments.

The following figure shows the basic plunger cycle and where the AutoCycle program windows affect production.

The following paragraphs provide more detail about the windows and their associated parameters.

1 .6 .2 Plunger Arrival Windows

The AutoCycle program makes the same adjustments to the Afterflow Time and Off Time that an on-site operator would make while tending the well. The AutoCycle program compares the actual time of arrival with the values of the set points for the windows.

Figure 1.3 Arrival Windows of the AutoCycle program



This comparison identifies the speed of the plunger and the category of arrival. Using this comparison, the AutoCycle program makes adjustments as described in the table below:

Plunger arrival Adjustments appliedGood None, within this window of time, the AutoCycle program does not make

adjustments. However, the program does identify minimum and maximum and maximum times. This arrival indicates best production of the well with an ideal arrival time. The depth of well divided by 800 equals the low limit of Good window. The depth of well divided by 600 equals the upper limit of Good window.

Fast Decrease down hole pressure; within this window of time, the plunger arrives too quickly. The AutoCycle program deducts from the Fall Time/Close Time (Off Time) and/or adds to the Sales Time (Afterflow time).

Slow Increase down hole pressure; within this window of time, the plunger has arrived too slowly. This indicates that the down hole pressure was too low. The AutoCycle program deducts from the Sales Time (Afterflow time) and/or adds to the Fall Time/Close Time (Off Time). The user can set options for No Afterflow on Slow Arrivals. The depth of well divided by 270 equals the upper limit of slow window.

No Increase down hole pressure if the plunger fails to arrive at the surface. The AutoCycle program deducts from the Sales Time (Afterflow time) and adds to the Fall Time/Close Time (Off Time).

No arrival might indicate well problems. If the plunger fails to arrive multiple times, The AutoCycle program informs the controller; the Well Program enters FALL mode and the well is shut-in. The controller raises a Plunger Error. The user needs to clear the error before production can resume.

Table 1.4 AutoCycle Program Adjustments

The user provides set points for times typical to the well. These set points define the windows of time so that the AutoCycle program can adjust the settings correctly. The arrival windows are dependent on the amount of time it takes for the plunger to reach the surface after the Production Valve (Tubing Valve) is open:



The figure below shows the area of the AutoCycle tab that specifies the values for evaluating plunger speed.

Figure 1.5 The set points in the Arrival Windows area on the AutoCycle program tab

The user provides the values for the plunger arrival times. The arrival time indicates the rate of speed. If the user knows the depth of the well, the user can specify the well information for the AutoCycle program. Given the depth of the well and the arrival time, the AutoCycle program calculates the speed by dividing the depth by the arrival time. (Distance/Time = Speed) Maintaining an appropriate speed is critical to the production and safety of the well. Plungers that arrive too fast can damage wellhead components at the surface. This damage might lead to failure. Plungers that arrive too slowly plungers might indicate that well pressures are falling. The pressure might be too low to raise the plunger. Maintaining a good plunger speed ensures safe and efficient production from the well.



The figure below shows the AutoCycle tab. The user can accept default values that are based on a depth of 8000 feet. The program can meet any level of control the user might want to apply. The user can supply an initial set of times specific to the well and allow the AutoCycle program to adjust automatically. Or the user can enter adjustments.

Figure 1.6 The AutoCycle Tab

To tailor the program to the well, the program has counters the user can change to match the characteristics of the well. The following section describes the counters and the section after that describes the adjustments.

1 .6 .3 Plunger Arrival Counts

The user can adjust the AutoCycle program by providing arrival counts that are associated with each window. Each window has an initial and a current counter.

• The Initial specifies the number of arrivals to match before the program responds. This count remains at the default value until the user changes it. The program does not adjust this number.

• The Current counter displays the number of remaining arrivals required to trigger a mode change. This counter reduces the value by one for each arrival in the window. When this counter equals zero (0), the program changes to the mode appropriate for the type of arrival.

The counts that close the well require the arrivals to be consecutive such as Early, Slow, or No Plunger. Requiring consecutive arrivals keeps the well open despite occasional plunger errors but triggers a shut-in for a pattern of errors. The counts that move the well program from A OPEN to SALES (AFTERFLOW) are nonconsecutive such as Fast and Good. The nonconsecutive counts



allow the well to produce for Fast or Good arrivals without interruption. The counters for Slow and No Plunger reset to the initial value immediately upon a Fast or Good arrival. The Early counter resets upon a Slow or No Plunger arrival. The counters for Fast and Good arrivals reset upon a Slow or No Plunger arrival.

The user needs to know the characteristics and pressures of the well to set the counts appropriately. No single set of values works for all scenarios. The default values are a basic set to begin operations.

Figure 1.7 The Default Values for Counts

Notice that the counts for the Fast Window are both zero (0). With these values, a Slow or No Plunger resets the Current to the Initial. Zero (0) triggers the SALES (AFTERFLOW) mode with the time adjustments for the Fast window. Therefore, a Fast Plunger always moves the program into SALES (AFTERFLOW) mode.

The same is true for the Good window default values. Notice that good arrivals have associated set points and not adjustments

• Current Afterflow (Sales Time)

• Current Off-Time (Close Time)

• Min Off-Time (Fall Time)

• Max and Min limits on Afterflow

Notice that the counts for the Slow window are equal at five (5). After five (5) consecutive Slow arrivals, the Current count is zero (0) and the program enters CLOSE mode. The program applies the time adjustments to influence the next cycle toward a Good arrival.



As long as the arrivals are in the Slow window, the program adds to the Off-Time (Close Time) and deducts from the Afterflow time (Sales Time) of the next cycle. The program continues to adjust the times until the plunger arrives in either a Good or Fast window. This change resets the Slow Count from zero (0) to the Initial count of five (5). The program continues to evaluate the arrivals and apply adjustments based on the arrival type and the counts.

The following table summarizes the description of the counts.

For the window…

Current shows # that are… Current Resets to Initial on…

Mode triggered when Current = 0

Early Consecutive Any other arrival type CLOSE

Fast Nonconsecutive Any Slow or No arrival SALES

Good Nonconsecutive Any Slow or No arrival SALES

Slow Consecutive Nonconsecutive and Fast or Good arrival

CLOSE*

No Plunger Consecutive Any Fast or Good arrival CLOSE * Unless the Enable Afterflow on Slow is selected on the AutoCycle tab

Table 1.8 Plunger Counts and Arrival Windows

The following section describes the adjustments for the arrival windows and the set points of the Good Window.

1 .6 .4 Automatic Time Adjustments

The AutoCycle program compares the actual time of arrival with the values of the window set points. This comparison identifies the speed of the plunger and the category of arrival. The program applies the adjustments to the Afterflow (Sales) time or the Off-Time (Close) if the plunger arrival is outside the Good Arrival window and the count for the window is zero (0). The adjustments can increase or decrease pressure to control the plunger speed. The Fast, Slow, and No Plunger windows have adjustment set points the user can specify.

• Afterflow (Sales): Afterflow (Sales) relieves pressure after the plunger arrives. Shorter Afterflow (Sales) relieves less pressure for the next Tubing On (Open) mode while longer Afterflow cycles relieve more pressure. Less pressure slows speed and increases time it takes for the plunger to arrive.

• Current Nff-Oime Adjustments: Tubing Off cycles allow pressure to build in order to lift the plunger and liquids to the surface. Longer Tubing Off (Close) modes result in more pressure buildup; shorter Tubing Off (Close) modes result in less pressure buildup. More pressure increase speed of the plunger and decreases the time it takes for the plunger to arrive.



Figure 1.9 Section of the AutoCycle tab for reading or specifying adjustments

Smaller Time AdjustmentsThe user can set the AutoCycle program to make proportional adjustments. Proportional adjustments are partial adjustments based on how far the plunger arrival is from the Good Arrival time.

NOTE If the arrival time is very close to the Good Arrival window use the option for proportional adjustment.

1 .6 .5 AutoCycle Pressure Set Points

The user can set the program to respond to pressure readings by using the Pressure Overrides feature. The user can specify pressure set points or differentials that move the program from A OPEN mode to AFTERFLOW (SALES) mode or to CLOSE mode.

The adjustments for the Casing Pressure, Tubing Pressure, and Differential Pressure Overrides on Fast, Slow, and No Arrivals are available.

The user can specify pressure set points that change the mode of the AutoCycle program under certain conditions. The following lists summarize the pressure conditions that trigger the production value (Tubing Valve) to open or close.

Open Production Valve (Tubing Valve) Overrides• If Casing pressure is greater than or equal to the set point

– Casing Pressure >=

• If Tubing pressure is greater than or equal to the set point

– Tubing Pressure >=



– If the differential of Tubing pressure and Line pressure is greater than or equal to the set point

– Tubing Pressure – Line Pressure >=

– Casing Pressure – Line Pressure >=

– Casing Pressure – Tubing Pressure <=

– Fluid Slug <= Casing Pressure – Tubing Pressure / Casing Pressure – Line Pressure

Close Production Valve (Tubing Valve) Overrides• If Casing pressure is less than or equal to the set point

– Casing Pressure <=

• If Tubing pressure is less than or equal to the set point

– Tubing Pressure <=

• If Line pressure is greater than or equal to the set point

– Line Pressure >=

– A delay time is optional

– Shuts in the well until the condition is no longer met

– High Line Delay Clear <Casing - Tubing <= (during afterflow)

– Flow Rate <= (during afterflow)

Safety Shut-Down – Casing Pressure >=





The figure below shows the AutoCycle Pressure Overrides dialog box.

Figure 1.10 The dialog box for pressure set points

By using the pressure overrides, the user sets the program to respond to the current pressure readings in addition to the passing of time.



1 .6 .6 Automatic Adjustment of Pressure Set Points

The user can set the program to adjust the pressure set points for the next cycle based on the plunger arrival.

Figure 1.11 Adjustments to Pressures for the Arrival Windows

After the user has enabled the program, the user can analyze the results of the optimization program.

NOTE For more information, see “Well Program Set Points for AutoCycle” in the Reference section of the Help Documents.


27Understanding Multi-Well Production

2 Understanding Multi-Well Production

The PCS Ferguson Multi-Well Masters, the 8800™ Site Manager and the 8400™, offer the Multi-Well™ application for controlling up to eight Plunger Lift Slaves. This document describes some of the typical components of a multi-well system and the advantages of grouping wells.

NOTE For information about tasks for configuring multi-well production, see the “Configuring Automation of Multiple Wells” section of this document.

The two advantages of using the Multi-Well application are to control multiple wells from one central location and to synchronize the production of multiple wells connected to one sales line and separator.

2.1 Centralized ControlOne Multi-Well Master can control up to eight Plunger Lift Slaves. The Multi-Well Masters have a keypad display but the primary user interface is the WellVision® application on a computer. The Plunger Lift Slaves are controllers at the site of each wellhead. These controllers do not have keypads or status displays. Typically, the user connects to the slaves through the master.

The Plunger Lift Slaves receive instructions from and reports information to the Multi-Well master. By default, if communications are lost, the Multi-Well master and the Plunger Lift Slaves continue their automation functions. The Multi-Well master reports the status for the slaves as “unknown.” The slaves continue their well program but wait for the Multi-Well master’s signal to open.

The WellVision application offers an Independence Mode for each slave that the user can enable. If enabled, the slave counts down 360 seconds from the time that communications with the master are lost. After 360 seconds, the slave, without direction from the master, continues its well program using the last data it has received. If the data sensors connect directly to the slave, it has the most current data and opens when ready. If the slave does not have direct access to current data, it uses the last values it received for inputs like casing pressure and tubing pressure and then opens when the data indicates that the well is ready. These values might be inappropriate if the well program is using differential pressures and one of the values, such as line pressure, is not current. For example, if the slave receives line pressure and flow from a translator, the values drop to zero and make the differential readings inaccurate.

NOTE For more information about setting this mode, see the Configuring Automation of Multiple Wells section of this document.

2.2 Synchronized ProductionIn Multi-Well scenarios, pressure backups can occur when multiple wells are flowing into the same production line. These backups happen when two or more wells are trying to sell gas simultaneously. The Multi-Well Master can prevent pressure backups by controlling the wells as a



group. For wells in a group, the Multi-Well Master allows one well to be open at a time. The other wells in the group are on hold even if they are ready to produce.

The user can manage a pad of wells and optimize production by configuring wells as part of a group. The user decides the exact groupings of the wells as appropriate for the well pad. For example, the user might have six wells and place all six into group one. Or, the user might want three producing as a group, two in a group, and one producing separately. The configuration in the following figure shows three groups containing the six wells.

Figure 2.1 Six Plunger Lift Slaves in three groups are under the control of one master

The application allows eight groups to provide the well system with one group for eight independent wells. The user must assign a unique group number to independent wells. However, to synchronize the production of a set of wells, the wells must be in the same group. The controller allows one well in the group to be open at a time. The other wells wait.

2.3 Basic Example of a Multi-Well SystemThe Multi-Well Master can manage a variety of components. This document uses a basic set of components as examples for configuring 8000 Series controllers in the WellVision application.



Figure 2.2 One Multi-Well Master can monitor and direct up to 8 Plunger Lift Slaves

The 8800 Site Manager is capable of expansion to many Modbus Remote Terminal Unit (RTU) devices.

NOTE For more information, contact a PCS Ferguson Sales and Service Representative.

2.4 Master and Slave Well ComponentsThe well system has one Multi-Well Master and multiple Plunger Lift Slaves. The Multi-Well Master hardware might be an 8800 Site Manager or an 8400. The Multi-Well Slave might be an 8200 Controller or a legacy controller such as the RM200. The system might also have devices that relay data such as an 8200 Remote IO Slave or an RM100. The Multi-Well Masters can support other third-party devices through a Translator or ISaGRAF automation program (8800 Site Manager only).

The Multi-Well Master monitors data and directs operations of the Plunger Lift Slaves. Each well has a Multi-Well Slave that has a well program, which directs the plunger lift operations.

The Multi-Well Master directs when each of wells open but the Multi-Well Slave specifies the period of time for each well mode. The slave uses the algorithms of the well program selected by the user. The slave records the times for the modes and the status of the well. The master polls this information from the slave to have all data in one central location for data viewing and logging purposes.



2.5 Production Order in a GroupThe Multi-Well Master uses the order that the user adds the wells to the WellVision application to determine the initial production order. When the user turns the master controller on, the controller prioritizes the wells based on the order that the user added the wells to the WellVision application.

For example, if the first well added is North Valley, and it is part of a group, this well is the first to open and sell gas. If North Valley is not ready, the Multi-Well Master queries South Valley in the same group. If South Valley is ready, the controller signals the Multi-Well Slave to open the Production Valve. The well program on the slave enters A OPEN mode.

Figure 2.3 The master polls the slaves in the order the user added them

The Multi-Well Master continues to poll the wells using the order that the user added them to the WellVision application. After a well enters A OPEN mode, that well moves to the end of the priority list.

Wells that were unready keep their position on the priority list. The next time the Multi-Well Master is ready to signal a well to open it polls the well at the top of the list. For example, if North Valley was not ready before it might be ready later. The Multi-Well Master polls the slave and then signals the Multi-Well Slave to open North Valley.

Priorities only affect wells within the same group. Independent wells in separate groups open when they are ready without regard to the status of wells outside the group. However, wells in separate groups can share a production line if the production line can handle the added pressure.



Figure 2.4 Groups with one well open independently when ready

NOTE For information about using the Multi-Well application, see the Configuring Automation of Multiple Wells section of this document.


32 Understanding Well Site Communications


The 8000 Series of controllers readily adapts to the communication requirements of the user and the well network. This document describes examples of the most widely used communication configurations for a well system.

This document organizes the communications into the following functions.

On site connections between the user and the 8000 Series controllers

Off site connection between the user and the 8000 Series controllers

Well Network between automation system components

NOTE For information, see “Connecting to Well Components” in the Guides section of the Help Documents. If the user wants to discuss details of their system, please contact a PCS Ferguson Sales and Service Representative.

3.1 On Site Communication with an 8000 Series ControllerThe user can connect to the controllers using wired or wireless communications. The wired options include a cable connecting directly to a serial port or the USB port.

NOTE For more information about the communications ports, see “8000 Hardware Diagrams and Specifications” in the Reference section of the Help Documents.

Figure 3.1 A connection with a USB cable

A user can connect through a laptop or a mobile device to the automation system. The 8000 Series controller needs an onboard Bluetooth® communication module to pair with a mobile device that is Bluetooth capable.


33Understanding Well Site Communications

Figure 3.2 Connection with Bluetooth

3.2 Off Site Communication with an 8000 Series ControllerThe user can connect through the internet. The user’s computer needs internet access. The 8000 Series Controller is capable of internet access through a modem. The following figures show the commonly used configurations.

Figure 3.3 A connection with TCP/IP

Setup of this communications network is outside the scope of this document.

NOTE For more information about customizing the 8000 Series controllers to an existing system or a designing a new system, contact a PCS Ferguson sales and service representative.

3.3 Well NetworksThe well network handles the communications between well components. The controllers use the Modbus protocol.



To enable communications, the user needs the following information about the device.

Modbus address Each well component must use the Modbus RTU protocol or have a wire to a Modbus RTU-enabled device. A Translator or 8200 Remote IO are examples of Modbus-enabled devices. Each device must also have a unique address. The user can find worksheets in the Help Files to plan and note the devices and Modbus addresses specific to the well system.

Baud Rate The baud rate set for the device must match that of the well system. The default baud rate for the well network is 9600 baud.

This section provides an overview of the commonly used well components and then a description of the well network between them.

3 .3 .1 Well System Components

A Well Site SCADA design is unique to every site but does have commonly used components. The following list shows the typical components the user might connect to and configure. PCS Ferguson continues to add to Well Site SCADA. Please visit the Web site for more information.

• Multi-Well Master: An 8800 Site Manager or 8400 with the Multi-Well application

• Wellhead controllers: One for each well, depends on the well system application

– Multi-Well can have 8 and they are called Plunger Lift Slaves

• Translator

• Remote IO

Typically, the user connects directly to a component to setup the automation system. After the initial setup, the user can connect, monitor, and configure all of the components through the Multi-Well Master.

NOTE For more information about setup, see the “Configuring Automation of Multiple Wells” section of this document.

3 .3 .2 Wireless Communications

The well network can use a variety of radios for communicating.

To communicate, the user must configure the radios to use the same Preamble (HP) and Network ID (ID) as the well network. To prevent interference, each well network in the area needs unique values for the Preamble and Network ID.

Figure 3.4 An example of a radio


35Understanding Well Site Communications

3 .3 .3 Wired Communications

Site conditions might require a wired network for communications. The 8000 Series Controllers have a communication port that supports RS-485.

Figure 3.5 RS-485 ports on a circuit board

For some applications, the well network might include an auxiliary network. The 8800 Site Manager and the 8400 provide a communication port to meet those needs. The AUX port supports RS-485 or RS-232 communication. Typically, well networks use RS-485 for AUX communication. Most PCS Ferguson firmware does not use the AUX port, but might in the future. The user might need to program the firmware to adapt to use the AUX port for custom purposes.

Figure 3.6 AUX port capable of RS-485 or RS-232 signals

NOTE For more details about the ports on the circuit boards, see 8000 Hardware Diagrams and Specifications in the Reference section of the Help Documents.



3.4 Security Access CodesThe PCS Ferguson 8000 Series components have two areas that the user can implement security access codes.

Remote Access Security: The user can add a security code to a wellhead controller. After enabling this feature, the WellVision application requests the code if the user connects with a remote connection. The user must enter this code to change the configuration on the controllers. Without entering the code, the user can view the controller’s tabs, but cannot set any changes. This feature is available in the Settings area of the controller’s Setup tab. This code is four (4) digits.

Walk Up Display Security: The user might want to prevent or limit the types of changes a user can make with the Walk Up Display. Configuration of this feature is only available using the WellVision application.

The figure below shows the limitations before and after the user configures the feature in the WellVision application.

Figure 3.7 Access Codes Limit the Available Commands on the Walk Up Display

The user can configure ten (10) unique administrator codes and ten (10) unique operator codes. Code assignments and policy decisions are not within the scope of this document. Operator access allows the user to complete most operations and settings for well operations. The administrator has access to commands for completing system level operations such as changing the Modbus address for the controller. The data log includes the access PIN for entries noting changes to the configuration.

NOTE For more procedures to configure the access codes, see “Connecting to Well Components” in the Guides section of the Help Documents. For more information about the keypad commands, see the “8000 Series Walk Up Display” section of this document.


37Configuring Automation of Multiple Wells

4 Configuring Automation of Multiple Wells

The 8800™ Site Manager and the 8400™ provide a well pad with master control of the plunger lift system, communications with third party devices, and general field automation. The Multi-Well Master continuously monitors the overall well system and the 8200™ Plunger Lift Slaves that control the individual wells. The Plunger Lift Slaves use the configuration settings to optimize the well’s production. The well pad might use 8200™ Remote IO devices to gather remote data. The master requests the data from the Remote IO and then sends it to the appropriate Multi-well Slave.

NOTE For more information, see the “Understanding the Multi-Well Application” section of this document.

The following list and figure show an example of a basic set of components the user might configure in the WellVision® application. The system can include but is not limited to the examples in the figure.

Automation Devices1. Multi-Well Controller The controller such as an 8800 Site Manager or 8400 with the Multi-

Well™ application

2. Multi-Well Slave The well head controller that contains all the well specific setting for the well it monitors such as an 8200 controller

3. Remote IN If needed, an 8200 remote IO device to relay data

Plunger Lift1. Digital output Devices such as the solenoids controlling the valve that opens and closes the

well

2. Analog input Devices such as the transducers for the pressure gauges

3. Digital input Devices such as the plunger arrival sensor that detects the arrival of the plunger

Production1. TElectronic Flow Meter The meter that measures the flow of gas

2. Oank system The site’s system for detecting tank levels



Figure 4.1 The user configures the components of the well system

4.1 PreparationFor successful setup and configuration of the Multi-Well Master, the user needs the following items installed and operational.

User’s Interface• WellVision application installed on a computer

User Connections (Choose 1)• Local Operator Interface (LOI)

• Cell modem

Hardware and Firmware• Multi-Well Master such as an 8800 Site Manager or 8400

• Multi-Well Slave for each well such as an 8200 Controller

• As needed, Remote IO such as an 8200 Remote IO

• Single or dual latch valve assembly to control the valves

• Other data I/O devices: transducers, translator, pressure gauges, tank level devices, and Electronic Flow Meter (EFM) for sales line pressure.

Well Network Communications• Wireless communication network such as radio

• Wired communication network on 485 or 232 communications bus



Configuration Information• Plunger Lift Slaves

– Modbus addresses

– Pressure transducers and all other analog or digital devices

– Shut in Switch settings

– EFM settings

– Preferred production method and associated set points

• Remote IO

– Modbus addresses

– Pressure transducers and all other analog or digital devices

– Shut in Switch settings

– EFM settings

• Multi-Well Master

– Modbus address (default is 5)

– Baud rate

– Translator address [Optional]

4.2 Configuration Task ListThe user needs to configure the Plunger Lift Slaves and the Multi-Well Master. If applicable, the user might configure remote IO devices or a Translator. This document cannot anticipate the design of the user’s well system. The user needs to evaluate which tasks are appropriate and what order to complete them. The Help Files include a worksheet for specifying the details of the user’s system.

The tasks in this document progress from the Plunger Lift Slaves, to the remote IO devices, to the translator, and finally the Multi-Well Master. The user can complete many of the tasks for the Plunger Lift Slaves and remote IO devices through the master. These procedures assume that the user connects locally to each Multi-Well Slave before configuring the Multi-Well Master. Connecting directly to the controller or device prevents issues from the well system network from masking configuration issues.

The following table shows a summary of the tasks the user completes to set up automation for a Multi-Well system.



Figure 4.2 Example of a Multi-Well Slave

Configure each Multi-Well Slave (direct connect). See “Preparing Plunger Lift Slaves” in this document.

• Set up well identity (Modbus address and well name).

• Configure the analog and digital inputs/outputs. See “Enabling and Configuring the Inputs and Outputs.”

• Configure the Shut in switches and other settings.

• Configure the production method. See “Configuring Plunger Lift Operations.”

• If applicable, set up radio communication to the master. See “Configuring a Radio” in this document.

Figure 4.3 Example of a Remote IO

If applicable, configure each Remote IO (direct connect). See Preparing a Remote IO Slave” in this document.

• Configure the Modbus address

• Configure inputs for each of the wells.

• Configure the Shut in switches and other settings.

• Configure the transducers.

• Configure other inputs and outputs (tank top level switch, a custom Shut in button, depending on the well system.

• Setup radio communication to the master, if necessary.

Figure 4.4 Example of a Multi-Well Master

On the Multi-Well master, do the following:

• In WellVision, set the date and time on the Multi-Well Master using the clock on the PC.

• Add wells and assign them to groups.

• Enable all devices in the well network with their appropriate Modbus address.

• Set the clock to match the EFM, if available

• Setup radio communication, if necessary

• Verify that the IO values are from the appropriate well.

• Back up the configuration data



This document assumes a direct connection from the computer using a USB cable to the circuit board.

NOTE For information about connection options, see “Connecting to Well Components” in the Guides section of the Help Files.

To connect directly using the LOI1. Attach the cable from the computer to the LOI port.

– For the 8800 Site Manager and 8400, use the LOI port on the keypad display or on the circuit board.

– For the 8200 Controller, use the port on the circuit board.

Figure 4.5 The user can connect to the LOI port on each circuit board

2. On the computer, open WellVision and select Connect Direct on the WellVision toolbar.

3. In the Connect dialog box, verify that the Modbus address is correct. The factory default value is five (5).

4. From the Connect to menu, select the controller or device for the connection.

For example, the menu has Direct Multi-Well Slave Setup, Direct Remote IO Setup, Translator Setup, and Multi-Well Master for each of the components.

5. From the CNM port menu, select PCS Ferguson 8000 Series USB (CNM#), and then select Connect.


42 Preparing Plunger Lift Slaves

5 Preparing Plunger Lift SlavesTypically, a well pad has a Multi-Well Slave for each wellhead. The user needs to configure each controller based on the well components wired to it. These components are onboard or local to the Multi-Well Slave.

Figure 5.1 An example of a slave with transducers and plunger sensor configured onboard

5.1 PreparationThe user needs the following information to complete the tasks for configuring a slave.

• New Modbus number

• Descriptive well name

• Specification information for onboard Inputs/Outputs

• Alarm preferences

5.2 Task List• The user can prepare each controller by completing the following tasks before adding them to

groups on the multi-well master.

– Set up the identity of the multi-well slave: Modbus address and well name

– [Optional] Set the security code

– Configure the analog and digital inputs/outputs

– Configure the alarms

– Configure Communication to the Multi-Well Master. The slave might have a radio onboard; see the Configuring a Radio section of this document.

5.3 Set the Well IdentityThe user needs to reset the Modbus address from the factory default to a unique address on the Well system. In addition, the user might want to add a descriptive name to the well. For


43Preparing Plunger Lift Slaves

example, company personnel might identify a well by its location, a numbering system, or other characteristics.

The following procedures describe how to specify the identity of a well. The user needs to complete these steps for each multi-well slave in the well system.

To reset the Modbus address1. Open WellVision, and connect to the Multi-Well Slave using the default Modbus address of

five (5).

2. On the Setup tab, select the Modbus/serial button in the Communications area.

NOTE The default address allows the initial connection and configuration. The user should reset the address to a number unique in the well network. This unique address prevents communication conflicts on the RS-485 network.

Figure 5.2 The Setup tab provides options for configuring a well

3. In the Change Modbus Address box, enter a number for the new address and select the Set button.

Figure 5.3 The use can reset the Modbus address and the port baud rates

4. In the Change Port Baud Rates area, specify the rate that matches the well system.

5. Select the Set button and then the Close Window (X) button.



For future connections to the slave, the WellVision application can detect the Modbus address of the device and connect immediately.

To set a descriptive well name [Optional]1. Open WellVision and connect to the well.

2. On the Setup tab, select the Well ame button in the Settings area.

Figure 5.4 The Settings area of the Controller Setup tab has the option to set a well name

3. In the Well ame dialog box, enter a name and select the Set Well ame button.

Figure 5.5 The yellow highlight indicates a change in value

NOTE A name can be 30 characters long including spaces.

4. Select the Close button.

5. Verify that the new name appears in the Well window.

To set a security code [Optional]1. Open WellVision and connect to the well.

2. On the Setup tab, select the Security Code button in the Settings area.

Figure 5.6 The Settings area of the Setup tab has the option to set a security code



3. In the Set New 4 Digit Security Code box, enter four (4) numbers for the well’s code.

Figure 5.7 The highlight shows the value is a change

4. Select the Set button.

5.4 Configure the Onboard Inputs and OutputsThe user needs to specify in the WellVision application which input and output devices are wired to the Multi-Well Slave. The following procedure describes how to enable devices, but cannot anticipate the configuration of the user’s slave. If the user completed an inventory and configuration worksheet, the user can specify inputs and outputs based on that information.

To enable and configure devices wired to the slave1. Open WellVision and connect to the Multi-Well Slave.

2. On the Setup tab, select TEnabled for the transducers in the Inputs/Nutputs area, as appropriate for the slave.

Figure 5.8 Some slaves have devices wired to the circuit board

3. If appropriate, select TEnabled for A Npen with B to control the valves.

NOTE Some well systems use a Valve B to release pressure through a vent. The user might set this to affect the plunger arrival times depending on the system configuration and the well conditions.



Figure 5.9 The Setup tab includes a valve control option

4. Select the Nnboard Analog/Digital button to specify the details for the inputs and outputs for the slave.

Figure 5.10 In this example, the user sets both analog and digital inputs

5. Select the Set Configuration button for each pane and then select the Close Window (X) button.

NOTE For more information about using this dialog box, see the “Enabling and Configuring the Inputs and Outputs” section of this document.

5.5 Set AlarmsDuring operations, the well conditions change and can indicate minor problems that need attention and actual emergencies that require an immediate shut in. The changes can affect the health of the well and its components (i.e. Plunger, Lubricator, etc.). The user can setup alarms to display notes in the Alarms area of the Well Status tab for selected conditions. The controller only displays notes for alarms that the user has enabled on the Setup tab. The user monitoring the well can judge how to react to the alarm conditions.



To set alarms1. Open WellVision and connect to the slave.

2. On the Well Status tab, select the Configure Alarms button in the Alarms area.

Figure 5.11 The Configure Alarms button is on the Well Status tab

3. In the Alarm Configuration dialog box, select the options appropriate for the well system.

NOTE The user can return to the previous settings by selecting the Read button or set every alarm by selecting the Check All button.

Figure 5.12 Some basic alarms are valuable for all well systems



Choose this alarm To display a note for this conditionLow battery voltage—well shut in The battery is low and the well was shut-in

Casing Press. Comm. Failure Communications with the device need attention

Casing Pressure is Zero No pressure, check conditions

High Casing Pressure The pressure has met the set point for the high value.

Low Casing Pressure The pressure has met the set point for the low value

Device Reset, Clock needs Set The device reset and the clock is incorrect

Flow Rate Comm. Failure Communications with the device need attention

Gas Temperature Comm. Failure Communications with the device need attention

Line pressure Comm. Failure Communications with the device need attention

Line Pressure is Zero No pressure, check conditions

High Line Pressure The pressure has met the set point for the high value

Low Line Pressure The pressure has met the set point for the low value

Sensor Comm. Failure Communications with the device need attention

Sensor Shorted Plunger arrival sensor needs attention

No Plunger Arrival Plunger arrival sensor or well settings need attention

Separator Temp Comm. Failure Communications with the device need attention

Separator Temperature The temperature switch is activated.

Surface Casing Comm. Failure Communications with the device need attention

Surface Casing High The pressure has met the set point for the high value.

Tank Level <x> Comm. Failure (1-5) Communications with the device need attention

Tank SW 1 Comm. Failure (1-5) Communications with the device need attention

Tank Switch <x> Triggered (1-5) Conditions triggered the switch on tank x and needs attention

Tank Level <x> High (1-5) The level in tank x is high and needs attention

Tubing Press. Comm. Failure Communications with the device need attention

Tubing Pressure is Zero No pressure, check conditions

High Tubing Pressure The pressure has met the high value for the set point.

Low Tubing Pressure The pressure has met the set point for the low value

Remote Production Valve incorrect The state of the Production Valve is unknown

Remote Tank Valve incorrect The state of the Tank Valve is unknown

Stuck Valve Detected The valves need attention

Production Valve Comm. Failure Communications with the device need attention

Tank Valve Comm. Failure Communications with the device need attention

Undefined alarm Reserved for future specification

Table 5.13 Descriptions of Alarms

4. Select the Set button and then the Close button.

NOTE Always select the Low Battery Voltage alarm. If the controller detects low voltage, it shuts the well to prevent damage to the well system. If the user does not set this alarm, the controller can lose power and fail. The well might remain open.



The WellVision application can monitor and respond to a tank level system.

NOTE For more information, see the “Monitoring Tank Levels” section of this document.

The user can set the WellVision application to send notifications as emails or SMS text messages when conditions trigger an alarm.

NOTE For more information, see Notifications in “Monitoring Well Performance” in the Help Documents.

5.6 Set the Slave’s Response if Master is Unavailable [Optional]The user can set the slave to open without a command or data from the master. The WellVision application offers an Independence Mode. By default, the application disables this mode because the well site configuration determines the mode’s usefulness.

NOTE Only enable Independence Mode for Plunger Lift Slaves that connect directly to the inputs that the well program uses and well sites with a production line can handle flow from multiple wells working independently.

To enable Independence Mode1. Open WellVision and connect to the slave.

2. On the Well Status tab, select TEnabled in the Independence Mode box in the Communications area.



50 Preparing a Remote IO Slave

6 Preparing a Remote IO SlaveThe well system might include other components, such as pressure gauges or switches, located offsite from the master or Plunger Lift Slaves. The user can configure 8200 Remote IO devices to relay additional data to the controller. Before completing these procedures, ensure that the device is installed and operational.

Figure 6.1 Valves wired to an 8200 Remote IO Slave

These devices communicate using the Modbus protocol. The Remote IO device reads the data from the analog and digital inputs that are local to it. These inputs are onboard analog and digital readings. The Remote IO device then relays the data to the controller. The controller reads the data and optimizes well operations.

The following procedure describes how to enable the Remote IO. The steps to configure the inputs and outputs on a Remote IO are the same as those for the controller. The user can follow the steps in the Enabling and Configuring the Inputs and Outputs section of this document.

6.1 PreparationThe user needs to configure the Remote IO device to match the configuration of the well system. The factory sets the Modbus address to five (5) for the initial connection at the well site. After connection, the user can configure the following settings:

• New Modbus address of each Remote IO

• If applicable, analog and digital inputs/outputs

• If applicable, radio communication settings for remote communications

– Preamble (Hopping Channel)

– Network ID (Destination Address)

6.2 Task List• Reset the Modbus address

• Configure the radio [Optional]

• View the data


51Preparing a Remote IO Slave

6.3 Prepare the Remote IO SlaveThe well system might require Remote IO Slaves. The device must be installed and operational.

The user needs the following connection information for the Remote IO Slave:

• Modbus address (factory default is 5)

• Baud rate

6.4 Reset the Modbus addressThe user can connect to the Remote IO device directly. After connecting, the user needs to reset the Modbus address to prevent conflicts in communications.

To connect to a Remote IO Slave1. At the well site, connect a USB cable to the PC and to the LOI port on the 8200 Remote IO

Slave.

2. Open WellVision, and select Connect Direct.

3. In the Connect dialog box, enter the factory default, 5, In the Modbus Address box.

4. From the Connect Oo box, select Direct Remote IN Setup.

5. Select a connection option and specify the settings.

6. Select the Connect button.

To reset the Modbus address1. Open WellVision, and connect to the Remote IN Slave to open the Remote IN Window.

2. On the Setup tab, select the Modbus/serial button in the Communications area.

NOTE The default address allows the first connection and configuration. The user should reset the address to a number unique to the system. This unique address prevents communication conflicts on the RS-485 network.

Figure 6.2 The Setup Tab has a Communications area



52 Preparing a Remote IO Slave

Figure 6.3 The Change Communication Settings dialog box is available from the Setup tab


6.5 View Data from the 8200 Remote IO SlaveThe user can verify the configuration of the Remote IO Slave. The Status tab shows values from the inputs. The user can also verify the digital inputs by viewing the frequency of the communications.

To get status from a Remote IO Slave1. Open WellVision, and connect to the Remote IN device.

2. On the Status tab, review the data.

Figure 6.4 The Status tab for a Remote IO Slave shows the current data for devices


53Preparing a Remote IO Slave

3. To update the data, select Refresh Status.

4. To automate updates to the view, select the Refresh TEvery option and enter a number in the Seconds box.

The user can review the pulse counts for digital devices connected to the Remote IO Slave. The Pulse Counters track and display the daily counts for up to 10 days.

To examine digital counts1. Open WellVision and connect to the Remote IO Slave.

2. On the Counters tab, view the number of digital pulses coming from the digital devices.

For example, the user might want to view the counter for calculating liquid flow for a turbine meter.

Figure 6.5 The Counters tab shows the number of digital pulses

3. Close the Remote Device IN window.


54 Configuring the Multi-Well Master

7 Configuring the Multi-Well MasterThe Multi-Well Master provides a single point for monitoring, analyzing, and updating the configuration of the well system.

Figure 7.1 Configuration of the Multi-Well Master allows synchronization of multiple wells

This document assumes that all of the well components are installed and operational.

7.1 PreparationThe documentation set has a multi-well inventory worksheet available under the Worksheets folder on the Help Files menu. Using this worksheet, the user can note the Modbus addresses and other information needed to configure the Multi-Well Master.

• Modbus address (default is five (5))

• Baud rate

• Translator address [Optional]

7.2 Configuration Task List• Reset the Modbus address from the default

• Set the date and time on the Multi-Well Master

• Add wells and assign them to groups

• Enable and configure other devices communicating with the master

• Set clock to match the EFM [Optional]

• Verify the inputs and outputs

7.3 Reset the Modbus addressTypically, the user does this step one time. The default address allows the initial connection and configuration. The user should reset the address to a number unique to the system. This unique address prevents communication conflicts on the RS-485 network.


55Configuring the Multi-Well Master

To reset the Modbus address1. Open WellVision, and connect to the Multi-Well Master using the default Modbus address of

five (5).

2. On the System Setup tab, select the Modbus/serial button in the Communications area.

Figure 7.2 The System Setup tab has the communications settings


NOTE The Multiwell Master, and only the Multiwell Master handles extended Modbus addressing. This means a valid Modbus address can range from 1-32766.

Figure 7.3 The use can reset the Modbus address and the port baud rates

4. In the Change Port Baud Rates area, specify the rate that matches the well system.




7.4 Use the PC Clock to Set the Multi-Well Master’s ClockDate and time are crucial data for automating and optimizing the well system. All of the controllers and devices need to use the same standard. For setup purposes, the user synchronizes the Multi-Well Master to the PC.

Later, if the system includes an EFM, the clock on the EFM becomes the standard for operations. To prevent data loss from a time change, the user can save the data logs to the PC and then continue configuration.

To synchronize with the PC’s clock1. Open WellVision and connect to the Multi-Well Master.

2. On the System Setup tab, select the Refresh button in the Well Clock area.

Figure 7.4 The Well Status tab has the option to use the PC clock as the time standard

3. Compare the time for the Well Clock with the PC’s clock and decide if the potential data loss is acceptable.

4. If the potential loss is acceptable, select Sync Clock.

5. Select Close.

The data logs use the new time and the user can continue configuring the well.

7.5 Add Wells and Assign GroupsOn the Multi-Well Master, the user can add the wells, assign groups, and enable inputs and outputs. The user must add the well’s Modbus address to specify a well. However, the user can add and update the other configuration information in any order. To complete these tasks, the user needs the following information for each well.

• Modbus addresses associated with the Plunger Lift Slaves

• Modbus addresses for remote sources of data such as a Remote IO Slave or Translator

• Group numbers

To add a well and assign a group1. Open WellVision and connect to the Multi-Well Master.



Figure 7.5 A column represents a well; the rows set the configuration

2. On the Configure All Wells tab, select appropriate values for the configuration of each well in the well system. The figure and list that follow provide an example and descriptions.



Figure 7.6 Multi-Well Slave with an associated Remote IO Slave

3. For each well, select the appropriate option in the rows.

For each well OptionsGroup Group numbers 1-8

Modbus Number for the Modbus address of the Multi-Well Slave on the well

Production Valve and Tank Valve

WC Local Modbus address for a device Disabled

Pressure readings WC Local Modbus address for a device Disabled

Temperature readings WC Local Modbus address for a device Disabled

Shut in switches 1-5 WC Local Modbus address for a device Disabled

Flow EFM WC Local Modbus address for a device Disabled

Read Today/Yesterday Accumulation

Yes or No Availability depends on the EFM

Translator has accumulation Yes or No



For each well OptionsAssign closed flow to the “9th well

Yes or No

Synchronize clock to the EFM

Yes or No

Enable Sleep Control Yes or No

Meters: Oil and Water WC Local for Multi-Well Slave Modbus address for a device Disabled

Table 7.7 Descriptions of the columns of the Configure All Wells Tab

7.6 Use the EFM Clock to Set the Multi-Well Master’s Clock [Optional]This setup option sets the clock of the Multi-Well Master and all Plunger Lift Slaves to match the clock of the EFM. The WellVision application recognizes only the EFM on the well that the user first adds to the Multi-Well Master. After the initial setup, the Multi-Well Master uses the EFM clock to synchronize the Plunger Lift Slaves every hour.

To synchronize with the EFM Clock on the first well1. Open WellVision and connect to the Multi-Well Master.

2. On the Configure All Wells tab, scroll to the Synchronize Well Clock to Ohis TEFM option in the column for the first well.

Figure 7.8 The Configure All Wells tab has the option to synchronize to the EFM clock

3. Select Set Config to commit the change.



7.7 Backup the Configuration Data [Optional]After configuring the master, the user can back up the initial configuration data. The system maintains a daily back up in the evening. However, the user can safeguard the data by making a backup immediately.

To perform a backup1. Connect to the Multi-Well Master.

2. On the System Setup tab, select the File System button.

3. In the File System Operation dialog box, select Backup the configuration to the Internal Flash from the box in the Advanced Nperations area.

Figure 7.9 The backup operation is available in the File System Operations dialog box

4. Select the Start button and then note the progress and result in the Status area.

5. This operation creates a backup version of the configuration data currently stored in RAM to the NAND flash drive.


61Enabling and Configuring the Inputs and Outputs

8 Enabling and Configuring the Inputs and Outputs

The user specifies the inputs and outputs in WellVision by enabling the source device and then by specifying the individual devices connected to that source. For example, the controller might have the solenoids directly wired to the Multi-Well Slave (local) but a Remote IO Slave has the transducers for the pressure gauges. The user can complete the following procedures to configure the inputs and outputs.

NOTE The documentation set offers a worksheet, Multi-Well IO Planner, the user can complete to simplify configuration and avoid mistakes in the field. See the Worksheets for Well Site SCADA folder of the Help Documents.

8.1 Configuration Task List for Inputs and Outputs• Enable the port for the inputs/outputs on the component’s setup tab.

• Specify the details for the device using that port in the Analog Digital Configuration dialog box.

8.2 Enable Onboard Inputs/Outputs on the ComponentFor each component, the user needs to enable the ports on the components.

To enable the inputs and outputs1. Open WellVision and select Direct Connect to connect to the appropriate component with the

onboard inputs and outputs to configure.

– Multi-Well Master

– Multi-Well Slave

2. On the appropriate tab, select the Nnboard Analog/Digital button in the Inputs/Nutputs area.

– Multi-Well Master—System Setup tab

– Multi-Well Slave—Setup tab

3. For each item in the Inputs/Nutputs area, select the appropriate value.

– If wired to the controller, select Local

– If wired to a remote device, select the Modbus address for that device such as an 8200 Remote IO Slave

– If not in use, select Disabled.




8.3 Configure Onboard Analog InputsThe user needs to configure the analog channels to detect and report the data specific to the sensor, transducer, meter, or other input. The channels match the inputs/outputs on the circuit board.

The following table describes the Configuration options in the Analog pane.

Analog Input Associated Device Typical UsePressures:

Casing Tubing Line Surface Casing

Transducers Plunger Lift

Temperature Temperature probe Gas Lift Manager

Pressure Aux 1-2 Transducers Gas Lift Manager

Temperature Aux 1-2 Temperature probe Gas Lift Manager

Pressure Manifold 1-4 Transducers Gas Lift Manager

Valve position Well 1-8 Valve positioner Gas Lift Manager

Table 8.1 The Analog pane offers several configuration options

To complete the following procedure, the user must know the transducer type for each analog input. The WellVision application keeps a database of common transducers and specifications. The user can select a common one from the list or specify a custom transducer.

When a user selects a transducer from the common list, the application uses the specifications for the model to configure it automatically.

To configure a common transducer1. Open WellVision and connect to the PCS Ferguson device.

2. On the Setup tab, select the Onboard Analog/Digital button.

Figure 8.2 The button is available on the setup tabs for all three devices

3. In the Analog Digital Configuration dialog box, locate the Analog Inputs pane.



Figure 8.3 The Analog Inputs pane specifies inputs

4. In the Oransducer column for the analog input, select the transducer from the list.

Figure 8.4 The database has common transducers and settings

5. Select the Set Configuration button below Analog pane.

The well system might use a transducer that is not in the WellVision database. Using the WellVision application, the user can configure other transducers.

To configure a custom transducer1. In the Inputs/Nutputs area, select the Nnboard Analog/Digital button to configure inputs.

2. In the Analog Digital Configuration dialog box, locate the Analog Inputs pane.

Figure 8.5 The Analog Digital Configuration dialog box configures a list of analog inputs

3. In the Oransducer column, select Custom and then enter the appropriate settings the row for the device.



NOTE The user can find the settings for specific devices in the documentation provided by the device manufacturer. For general information, see the table below the figure.

Figure 8.6 The Analog provides a custom option to specify devices unique to the well system

Column Value based on Example

Channel Circuit board location (Read-only) AIN1 label on board

Configuration User selection Pressure Casing

Transducer User selection ECP-T3000F 1000 PSI

Description Transducer 1000 PSI

Min scale Transducer 0

Full scale Transducer 1000

Input range Transducer 1-5 V

Status Real-time data * (Read-only)

Input voltage Real-time data * (Read-only)

AD count (Out of 4095) Real-time data * (Read-only)

* Real-time data is available after selecting the Set button to configure the inputs.

Table 8.7 Descriptions of the columns for digital devices

4. Under the Analog Inputs pane, select the Set Configuration button.

8.4 Configure Onboard Digital Inputs for Plunger LiftThe user needs to configure the digital channels to detect and report the data specific to the sensor, shut in switches, or other digital inputs. The channels match the inputs/outputs on the circuit board.

NOTE For more information about the boards, see the “8000 Series Hardware Diagrams and Specifications” in the Help Documents.

• Plunger arrival sensor

• Shut-in switches

• High–Speed Pulse Counters

The following table describes the configuration options available in the Digital Inputs pane.



Digital Input Typical Use*Plunger Arrival Sensor Production Method

Shut In Switch 1-2 Emergency Shut in a well

Site ESTOP Emergency Shut In of the well site

Separator Temperature Switch Low temperature indicates pilot for the burner is out

Flare Stack Temperature Switch Low temperature indicates pilot for the burner is out

Vapor Recovery Reduce gas waste

Pulse Switch Count 1 & 2 Fluid Production Monitoring

Pulse/Switch Fluid Counter 1 & 2 Fluid Production Monitoring

Aux 1-6 Gas Lift Manager

*Required on Sensor Channel because the sensor needs the power port

Table 8.8 Summary of the digital devices available in the Digital Inputs pane

The Plunger Lift System requires an Arrival Sensor. The sensor is hardwired to the first channel. Although the user can select other options, the sensor requires the power port available on the first channel.

To configure a PCS Ferguson Plunger Arrival Sensor1. On the Controller Setup tab, select the Nnboard Analog/Digital button.

2. In the Analog Digital Configuration dialog box, locate the Digital Inputs pane.

Figure 8.9 The Analog Digital Configuration dialog box configures a list of digital inputs

3. In the Configuration column for the digital input, select Plunger Arrival Sensor from the list.

4. In the Switch Contact column, select ormally Npened.

5. Under the Digital Inputs pane, select the Set Configuration button.

The well system might include high speed pulse counters. The channels DIN1 and DIN2 are the high speed digital inputs. The user can also use those channels for other digital inputs.

To configure a Pulse Counter1. On the Controller Setup tab, select the Nnboard Analog/Digital button.

2. In the Analog Digital Configuration dialog box, locate the Digital Inputs pane and channels DI 1 and DI 2.

3. In the Configuration column for the digital input, select a counter from the list.

4. In the K Factor column, select enter the conversion factor for engineering units appropriate for the counter.




To complete the following procedure, the user must know if the switch for a device is normally open or closed. The settings depend on the specific device. Consult the manufacture’s documentation for more details.

To configure other digital inputs1. In the Analog Digital Configuration dialog box, locate the Digital Inputs pane.

Figure 8.10 The Analog Digital Configuration dialog box has a pane for digital inputs

2. Specify the settings for the device based on the documentation provided by the device manufacturer. For general information, see the table below.

Column Value based on NotesChannel Circuit board location (Read-only) Applies to DIN# label on the

circuit board DIN 1 and 2 are the High Speed channels. Use them for pulse counters

Configuration User selection User input

Switch Contact User selection Sets the default setting for the input: Normally opened or normally closed

Description User input User input

K Factor (For liquid accum)

User input Applies to Pulse Switch options only

Status/Count Real-time data * (Read-only)

Today Accum Real-time data * (Read-only)

Flow rate/day Real-time data * (Read-only)

Lifetime Accum Real-time data * (Read-only)

Frequency Hz Real-time data * (Read-only)

* Real-time data is available after selecting the Set button to configure the inputs.

Table 8.11 The Digital Inputs pane offers the configuration and status information


8.5 Verification of the InputsAfter setting the configuration for the inputs, the user can verify that the component is receiving the proper data in the following WellVision features.

• (Controllers and Remote IO Slaves) The rows of the Analog Digital Configuration dialog box contain real time data columns for operational devices.

• The Well Status tab of a controller displays real time data from the inputs onboard a controller or, if configured, a Remote IO Slave.



• The Status tab displays the real time data from the inputs onboard the Remote IO Slave.

• (Remote IO Slave only) The Counters tab displays digital pulse statistics.

The user can verify that the Remote IO Slave is reading from the appropriate field equipment. The user might adjust the equipment at the site and want to examine the effects the changes have on the readings.

To verify the inputs from the Remote IO1. Open WellVision and select the Direct Connect button.

2. In the Connect dialog box, enter the Modbus address for the Remote IO Slave, select Direct Remote IN Setup, and specify a connection option.

3. On the Status tab, review the data.

Figure 8.12 The Status tab for a Remote IO Slave showing current data

4. To update the values, select the Refresh Status button.

5. To automate updates to the view, select the Refresh TEvery option and enter a number in the Seconds box.

The user can review the pulse counts for digital devices connected to the Remote IO device. The Pulse Counters tracks and displays the daily flow accumulation for up to 10 days.

To examine digital counts1. Open WellVision and connect to the Remote IN device.

2. On the Counters tab, view the number of digital pulses coming from the digital devices.



For example, the user might want to view the counter for calculating liquid flow for a turbine meter.

Figure 8.13 The Counters tab shows the number of digital pulses

3. Close the Remote Device IN window.


69Configuring a Radio [Optional]

9 Configuring a Radio [Optional]The well components might radio communications to communicate. For each component with a radio onboard, the user needs the following information to configure the radio.

• Preamble ID (HP)

• Network ID (ID)

• Radio Frequencies of the installed radio (900 or 2.4 GHz)

To configure radio communications1. In WellVision, locate the Radio button in the Communications area for the well component.

– For the Multi-Well master, use the Direct Connect tool to connect and go to the System Setup tab.

– For the Multi-Well slave, use the Direct Connect tool to connect and go to the Setup tab.

– For the Remote IO Slave, use the Direct Connect tool to connect and go to the Setup tab.

Figure 9.1 The Radio Configuration dialog box is specific to the onboard radio

2. In the Radio Configuration dialog box, enter the value for the Preamble ID (HP) and the etwork ID (ID).

NOTE The terminology for the values might vary from the figure above. The user might see Hopping Channel (HP) instead of Preamble; Destination Address (DT) instead of Network ID. The values must match the well system regardless of the labels.

3. Select the Set button and then the Close button.


70 Configuring Plunger Lift Operations

10 Configuring Plunger Lift OperationsThe controller can automate the plunger lift operations based on data from the wells. The key to production control is the state of the Production Valve. A well program specifies which data points WellVision uses to control the Production Valve. The WellVision application supports three basic methods of production control.

• Time method

• Pressure methods

• Time method with AutoCycle

An analysis of the well data reveals the typical characteristics and condition of a well. The results of this analysis determine the choice of production method and configuration settings. The well analysis and decision making is outside the scope of this document. However, the worksheets in the appendix can assist the user with the set points for the best configuration.

10.1 PreparationBefore setting a production method, the well system needs the following minimum set of components installed, operational, and configured using WellVision.

Hardware• Well with plunger lift hardware

• Electronic controller: 8800 Multi-Well Master, 8400, or 8200 Remote IO Slave

• Motor valve and pneumatic plumbing

Optional Field Equipment• EFM

• Translator

• Tank monitor

• Other controllers and devices

Sensors• Plunger Arrival sensor

• Casing pressure sensor

• Tubing pressure sensor

• Sales line pressure sensor

Well Analysis• Choice of production method

• Average production times

• Average pressures values

• Choice of Production Valve position when Tank Valve is open


71Configuring Plunger Lift Operations

10.2 Configure the Time MethodWhen set to Time Method, the Wellhead controller changes the Production Valve and Tank Valve based on the countdown timer solely. The controller continues to monitor and log the pressures and flow of the well. However, the controller does not use the readings to adjust the plunger cycle.

From a well analysis, the user needs the following information.

Primary Set Points for using the Time Method:• Fall Time

• Close Time

• A Open Time

• Sales Time

Secondary Set Points for using the Time Method:Latch valve B is optional.

• Delay Close Time

• Mandatory Shut-in Time

• B Open Time

• B Delay Time

• Low Line Close Pressure

• High Line Close Pressure

After collecting the set point information, the user can configure the well to use the Time Method and save notes about the well configuration.

To configure the Time method1. Open WellVision and connect to the well.

2. On the Well Program tab, select Oime Method in the Production Method box and then, in the Program Values area, locate the primary set points and enter values appropriate for the well.

Figure 10.1 The primary set points are on the Well Program tab

3. Locate the secondary set points and enter values appropriate for the well.



Figure 10.2 The secondary set points are on the Well Program tab

4. Select Set Controller to commit the changes.

5. [Optional] Select Save Program Oo Well otes.

6. [Optional] In the otes dialog box, enter information to explain the source of the setting information.

7. For example, the user might want to note the date of the well analysis used to set the values for the current program.

8. [Optional] Select Save ote and select TExit.

10.3 Configure a Pressures MethodThe pressure methods allow the user to adjust production based on differences in pressure readings on the well. For example, the Casing- Line method calculates the difference between the readings for Casing pressure and the Sales Line pressure. If Tubing was 200 psi and Sales Line is 120 psi then the difference is 80 psi. The user provides WellVision with the set points unique to the well. If the user has historical data, that data might provide the initial set points.

The following table shows the pressure differential, the effect of the set point, and a typical well it optimizes.

Basis for differential Well opens if pressure difference is:

Well example

Casing pressure – Line pressure

Greater than (>) the setting Most well configurations

Tubing pressure – Line pressure

Greater than (>) the setting Wells with a packer and no annular pressure

Casing Pressure – Tubing pressure

Less than (<) the setting Wells with slow building casing pressures

Casing pressure – Line pressure/Tubing pressure – Line pressure

Either or Both Wells that users want to respond to two differentials

Table 10.3 The well determines the choice of differential

10 .3 .1 Setup the Casing-Line Method

The Casing-Line method uses the difference between pressure measurements on the casing and on the sales line. This method requires the well system to have a sensor on the casing and an EFM installed and operational.



From a well analysis, the user needs the following information:

Primary Set Points for using the Casing-Line method:• Fall Time

• Close Time

• A Open Time

• Sales Time

• Differential Open Pressure

Secondary Set Points for using the Casing-Line method:



• B Open Time

• B Delay Time

• Load Factor

• Low Flow Rate

• Critical Flow (K Factor)

• Casing Drop Pressure



• High Line Shut-In Delay

• High Line Pressure Shut-in Delay

After collecting the set point information, the user can configure the well to use the differential pressure and save notes about the program.

To configure the Casing-Line method1. Open WellVision and connect to the well.

2. On the Well Program tab, select Casing-Line in the Production Method box and in the Program Values area, locate the primary set points, and enter values appropriate for the well.









7. For example, the user might want to explain that the current program uses estimates.


The user can monitor the plunger runtimes. Using those runtimes, the user can adjust the value of the Differential Open Pressure. To respond to slow runtimes, increase the differential value. To respond to fast times, decrease the differential value.

10 .3 .2 Setup the Tubing-Line Method

The Tubing-Line method uses the difference between pressure measurements on the tubing and on the sales line. This method requires the well system to have a tubing sensor and an EFM installed and operational.


Primary Set Points for using the Tubing-Line method:• Fall Time

• Close Time

• A Open Time

• Sales Time




Secondary Set Points for using the Tubing-Line method:



• B Open Time

• B Delay Time

• Load Factor

• Low Flow Rate






• High Line Pressure Shut-In Delay


To configure the Tubing-Line method1. Open WellVision and connect to the well.

2. On the Well Program tab, select Oubing-Line in the Production Method box and then, in the Program Values area, locate the primary set points and enter values appropriate for the well.











The user can monitor the plunger runtimes. Using those runtimes, the user can adjust the value of the Differential Open Pressure. To respond to slow runtimes, increase the differential value. To respond to fast times, decrease the differential value.

10 .3 .3 Setup the Casing-Tubing Method

The Casing-Tubing method uses the difference between pressure measurements on the casing and on the tubing. This method requires the well system to have sensors on the casing and tubing installed and operational.


Primary Set Points for using the Casing-Tubing Method:• Fall Time

• Close Time

• A Open Time

• Sales Time




Secondary Set Points for using the Casing-Tubing Method:



• B Open Time

• B Delay Time

• Load Factor

• Low Flow Rate






• High Line Pressure Delay


To configure the Casing-Tubing method1. Open WellVision and connect to the well.

2. On the Well Program tab, select Casing-Oubing in the Production Method box and then in the Program Values area, locate the primary set points and enter values appropriate for the well.











The user can monitor the plunger runtimes. Using those runtimes, the user can adjust the value of the Differential Open Pressure. To respond to slow runtimes, decrease the differential value. To respond to fast times, increase the differential value.

10 .3 .4 Setup the Casing-Line/Tubing-Line Method

The Casing-Line/Tubing-Line method specifies a well program that can respond to set points for two differentials. This method can use the difference between pressure measurements on the casing and tubing in relation to the sales line. This method requires the well system to have sensors on the casing, tubing, and the sales line installed and operational.

The user can select how the well program applies the two differentials to enter A OPEN mode. Label for this selection is the “Secondary Pressure Mode.”

• TEither When conditions meet one of two set points, the well program responds. This option expands the number of possible conditions that can trigger a change in mode.

• Both When conditions meet both set points, the well program responds. This option limits the number of possible conditions that can trigger a change in mode. The well must meet two differential set points instead of one.


Primary Set Points for using the Casing-Line/Tubing-Line Method:• Fall Time

• Close Time

• A Open Time

• Sales Time

• Casing-Line Open Pressure

• Secondary Tubing-Line Pressure

• Secondary Pressure Mode

Secondary Set Points for using the Casing-Tubing Method:



• B Open Time

• B Delay Time

• Load Factor

• Low Flow Rate






• High Line Pressure Delay




To configure the Casing-Line/Tubing-Line method1. Open WellVision and connect to the well.

2. On the Well Program tab, select Casing-Line/Oubing-Line Method in the Production Method box and in the Program Values area, locate the primary set points, and enter values appropriate for the well.

Figure 10.10 The primary set points include the Secondary Pressure Mode


Figure 10.11 The secondary set points for the two d are on the Well Program tab




For example, the user might want to explain that the current program uses estimates.




The user can monitor the plunger runtimes. Using those runtimes, the user can adjust the value of the Differential Open Pressure or Secondary Open Pressure. To respond to slow runtimes, increase the differential values. To respond to fast times, decrease the differential values.

NOTE For more information about monitoring performance, see “Monitoring Well Performance” in the Help Documents.

10.4 Configuring the Time Method with AutoCycleThe AutoCycle program uses the plunger speed to optimize production. The user provides values for a set of arrival times. These values depend on the specific well.

10 .4 .1 Preparation

The AutoCycle program is an addition to a basic plunger lift system. The user needs the following hardware, firmware, and information to configure the program.

Well System Information• Well depth

• Settings for plunger arrival times

– Early

– Good

– Slow

– No

• Settings for pressure overrides, if appropriate

– Tubing

– Casing

– Line

– [Optional] Flow Rate meter

10 .4 .2 Configuring the AutoCycle Program

After verifying that the well system is installed and operational, the user can configure the AutoCycle program.

To configure the AutoCycle program and time set points1. Open WellVision and connect to the well.

2. On the Well Program tab, select AutoCycle Method in the Production Method box.



Figure 10.12 The Well Program tab has the option to set the production method

3. Select the Set Controller button to commit the change on the controller.

4. Select the Reset Defaults button and then select the Set Controller button to clear the time and pressure settings.

NOTE If the user continues without resetting, the user might experience unexpected results. Pressure Overrides might still be in effect. A reset clears the pressure overrides.

Figure 10.13 Reset Defaults prevents previous settings from affecting the new program

5. Enter the times for the plunger windows.

NOTE The Early Window is optional. To make the time and counts available, select the TEnable TEarly Arrival box

The figure below shows the default values that the AutoCycle program has when the user selects the AutoCycle tab.

Figure 10.14 The times for the windows identify the type of arrival



If the plunger arrives (⇑) relative to the set point

Arrival Window

in less than (<) 2 minutes Early window, if enabled

in less than (<) 10 minutes Fast window

between (<>) 10 and 14 minutes Good window

between (<>) 14 and 1 hour Slow window

greater than (>) 1 hour No arrival

Table 10.15 Default settings assume a well depth of 8000 feet

6. In the adjustment boxes for each window, enter the values for Initial and Current counts.

Figure 10.16 The counts determine how many arrivals trigger an exit from A OPEN mode

NOTE The Initial Count specifies the total number of arrivals required before the program exits A OPEN mode and applies the adjustments. The Current Count displays the number of arrivals remaining before the adjustments are applied. If the Current count is zero (0), the program enters the next mode and applies the adjustments. The countdown resets to the Initial value depending on the window of the next arrival.

7. For each window, enter appropriate values to add or subtract from the set points.



Figure 10.17 The user can accept default adjustments or enter their own

NOTE Enter values that make small changes between cycles. Large changes to time adjustments can interfere with production instead of optimize it.

For example, if the Fast Window adjustments take five (5) minutes from the Off Time (Close Time) and add two (2) minutes increase to the Afterflow Time (Sales Time), the Off Time (Close Time) value would reduce from 4:15 to 4:10 and Afterflow Time (Sales Time) increases from 20 to 22 minutes. This slight change might go unnoticed on a pressure gauge if the user was at the well location. However, after the next five (5) cycles, if the well continues to be fast, the Off Time (Close Time) becomes 3:45 and the Afterflow Time (Sales Time) becomes 32 minutes. This cumulative change might make a noticeable difference in production rates and operating pressures in a 24-hour period.

8. Select the Set Controller button to commit the changes to the configuration.

The user might want to use pressure readings along with the time set points. The user can add pressure settings that override the time set points. The program can use the arrival windows to adjust the pressure set points. The following procedure has the steps for configuring the pressure set points.

To configure pressure set points in AutoCycle1. In WellVision, configure the controller to use the AutoCycle program and enter the time set

points.

2. On the AutoCycle tab, select the Pressure Nverrides button to open the AutoCycle Pressure Nverrides dialog box.

3. In the AutoCycle Pressure Nverrides dialog box, enter the values for entering TBG ON mode in Npen Oubing If area.



Figure 10.18 The user can specify pressures to trigger A OPEN and CLOSE modes

4. In the AutoCycle Pressure Nverrides dialog box, enter the values for entering CLOSE mode in the Close Oubing If area.

NOTE The program applies the set points in this area only during the AFTERFLOW (SALES) mode.

5. In the Plunger Npen Adjustments and Plunger Npen Adjustments the areas, enter the values for adjusting the pressures for the next plunger cycle.



Figure 10.19 The AutoCycle program can adjust production using pressure settings

6. Select the Set button and then select the Close button.

10 .4 .3 Monitoring the AutoCycle Program Operations

After configuring and starting the AutoCycle program, the user can monitor the results of the AutoCycle adjustments. The user views the Well Status tab, the Well Program tab, and the AutoCycle tab.

To monitor the well and plunger performance1. Open WellVision and connect to the well.

2. On the Well Status tab, examine the pressures in the Live Data area.

3. On the Well Program tab, examine the time settings.

4. On the AutoCycle tab, examine the data for the plunger cycles.

NOTE To reset the plunger data, select the Clear Ootals button.

5. Review the current settings or modify them to change how AutoCycle applies the adjustments.

10 .4 .4 Modifying How AutoCycle Applies Adjustments

After the AutoCycle program has adjusted the program to match the well data, the user can change how the program applies adjustments or stop the adjustments but continue using the settings.



To stop the adjustments and keep the program settings1. Open WellVision and connect to the well.

2. On the AutoCycle tab, select Disable Adjustments and select Set Controller.

The well program remains in AutoCycle and uses the settings made during the last adjustment. The user can continue to monitor production to determine if additional action is required.

The user can make adjustments in increments than the current well data suggests to the program.

To decrease the adjustment scale1. Open WellVision and connect to the well.

2. On the AutoCycle tab, select the TEnable Proportional Adjustments option and the select the Set Controller button.


87Set Points for Plunger Lift Operations

11 Set Points for Plunger Lift OperationsThe user can analyze the well’s performance over time and fine-tune the production method based on trending data. A user examines a current analysis of a well’s performance to set and adjust the frequency of the plunger cycles based on conditions of the well. The rate of liquid accumulation is unique to each well. Changes to the Production Valve state control the plunger cycle. An electronic controller at the surface automates the state of the Production Valve.

This document organizes the set points into control and adjustment categories:

• Control Production Modes

• Adjustments to Open Pressure Values

• Adjustments for Plunger Misses

• Control Exit of SALES Mode

• Control Shut-in

• Control Alarms

The user can specify the following set points to adjust when and how the controller directs the Well Program to respond to well conditions.

11.1 Control Production ModesThe user chooses the set points depending on the well conditions and the production method. For the Time method, if Well Program’s value for sales time is 00:00:00, the controller closes the Production Valve when the plunger arrives. For a pressure method, the controller opens the Production Valve in response to wellhead pressures. On the Well Program tab, the WellVision™ application offers only the set points appropriate for the method. The other set points are visible but gray.


88 Set Points for Plunger Lift Operations

Figure 11.1 Program Values area shows the set points available based on the production method

11 .1 .1 Fall Time (All production methods)

Format: HH:MM:SS Oypical Value: 1:00:00 Disable Value: 00:00:00

Specify a minimum shut-in time to allow the plunger to fall to the bottom of the well. During Fall Time, the user must use the Select Open Production Valve on the Status tab of the well or use the ON button on the Walk Up Display to open the well. The controller does not use other set points to direct the well to open during this time.

11 .1 .2 Close Time (All production methods)

Format: HH:MM:SS Oypical Value: Time method: 2:00:00; Pressure methods: 00:00:00 Legacy Label: TUBING OFF

Specify a shut-in time that ensures pressure build up in the well to surface the plunger with a liquid load before the controller opens the Production Valve for the next production cycle.

Usage: For pressure methods, this set point is typically set to 00:00:00 because the controller opens the Production Valve in response to changes in pressure. If the user wants the Production Valve to open after time regardless of pressure changes, the user can set the Close Time. If a Close Time is set, the value must be greater or equal (>=) the Fall Time.



11 .1 .3 A Open Time (All production methods)

Format: HH:MM:SS Oypical Value: Time method: 1:00:00 Legacy Label: Open Time, TUBING ON for the Sales valve

Specify the time that the well is open and gas is flowing through the Production Valve. During Open Time, the plunger starts to surface and the well produces its initial head gas. Allow enough timing for the plunger to surface with the liquid load. A zero time setting (00:00:00) leaves the well open indefinitely or until a plunger arrival triggers Sales Mode.

11 .1 .4 Sales Time (All production methods)

Format: HH:MM:SS Suggested Minimum Value: 00:00:15 Disable Value: 00:00:00 to close the Production Valve on plunger arrival Legacy Label: DELAY TIME, Afterflow Time

Specify additional time the controller allows gas flow after the plunger arrival. The countdown starts after the plunger sensor detects the plunger at the wellhead surface. For the 8000 Series to log the plunger arrival properly, the value for Sales Time must be greater than or equal to (=>) 15 seconds.

Usage: Typically, the user sets this value as a backup to close the well if the well conditions do not meet other set points within an appropriate time.

For example, the well’s production might be highest when based on meeting a certain pressure, rate, or other value. Typical set points might be one of the following:

• D.I.P Close Pressure,

• Low Gas Flow Rate,

• Critical Flow K Factor

NOTE Set the Sales Time higher than the normal time the well is able to sell gas.

11 .1 .5 Delay Close Time (Pressure methods)

Format: HH:MM:SS Disable Value: Use 10-30 seconds

Specify the time to wait and evaluate whether an increase in the casing pressure is a brief spike or an actual, sustained increase. This set point is evaluated and effective during SALES MODE only. The user can set this to work with Low Gas Flow Rate also.

NOTE If the D.I.P. Close Pressure is set to 1, 2, or 3 psi, set Delay Close Time to 10, 20, or 30 seconds. Under most conditions, this set point provides time for gas to clear remaining liquids out of the line into the separator. This practice can prevent water from freezing and damaging the line in cold temperatures.



CAUOIN Do not set the Delay Close Time to 00:00:00. The controller might close the well too soon while the casing pressure is still falling. For more details, see D.I.P Close Pressure and Low Flow Gas Rate.

11 .1 .6 Mandatory Shut-In Time (All production methods)

Format: HH:MM:SS Oypical Value: 2 times the typical Close Time Disable Value: 00:00:00 Legacy Label: Recovery Time

Specify the time to countdown when a plunger does not surface.

Usage: If the Production Valve and Tank Valve are open and the plunger does not surface, the well probably needs more time to build pressure. The user might set the Mandatory Shut-In Time to two times or more than the time required to build enough pressure to surface the plunger.

For example, if a well takes two (2) hours to build enough pressure to surface the plunger, set Mandatory Shut-In Time to four (4) hours or more.

NOTE The Mandatory Shut-In Time must be greater than 2 times the Close Time. If the plunger does not surface, Mandatory Shut-In Time replaces Fall Time. Mandatory Shut-In Time is not in addition to Fall Time.

11 .1 .7 Casing Peak Pressure Time (Pressure methods)

Format: HH:MM:SS Oypical Value: For a well that builds pressure quickly: 00:10:00 – 00:12:00 minutes; for a well that builds pressure slowly: 00:30:00 minutes Disable Value: 00:00:00 Legacy Label: Casing Peak Time

Specify the time that the controller opens the Production Valve after the casing pressure meets a high value and does not increase in this specified time period. The controller monitors the casing pressure independently of the Differential Open Pressure. The controller counts down the Casing Peak Pressure Time. The counter restarts if the casing pressure increases by 1 psi.

Usage: For example, assume that the value for Casing Peak Pressure Time is 10 minutes. After the Production Valve closes, the controller counts down the Casing Peak Pressure Time. If the pressure builds 1 psi after 7 minutes and the counter for Fall Time reaches zero, the controller restarts the countdown of Casing Peak Pressure Time. If the casing pressure increases less than (<) 1 psi within 10 minutes, the controller counts down the Casing Peak Pressure Time to zero. The controller checks the current value of the Fall Time countdown. If both the Casing Peak Pressure Time and Fall Time countdowns are at zero, the controller opens the Production Valve.

The user can use both Differential Open Pressure and Casing Peak Pressure Time to control the well program. If the user wants to use only the Casing Peak Pressure Time, the user should set the Differential Open Pressure to an extremely high value.



11 .1 .8 High Line Pressure Shut-In Delay (All production methods)

Format: HH:MM:SS Oypical Value: 00:00:00 Disable Value: 00:00:00

Specify a time to wait after detecting a shut-in condition on the line to allow for normal spikes in pressure.

Usage: If the user sets the High Line Pressure, the user can set High Line Pressure Shut-in Delay to keep a brief spike or drop from closing the well. Spikes in pressure often occur when the controller opens the well after an extended shut-in period. After opening the Production Valve, the controller briefly ignores the sales line pressure during the High Line Pressure Shut-in Delay period. The High Line condition is re-evaluated at the end of the High Line Pressure Shut-In Delay period. If the High Line condition is still valid, the well is shut-in.

For example, the user might set the High Line Pressure Shut-in Delay to six minutes (00:06:00). When the controller opens the well, it starts to count down the Open Time. The pressure might spike for 3 to 5 minutes after opening. For the first six (6) minutes of the A Open Time countdown, the controller keeps the well open even if the High Line Close Pressure is met. If the pressure still meets the shut-in pressure after six (6) minutes, the controller shuts in the well.

11 .1 .9 B Open Time (All production methods)

Format: HH:MM:SS Disable Value: 00:00:00 Legacy Label: TANK ON for the Vent valve

Specify the duration to open the vent, if the well system has one.

Usage: This period is after sales of its initial head gas, but before plunger arrival. During B Open Time, the plunger surfaces with its liquid load. Typically, the controller vents gas during B Open Time to the low side of the separator or to a tank.

11 .1 .10 B Delay Time (All production methods)

Format: HH.MM.SS Disable Value: 00:00:00 Legacy Label: TANK DELAY for the Vent valve

Specify additional time to keep the Tank Valve open after a plunger arrival.

Usage: This period is after the arrival of the plunger and before the close of Tank Valve. Typically, the user sets B Delay Time to 00:00:00 to close the Tank Valve immediately when the plunger arrives. A System Engineer can use a delay to allow liquids that follow the plunger to drain out of the dump valve on the Separator.

If the user sets the B Delay Time and the plunger arrives during the Tank Open Time countdown, the controller delays closing the Tank Valve by starting the Tank Delay Time countdown. When the countdown reaches zero, the controller closes the Tank Valve and starts the Sales Time countdown by opening the Production Valve.



11 .1 .11 Differential Open Pressure (Pressure methods)

Format: Pressure value (psi) Disable Value: 0

Specify a difference in pressures that that triggers the controller to open the Production Valve and the Well Program to enter OPEN mode. The two pressures that determine the Differential Open Pressure depend on the Production Method the user selects:

• Tubing pressure minus sales line pressure must be greater than the Differential Open Pressure to start well production

• Casing pressure minus tubing pressure must be less than the Differential Open Pressure to start well production

• Casing pressure minus sales line pressure must be greater than the Differential Open Pressure to start well production

• (Multi-Well only) Casing pressure minus Line pressure and/or Tubing pressure minus Line pressure. Both must be greater than their respective Differential Open Pressure, but opening is also determined by the ‘Either’ or ‘Both’ setting. Please see {{}} for more information.

Usage: The user considers the typical plunger arrival time to choose an appropriate value for the well. The optimal plunger speed is between 500 and 1000 feet per minute.

• If the plunger is running fast, > 1000 feet per minute, lower the Differential Open Pressure.

• If the plunger is running slowly, < 500 feet per minute, increase the Differential Open Pressure.

The Well Program for the Multi-Well application offers an additional pressure method that incorporates evaluation of two differentials. This method offers a set point for the secondary open pressure and a mode to specify how the Well Program responds. The user can also specify an Open Pressure Multiplier.

11 .1 .12 Secondary Tubing-Line Pressure (C-L/T-L Pressure Method)

Format: Differential Pressure value (psi) Disable Value: Select a different Production Method

Specify the pressure differential for the Tubing-Line value that the Well Program uses to open the Production Valve.

11 .1 .13 Secondary Pressure Mode (C-L/T-L Pressure Method)

Format: User selection Oypical Value: Either or Both Disable Value: not applicable

Specify how the Well Program applies the two differentials. If the user selects TEither, well conditions can meet one or the other for the Well Program to respond. If the user selects Both, the well conditions must meet both differentials for the Well Program to respond.



11 .1 .14 Load Factor (Fluid Slug) (Pressure methods)

Format: Percentage (%) Oypical Value: 40-60 Disable Value: 00

Specify a percentage value for the ratio between two differential pressures. These two differentials are Casing Pressure minus Tubing Pressure to Casing Pressure minus Line Pressure.

Usage: (Not commonly used) Ratio of fluid in the well to energy available to raise the fluid. Must meet the differential and load factor to open.

The top value estimates the fluid and the bottom estimates the available energy.

Figure 11.2 Load Factor

This ratio can indicate if pressure in the well is strong enough to lift the liquid load in the tubing. If the Load Factor (Fluid Slug) is greater than zero (> 00), the controller keeps the well closed until the well conditions meet two set points for pressure:

• The Controller compares the line pressure to the tubing pressure (Tubing-Line) or the casing pressure (Casing-Line).

• In both methods, the Controller compares casing, tubing, and line pressures as a ratio to determine the net lifting energy. When conditions in the well meet both set points and all other criteria for opening, the Well Program enters OPEN mode. Normal values for Load Factor (Fluid Slug) range from 40% to 60% depending on the well’s individual characteristics. The value, 00 percent, disengages the Load Factor (Fluid Slug) set point. The primary set point is the Differential Open Pressure. Load Factor (Fluid Slug) is the ratio of casing pressure minus tubing pressure to casing pressure minus line pressure. Load Factor (Fluid Slug) = (Casing Pressure - Tubing Pressure)/(Casing Pressure - Line Pressure)

For example, if the Load Factor (Fluid Slug) is 50, the controller opens the Production Valve when the ratio is 50% or lower and the well conditions have met all other set points for opening.

If Casing Pressure - Tubing Pressure = 100 psi AND Casing Pressure - Line Pressure = 500 psi THEN 100/500 = 20% 20% is less than 50%, so the Well Program enters OPEN mode.

11 .1 .15 Casing Drop Pressure (Pressure Methods)




Specify the drop in the casing pressure that can initiate the Sales Time countdown without input from the Arrival Sensor.

Usage: Specify this set point as a backup in the following cases:

• The Arrival Sensor fails to detect a plunger arrival

• The sensor malfunctions

• The well does not have a plunger installed

The wellhead configuration affects the plunger travel into the lubricator. The plunger can arrive but the plunger arrival sensor might not detect the plunger every time. Use Casing Drop Pressure as a backup. A drop in pressure on the casing can indicate that the well is unloading and can allow gas flow.

The user can let the well run without a plunger. Casing Drop Pressure allows the well to enter SALES mode without plunger detection.

Apply as a temporary fix for a faulty arrival sensorIf the plunger arrival sensor malfunctions, the user can apply the Casing Drop Pressure as a backup for the sensor temporarily. Setting the Casing Drop Pressure can prevent the Tank valve from opening if the well is unloading. This set point can prevent abrasion on the plunger.

The user needs the value for casing pressure at the time that the Production Valve opens and from the moment the plunger surfaces. The user can get this information from the datalogs.

To use Casing Drop Pressure as a backup arrival sensor1. From the raw data in the data logs, note the Casing pressure the moment the Production

Valve opens and when the plunger surfaces. The figure below shows the two values: 472 and 405.

Figure 11.3 The datalog shows the pressure values

2. Calculate the difference and add 10-15 psi.

The 10-15 psi provides a buffer that ensures that the plunger surfaces before the casing pressure reaches the set point for Casing Drop Pressure.

For example, Casing pressure A Open reading is 472 psi minus (–) arrival reading of 405 psi = 67 psi. The difference, 67 psi, plus (+) the buffer, 15 psi, equals (=) 82 psi. Without a buffer, the Casing Drop Pressure might indicate a plunger arrival too closely and initiate a change by the controller before the plunger actually surfaces.

3. In the Casing Drop Pressure box, enter the calculated value.



11 .1 .16 Low Line Pressure Substitute (C-L, T-L, C-L / T-L)


Specify a value to compensate for line configurations at the well site that compromise the effectiveness of the reading for line pressure. For example, the location of check valves might make the line pressure reading less than the actual line pressure reading downstream that the user wants in the production method calculation. A line pressure reading below the Low Line Pressure Substitute uses the Low Line Pressure Substitute value for the differential calculation rather than the actual line pressure.

11.2 Adjust Open Pressure Value (T-L or C-L)The configuration of a well site can affect the Line Pressure input to the controller. The user might want to adjust the differential pressure calculation used by the controller. The Well Program tab provides the Open Pressure Multiplier area. These settings are only available for the Tubing-Line or Casing-Line pressure methods.

Figure 11.4 The Open Pressure Multiplier Area on the Well Program Tab

To overcome the line pressure, the user can set the Open Pressure Multiplier values.

11 .2 .1 Multiplier (T-L or C-L)

Format: Numeric

Specify a number that adjusts the Open calculation to counteract increases in Line Pressure. An increase in Line pressure requires extra energy by the well to surface the plunger. Entering a multiplier greater than 1.0 allows the extra buildup of well energy needed to overcome higher than normal line pressure. A value of zero disables this feature.

11 .2 .2 Threshold (T-L or C-L)

Format: Pressure value (psi)

A Line pressure below the threshold value computes differential open pressure normally. A Line pressure above the threshold value places the Line pressure into an equation to compute the adjusted Differential Open Pressure.

The user can insert values into the following equations to identify the set points appropriate for a well. The equations use the following abbreviations for the multiplier set points.



• NPM: Open Pressure Multiplier (See Section 1.2.1 Multiplier above)

• NPM_Ohreshold: Open Pressure Multiplier Threshold

• DNP: Differential Open Pressure

The equation for opening the well for the Tubing-Line pressure method:

Oubing Pressure – Line Pressure > ((Line Pressure – NPM_Ohreshold) x NPM) + DNP

Figure 11.5 Open the Well Tubing-Line

The equation for opening the well for the Casing-Line pressure method:

Casing Pressure – Line Pressure > ((Line Pressure – NPM_Ohreshold) x NPM) + DNP

Figure 11.6 Adjust the Differential Open Pressure

11.3 Adjust for Plunger MissesThe user can configure the Well Program to respond to missed plunger arrivals by increasing the values of the open pressure set points for the production method.

Figure 11.7 Configure the Incremental Pressure Mode

11 .3 .1 Mode (All Production Methods)

Format: User selection TEnable Value: Increment Mode Once or Increment and Hold Disable Value: Increment Mode Off

Specify that the user wants the Well Program to adjust the pressure values after the number of plunger misses specified in Plunger misses before increment.

Increment Nnce: The Well Program uses the incremented value for one cycle and then uses the original value for the Differential <Production Method>Open Pressure for the next cycle.

Increment and Hold: The Well Program uses the incremented value for all subsequent cycles.



11 .3 .2 Incremental Pressure (All Production Methods)


Specify the amount of the adjustment the Well Program makes to the Differential Open Pressure after the specified number of plunger misses.

11 .3 .3 Increment Pressure, T-L (Multi-Well Only: C-L/T-L Pressures Method)


Specify the value to add to the Secondary Tubing-Line Pressure if the Well Program is using the Incremental Pressure Mode.

11 .3 .4 Plunger misses before increment (All Production Methods)

Format: User selection Oypical Value: 2 Disable Value: Not applicable

Specify the number of times a plunger arrival is missed before the Well Program applies adjustments to value of Differential <Production Method> Open Pressure.

11.4 Control Exit of SALES Mode (Pressure Methods Only)The user can configure the Well Program to use pressure values to exit the SALES mode immediately.

Figure 11.8 Some set points initiate the end of SALES mode

11 .4 .1 D .I .P . Close Pressure (Pressure Methods)

Format: Pressure value (psi) Oypical Value: 1, 2, or 3 psi for many wells Disable Value: 0 Legacy Label: Differential Close Pressure

Specify the minimum pressure difference that causes the controller to close the well and the Well Program to exit SALES mode.



Usage: After the plunger surfaces, the casing pressure falls and levels off. The liquids begin to accumulate and the casing pressure starts to increase. The higher the user sets the D.I.P Close Pressure, the longer the well attempts to sell gas.

For example, if the user sets the D.I.P. Close Pressure to 3 psi, the controller stops the sale of gas and closes the well when the Casing Pressure rises to 153 psi. 153-150 = 3.

For example, if the user sets the D.I.P. Close Pressure to 10 psi, the Controller stops the sale of gas and closes the well when the casing pressure rises to 160 psi. 160-150 = 10.

NOTE To keep the controller from closing the well too soon, the user can set the Delay Close Time. This delay can account for fluctuations as the casing pressure falls.

Typically, the user might set the minimum D.I.P. Close Pressure to 1 psi. If the user disables the Delay Close Time with the value 00:00:00, the controller immediately closes the well when the casing pressure increases. Because the casing pressure is still falling, the controller might close the well too soon.

11 .4 .2 Gas Low Flow Close Rate (Pressure Methods)

Format: numeric Disable Value: 0 Legacy Label: Low Flow Rate

Specify a minimum rate of flow to trigger the controller to close the Production Valve and the Well Program to exit SALES mode. Gas Low Flow Close Rate works with Delay Close Time to ensure the Flow Rate is actually low and not a brief gas flow fluctuation from the EFM. The well program evaluates this condition only during SALES MODE.

Usage: The user might set this by itself or with the Critical Flow Constant. If the Flow Units on the EFM is set to metric (E3M3), the flow rate unit of measurement is one thousand cubic meters.

For example, if the Gas Low Flow Close Rate is set to 300, the Controller closes the Production Valve when the flow rate falls below 300 mcf. This function keeps the flow rate from dropping to the point where liquids fall back into the tubing.

11 .4 .3 Critical Flow Constant (Pressure Methods)

Format: Numeric Disable Value: 0 Legacy Label: Critical Flow K Factor

Specify a gas constant to compensate for pressure fluctuations on the Sales Line and to prevent liquids from returning into the tubing. The Well Program can use this set point along with the Gas Low Flow Close Rate to prevent low pressure on the Sales Line

If the user specifies a well program that closes the Production Valve when the flow rate of the sales line is less than a critical flow rate computed with Turner’s equation, set both the Gas Low Flow Close Rate and the Critical Flow Constant. The constant is K factor that allows for



fluctuating pressures on the Sales Line. Using these two set points, the well program keeps the flow rate, in combination with fluctuating sales line pressure, from dropping low enough for liquids to flow back into the tubing.

For example, if the user sets Critical Flow Constant to 65506 and sets Low Flow Rate to 300 mcf, the Controller closes the Production Valve when the flow rate falls below 300 mcf or the Critical Flow Constant falls below 65506.

11.5 Control Shut-InThe user can specify pressure values that initiate a shut-in. The user can specify set points that delay the Well Program’s response to these pressures.

Figure 11.9 The user can specify values that immediately shut-in the well

11 .5 .1 Low Line Pressure (All Production Methods)


Specify the lowest value for pressure on the Sales Line that the controller should use to close the Production Valve and direct the Well Program to enter CLOSE mode or to prevent the well from opening. A very low line pressure can indicate a rupture in the line.

11 .5 .2 High Line Pressure (All Production Methods)


Specify the highest value for pressure on the Sales Line that the controller uses to close the Production Valve or prevent it from opening. The user can set this value to respond to backpressure that prevents the plunger from surfacing.

Venting: If the well system has a Tank Valve and the Well Program includes settings for B Open Time and B Delay Time, the High Line Close Pressure does not close the Tank Valve.

11.6 Specify Shut-in ConditionsThe user can specify the pressures that cause the WellVision application to shut-in the well automatically. These alarms are separate from those the user can enable and disable to add a message to the Status tab. To clear these alarms, the pressure condition must clear naturally or by



user intervention. In addition, the user must select the Reset Alarms button and select one of the Valve Control buttons on the Status tab.

Figure 11.10 Set pressure values that shut-in the well automatically

11 .6 .1 Low Casing Pressure (All Production Methods)


Specify the low value for casing pressure that triggers an alarm and shuts the well.

11 .6 .2 High Casing Pressure (All Production Methods)


Specify the high value for casing pressure that triggers an alarm and shuts the well.

11 .6 .3 Low Tubing Pressure (All Production Methods)


Specify the low value for tubing pressure that triggers an alarm and shuts the well.

11 .6 .4 High Tubing Pressure (All Production Methods)


Specify the high value for casing pressure that triggers an alarm and shuts the well.

11 .6 .5 High Surface Casing Pressure (All Production Methods)




Specify the high value for the Surface Casing pressure that triggers and alarm and shuts the well.

11.7 Control the Valve Timer for the Separator PilotThe user can configure the WellVision application to open the well to send gas to the prime the pilot on the separator if the well closes for an extended time. This additional open setting can cause unexpected opening of the well.

Figure 11.11 Set the number of seconds for the Valve Timer

11 .7 .1 Open timer, sec

Format: SS Disable Value: 0

Specify the number of seconds the well is in CLOSE mode before the Controller opens the well to prime the pilot on the Separator.

11 .7 .2 Open duration, sec

Format: SS Disable Value: 0

Specify the number of seconds the well is open to prime the pilot on the separator. This is usually a small value of less than a minute.


102 Set Points for the AutoCycle Program

12 Set Points for the AutoCycle ProgramThe user can configure the AutoCycle program to analyze the well’s performance over time and fine-tune the production method based on the speed of the plunger. The user enters a set of time values that categorizes the arrivals. Using the categories and number of plunger arrivals, the program applies adjustment values to the primary set points that control the plunger’s speed.

This document organizes the set points into control and adjustment categories:

• Arrival Window Times and Adjustment Set Points

• Pressure Overrides

The user can specify the following set points to adjust when and how the controller directs the Well Program to respond to well conditions.

12.1 Overview of Arrival Windows

Figure 12.1 Set points the user enters to specify the limits on the arrival windows

• TEarly Window: (Optional) Plunger runtime between the start of A Open Time and the value for the Early Window.

• Fast Window: Plunger runtime between the values for Early Window and Fast Window. Without the Early Window enabled, the Fast Window is between the start of A Open Time and the value for Fast Window.

• Good Window: Plunger runtime between the values for Fast Window and Good Window. The Good Window value in the user interface is the same as the AutoCycle keypad value for Slow Time or on the Well Program tab, A Open Time. The user might also find it referred to at TUBING ON time in legacy documents.

• Slow Window: Plunger Runtime is between the value for Good Window and Current On-Time (A Open Time).

• o Plunger: Any time after A Open Time expires.


103Set Points for the AutoCycle Program

12 .1 .1 Reset Defaults Button

Resets the set points in the windows to the default values and clears the totals and counts.

12.2 Early Window AreaThe user might want the program to shut in the well for arrivals that are dangerously fast. For these conditions, the AutoCycle program offers an optional Early Window.

12 .2 .1 Enable Early Arrival Option

Adds or disables the Early Arrival Window to the AutoCycle program. Allows the user to configure the program to shut in the well if conditions cause the plunger to travel at dangerous speeds.

12 .2 .2 Hr Min Sec in the Early Window area

Format: HH:MM:SS Oypical Value: 00:00:08 Legacy Keypad Command: 27 Legacy Label: EARLY TIME

Specify the time that sets the limit between the start of A Open time and the Fast Window.

12 .2 .3 Initial Count in the Early Window area

Format: ## Oypical Value: 2 Legacy Keypad Command: 28 Legacy Label: INITIAL EARLY

Specify the number of arrivals within the Early Window before the controller closes the well. This value provides a delay to shut in for a single dangerous arrival. The user can accept the default of two (2) or specify a new value. The value does not change automatically.

12 .2 .4 Current Count in the Early Window area

Format: ## Oypical Value: 2 Legacy Keypad Command: 29 Legacy Label: CURRENT EARLY

After the initial setting by the user, this counter indicates the number of consecutive arrivals that have occurred within the Early Window. The AutoCycle program reduces this count for each arrival in the Early Window. When this counter reaches zero (0), the controller shuts in the well. The AutoCycle program resets this counter to the initial value if plunger arrives within the Fast or Good windows.



12.3 Fast Window AreaThis area provides the limits and values for adjusting the set points to influence the plunger arrival toward a good arrival.

12 .3 .1 (Fast Plunger Time) (Hr Min Sec)

Format: HH:MM:SS Oypical Value: Tubing depth/800 Legacy Keypad Command: 01 Legacy Label: FAST TIME

Specify the time that sets the limit between Fast Window and Good Window. The user can calculate a good initial value using this equation:

Fast Window=Depth of Tubing / 800

Figure 12.2 Fast Time

12 .3 .2 Initial in the Fast Window area

Format: ## Oypical Value: 5 Legacy Keypad Command: 15 Legacy Label: INITIAL FAST

Specify the number of arrivals in the Fast Window before the controller starts to adjust Current Off Time and Current Afterflow. Fast Arrivals the plunger must make before allowing Afterflow to commence. The user can accept the default or specify a new value. The value does not change automatically.

12 .3 .3 Current in the Fast Window area

Format: # Oypical Value: Equal to the Initial value for the Fast Window Legacy Keypad Command: 16 Legacy Label: CURRENT FAST

After the initial setting by the user, this counter indicates the number of arrivals that have occurred within the Fast Window. The AutoCycle program reduces this count for each arrival in the Fast Window. When this counter reaches zero (0), the controller applies the adjustments specified in the Fast Window area. After this counter reaches zero (0), the controller enters Afterflow (SALES mode). The AutoCycle program resets this counter to the initial value if plunger arrives within the Slow Window or in the No Plunger Window.



12 .3 .4 Hist (Read Only)

Format: ## Legacy Keypad Command: 52 Legacy Label: ARRIVAL HISTORY

Indicates the number of plunger arrivals within this window since the user selected the Clear Totals button.

12 .3 .5 Deduct from Off-Time in Fast Window

Format: HH:MM:SS Oypical Value: 1-5 Minutes Legacy Keypad Command: 09 Legacy Label: OFF FST (-)

Specify the amount of time to deduct from the Current Off-Time if the arrivals are within the Fast Window. If the Current Off-Time reaches the set point for Minimum Off Time, the controller ignores this value. A low value, such as the typical values, allows the controller to make small changes.

12 .3 .6 Add to Afterflow in Fast Window area

Format: HH:MM:SS Oypical Value: 1-5 minutes Legacy Keypad Command: 10 Legacy Label: A/F FST (+)

Specify the amount of time to add to the Current Afterflow if the arrivals are within the Fast Window. If the Current Afterflow time reaches the set point for Maximum Afterflow, the controller ignores this value. “A low value as specified in the typical values of 1-5 minutes allows the controller to make small changes.

12.4 Good Window AreaThis area provides the limits for the window and the set points that define a good arrival.

12 .4 .1 No Label (Hr Min Sec)

Format: HH:MM:SS Oypical Value: Tubing depth/600 Legacy Keypad Command: 02 Legacy Label: SLOW TIME

Specify the time that sets the limit between Good Window and Slow Window. A plunger arrival time that is greater (>) than the Slow Time is in the Slow Window. An arrival time that is greater (>) than the Current On-Time is in the No Plunger window. The user can calculate a good initial value using this equation:



Good Window=Depth of Tubing/600

Figure 12.3 Good Window

12 .4 .2 Initial in the Good Window area

Format: ## Oypical Value: 5 Legacy Keypad Command: 17 Legacy Label: INITIAL GOOD

Specify the number of arrivals in the Good Window before allowing the well to enter SALES mode (AFTERFLOW) This counter is the initial setting for the Good Window. The user can accept the default or specify a new value. The value does not change automatically.

12 .4 .3 Current in the Good Window area

Format: ## Oypical Value: 5 Legacy Keypad Command: 18 Legacy Label: CURRENT GOOD

After the initial setting by the user, this counter indicates the number of plunger arrivals within the Good Window. The AutoCycle program reduces this count for each arrival in the Good Window. When this counter reaches zero (0), the controller enters SALES (Afterflow) mode. The program resets this counter to the initial value for a No Arrival or the plunger arriving in the Slow Window.

12 .4 .4 (History Read Only)

Format: ## Legacy Keypad Command: 52 Legacy Label: ARRIVAL HISTORY

Indicates the number of plunger arrivals within this window. This value accumulates from the time the user selected the Clear Totals button.

12 .4 .5 Current Afterflow in the Good Window area

Format: HH:MM:SS Oypical Value: Legacy Keypad Command: 06 Legacy Label: AFTFLW

Specify the time period that the well is open after a plunger arrival.

If the user begins by shutting in on plunger arrival, the afterflow might initially be set at zero (0). The user might want to the program to enter Afterflow (SALES mode) immediately. The user needs to set the time and the well enters Afterflow on the first cycle. The first cycle occurs after the initial counts are satisfied. The limits on this value are the Minimum Afterflow Time and Maximum Afterflow Time. In either case, the Afterflow Time can change as plunger cycles progress.



12 .4 .6 Current Off-Time

Format: HH:MM:SS Oypical Value: Legacy Keypad Command: 04 Legacy Label: Total Off

Specify the total amount of time the well is off or shut in. The AutoCycle program adjusts this set point and the set point, Current Afterflow, in response to arrival times. Limits: This value cannot be set or adjusted to a value less than (<) than Minimum Off Time or greater than (>) the Maximum Off Time.

12 .4 .7 Min Off-Time

Format: HH:MM:SS Oypical Value: Tubing Depth / 200 Legacy Keypad Command: 05 Legacy Label: MIN OFF

Specify the lowest value that the program can reduce the Current Off-Time. This value ensures that the plunger has time to reach the bottom of the tubing before the well opens. The user can calculate a good initial value using this equation:

Min Off-Time= Depth of Tubing / 200

Figure 12.4 Min Off Time

12 .4 .8 Min Afterflow

Format: HH:MM:SS Oypical Value: Legacy Keypad Command: 07 Legacy Label: MIN AFLW

Specify the lowest value the Current Afterflow Time can reach. The user might want to set this to prevent a possible dry plunger run.

12 .4 .9 Max Afterflow

Format: HH:MM:SS Oypical Value: Legacy Keypad Command: 08 Legacy Label: MAX AFLW

Specify the highest value the Current Afterflow Time can reach. This setting allows for pressure draw down and can aid in gas measurement and fluid entry problems.



12.5 Slow Window Area

12 .5 .1 Current On-Time

Format: HH:MM:SS Oypical Value: Tubing depth/400 Legacy Keypad Command: 03 Legacy Label: TUBING ON

Specify the maximum amount of time the well is open and waiting for the plunger to arrive. This value sets the boundary between the Slow Window and No Plunger. The user can calculate a good initial value using this equation:

Current On Time=Depth of the Tubing/400

Figure 12.5 Current On-Time

12 .5 .2 Initial in the Slow Window area

Format: ## Oypical Value: 5 Legacy Keypad Command: 19 Legacy Label: INITIAL SLOW

Specify the number of arrivals within the Slow Window before the controller closes the well and applies adjustments to Current Afterflow and Current Off-Time. This counter is the initial setting for the Slow Window. This number determines how many consecutive Slow Arrivals the plunger makes before the controller shuts in the well. The user can accept the default of five (5) or specify a new value. The value does not change automatically.

12 .5 .3 Current in the Slow Window area

Format: ## Oypical Value: 5 Legacy Keypad Command: 20 Legacy Label: CURRENT SLOW

After the initial setting by the user, this counter indicates the number of plunger arrivals within the Slow Window. The AutoCycle program reduces this count for each arrival in the Slow Window. When this counter reaches zero (0), the well enters CLOSE (TUBING OFF) mode. The program resets this counter to the initial value if a plunger arrival is within the Fast or Good Windows.

12 .5 .4 (History Read-Only)

Format: ## Legacy Keypad Command: 52 Legacy Label



Indicates the number of plunger arrivals within this window. This value accumulates from the time the user selected the Clear Totals button.

12 .5 .5 Deduct from Afterflow in Slow Window

Format: HH:MM:SS Oypical Value: 5-15 minutes Legacy Keypad Command: 12 Legacy Label: A/F SLW (-)

Specify the amount of time to reduce Current Afterflow if arrivals are in the Slow Window or No Plunger and the Count is zero. The controller adjusts the Afterflow Time for every arrival in the slow arrival or No Arrival after the initial count is met. If Current Afterflow reaches the set point for the Minimum Afterflow Time, the controller ignores this value. A medium time value, such as 5-15 minutes, allows the controller to respond and adjust the plunger speed more appropriately.

12 .5 .6 Add to Off-Time

Format: HH:MM:SS Oypical Value: 15-30 minutes Legacy Keypad Command: 11 Legacy Label: OFF SLW (+)

Specify amount of time to increase Current Afterflow if arrivals are in the Slow Window and the Count is zero (0). If Current Off Time reaches the set point for Maximum off Time, this value is ignored. A medium time, such as default of 15-30 minutes, allows the controller to respond and influence the plunger speed more appropriately.

12.6 No Plunger Area

12 .6 .1 Initial in the No Plunger area

Format: ## Oypical Value: 3 Legacy Keypad Command: 21 Legacy Label: INITIAL N/A:

Specify the number of arrivals that occur after Current Afterflow expires before the well enters CLOSE (TUBING OFF) mode and the controller applies the adjustment to Current Off-Time. This counter is the initial setting for the No Plunger arrival. This set point determines how many consecutive No Arrivals the well makes before the controller enters CLOSE model. The user can accept the default of three (3) or specify a new value. The value does not change automatically.

12 .6 .2 Current in the No Plunger area

Format: ## Oypical Value: 3



Legacy Keypad Command: 22 Legacy Label: CURRENT N/A:

After the initial setting by the user, this counter indicates the number of times the plunger either did not arrive or arrived after Current On Time expired. The AutoCycle program reduces this count for missed arrival. When this counter reaches zero (0), the well enters CLOSE (TUBING OFF) mode. The program resets this counter to the initial value if a plunger arrival is within the Fast or Good Windows.

12 .6 .3 (History Read-Only)

12 .6 .4 Add to Off-Time in the No Plunger area

Format: HH:MM:SS Oypical Value: 30-60 minutes, 1 hour is the default Legacy Keypad Command: 13 Legacy Label: OFF N/A (+):

Specify the amount of time to increase Current Off Time if arrivals are longer than the set point for Current On Time. The controller adjusts the Current Off Time for every No Arrival. If the Current Off Time reaches the set point for Maximum Off Time, the controller ignores this value. A high value, such as the default of 60 minutes, allows the controller to respond and influence the plunger speed more appropriately.

12 .6 .5 Max Off-Time in the No Plunger Area

Format: HH:MM:SS Oypical Value: 99:59:59 Legacy Keypad Command: 26 Legacy Label: MAX OFF-Time

Specify the highest value that the controller can increase the Off Time using adjustments. A high value, such as the default of 99:59:59 allows the controller to make unlimited adjustments but does set a limit should the well conditions require it.

12.7 Pressure OverridesThe following table summarizes the set points available on the Pressure Overrides dialog box. The user can open this dialog box by selecting the Pressure Overrides button on the AutoCycle tab.



12 .7 .1 Open Tubing Valve (Production Valve) If Area

Label UsageCP >= Open the Tubing Valve if the Casing Pressure is greater than or equal-to the PSIG setting and the

Minimum Off Time has expired.

TP >= Open the Tubing Valve if the Tubing Pressure is greater than or equal to the PSIG setting and the Minimum Off Time has expired.

TP-LP >= Open the Tubing Valve if the Tubing Pressure - Line Pressure is greater than the PSIG setting and the Minimum Off Time has expired.

CP-LP >= Open the Tubing Valve if the Casing Pressure - Line Pressure is greater than the PSIG setting and the Minimum Off Time has expired.

CP-TP <= Open the Tubing Valve if the Casing Pressure - Line Pressure is less than the PSIG setting and the Minimum Off Time has expired.

Fluid Slug <= Open the Tubing Valve if the Fluid Slug setting is less than or equal to the PSIG setting and the Minimum Off Time has expired.

12 .7 .2 Close Tubing Valve (Production Valve) If Area

This area offers pressure set points that direct the controller to apply Casing Pressure Off Overrides only during Afterflow if on (YES).

Label PurposeCP <= Close the Tubing Valve if the Casing Pressure is less-than or equal-to the PSIG setting.

TP <= Close the Tubing Valve if the Tubing Pressure is less-than or equal-to the PSIG setting.

LP >= Close the Tubing Valve if the Line Pressure is greater-than or equal-to the PSIG setting.

HLDC < Clear High Line Pressure condition when Line Pressure falls below this setting.

CP-TP <= Close the Tubing Valve if the Casing Pressure - Tubing Pressure is less than the PSIG setting and the Minimum On Time has expired.

Flow Rate <= Close the tubing valve if the Flow Rate is less than or equal to the setting in MSCF.

12 .7 .3 Plunger Open Adjustments

Label PurposeCP (-) for Fast Open if CP >= decrease adjustment for Fast Arrival.

CP (+) for Slow Open if CP >= increase adjustment for Slow Arrival.

CP (+) for None Open if CP >= increase adjustment for No Arrival.

TP (-) for Fast Open if TP >= decrease adjustment for Fast Arrival.

TP (+) for Slow Open if TP >= increase adjustment for Slow Arrival.

TP (+) for None: Open if TP >= increase adjustment for No Arrival.

TP-LP (-) for Fast Open if TP-LP > decrease adjustment for Fast Arrival.

TP-LP (+) for Slow Open if TP-LP > increase adjustment for Slow Arrival.

TP-LP (+) for None Open if TP-LP > increase adjustment for No Arrival.

CP-LP (-) for Fast Open if CP-LP > decrease adjustment for Fast Arrival.

CP-LP (+) for Slow Open if CP-LP > increase adjustment for Slow Arrival.

CP-LP (+) for None Open if CP-LP > increase adjustment for No Arrival.



Label PurposeCP-TP (+) for Fast Open if CP-TP < increase adjustment for Fast Arrival.

CP-TP (-) for Slow Open if CP-TP < decrease adjustment for Slow Arrival.

CP-TP (-) for None Open if CP-TP < decrease adjustment for No Arrival.

Fluid Slug (+) for Fast Open if FSLUG >= increase adjustment for Fast Arrival.

Fluid Slug (-) for Slow Open if FSLUG >= decrease adjustment for Slow Arrival.

Fluid Slug (-) for None Open if FSLUG >= decrease adjustment for No Arrival.

12 .7 .4 Plunger Close Adjustments Area

Label PurposeCP (-) for Fast Close if CP <= decrease adjustment for Fast Arrival

CP (+) for Slow Close if CP <= increase adjustment for Slow Arrival

CP (+) for None Close if CP <= increase adjustment for Slow Arrival

TP (-) for Fast Close if TP <= decrease adjustment for Fast Arrival

TP (+) for Slow Close if TP <= increase adjustment for Slow Arrival

TP (+) for None Close if TP <= increase adjustment for No Arrival

Flow Rate (-) for Fast Close if Flow Rate <= decrease adjustment for Fast Arrival

Flow Rate (+) for Slow Close if Flow Rate <= increase for Slow Arrival

Flow Rate (+) for None Close if Flow Rate <= increase for No Arrival

12 .7 .5 Safety Shut-Down (PSIG) Area

Label PurposeMAX CP Specify the highest Casing Pressure the controller uses to close the well to prevent

damage to the well site.

MIN TP Specify the lowest Tubing Pressure that the controller uses to close the well to prevent damage to well site.

MAX TP Specify the highest Tubing Pressure that the controller uses to close the well.

12.8 Controls for OperationsStart N Cycle Button: Select to force the well on at the start of the program.

Start NFF Cycle Button: Select to force the well off at the start of the program.

Current Mode and Countdown Oimer Displays: Read the status of the program.

12 .8 .1 Options for controlling adjustments

TEnable Afterflow on Slow Arrival: If a plunger arrives in the Slow Window, this option allows the well to enter SALES mode instead of CLOSE mode. Typically, the controller closes the well if the Current counter reaches zero (0). The user might want to select this option if the Afterflow Time is long. This feature can prevent the next cycle from running dry.



Disable Adjustments: Check this option to stop making adjustments. Plunger Arrival Adjustments can be turned off or on with one press of the key. If for some reason you need to discontinue making adjustments, you may use this feature instead of changing all the individual values in the F1 menu.

TEnable Proportional Adjustments: Set the AutoCycle program to make adjustments in proportion to the difference of the arrival time from the Good Window. This option allows larger time adjustments as the arrival time deviates farther outside the Good Window. For arrivals in the Fast Window, the program can make larger time adjustments to decrease the Off Time and increase the Afterflow Time. For arrivals in the Slow Window, the program can make larger adjustments to increase the Off Time and decrease the Afterflow Time.

The program uses graduated values from the Fast Time to 50% of the Fast Window and graduated values from the Slow Time to 50% of the Slow Window. The minimum adjustment in either window is 25% of the adjustment setting.

12.9 Activity History (Read-only)Plunger Run Oimes: Displays the hours, minutes, and seconds for the last nine (9) plunger runs and the average of these 9 run times. The controller does not clear these values when you clear the totals.


114 8000 Series Walk Up Display

13 8000 Series Walk Up DisplayThe 8000 Series master controllers have a Walk Up display in a case at the site. This display provides the user with a keypad interface to the well automation system. This keypad interface connects directly to the controller. The user can monitor basic well data and configure a basic well program for plunger lift operations. This document describes the functions and commands the user can perform using the keypad.

Figure 13.1 The Walk Up Display is the manual interface to the well controller

13.1 Basic Key SequencesIn general, the user wants to complete one of the following tasks. The keypad has a key for each task.

• View the value of a current setting such as the battery voltage: READ

• Enter a new value such as a set point: SET

• View a report of events such as plunger arrivals: READ

• Enable or disable a feature

• [For the Multi-Well applications only] Select a wellhead and complete other commands


1158000 Series Walk Up Display

The table below shows examples of commands and their results.

Task + Command + ENTER Display ResultTo view information READ E.g., READ 00 ENTER, power status

To change a value SET E.g., SET ON ENTER, a set point

To page through a report READ E.g., READ 10 ENTER + PAGE buttons, the plunger counts

To enable or disable a feature SET E.g., SET 33 ENTER, metric mode

To make a choice SET E.g., SET 11 ENTER, production method

To select a well SET E.g., SET 52 ENTER, select Well 2 (Multi-Well only)

Table 13.2 Table 251: Examples of Command Sequences

Some well sites use Walk Up Display security to require the user to enter access codes. With security enabled, the 8000 Series controllers require the user to enter a four (4) digit PIN. The WellVision™ application offers this feature through the Keypad Config button on the Setup tab of controller.

Figure 13.3 Figure 252: Prompt for an Access PIN

Most keypad commands are available after entering the operator’s code. Some administrative commands require an administrator’s code. In this document, the administrator commands are marked with an asterisk (*).



NOTE For more information, see the “Understanding Well Site Communications” section of this document.

13.2 The Multi-Well™ Application Keypad CommandsThe following table is a list of commonly used commands. The user needs to press the Enter key after each command sequence.

8000 Series Multi-Well Application

Command + ENTER With master selected (default)

Command + ENTER

With a slave (well) Scope

READ Master Firmware Version ON Well x Turn ON Well/Force A-Open

SET B 9* Reset to Factory Defaults OFF Well x Turn OFF Well/Force A-Close

READ 00 Master Battery and Solar Voltages B ON Well x Force B-Open

READ/SET 22* Modbus Address READ Well x Firmware Version

READ 32* Secure Digital Card READ/SET ON Well x A-Open Time Interval

SET 32* Prepare SD Card for Removal READ/SET OFF Well x Close Time Interval

READ/SET 33* Metric Mode READ/SET B ON Well x B-Open Time Interval

READ/SET 34* Host Radio Baud Rate READ/SET B 0 Well x A-Open with B

READ 39 Master Alarm Status READ/SET B 2 Well x B-Delay Time Interval

SET 51 Select Well 1 READ 00 Well x Battery and Solar Voltages

SET 52 Select Well 2 READ/SET 02 Well x Sales Time Interval

SET 53 Select Well 3 READ/SET 03 Well x Mandatory Shut-in Time Interval

SET 54 Select Well 4 READ/SET 05 Well x Fall Time Interval

SET 55 Select Well 5 READ 06 Well x Plunger Travel History

SET 56 Select Well 6 SET 06 Well x Clear Plunger Travel History

SET 57 Select Well 7 READ 07 Well x Flow & Accums

SET 58 Select Well 8 READ/SET 08 Well x Delay Close Time Interval

READ 10Well x Totals-Counts, Time, Flows, History

SET 10 Well x Clear Totals

READ/SET 11 Well x Production Method

READ/SET 12 Well x Differential A-Open Pressure

READ/SET 13Well x Differential A-Close Pressure (DIP)

READ/SET 14 Well x High Line Close Pressure

READ/SET 15 Well x Low Line Close Pressure

READ 19 Well x Read Last A-Open/Close Times

SET 19 Clear Last A-Open/Close Times

READ/SET 20 Well x Casing Drop Pressure

READ/SET 21 Well x Casing Peak Time

READ/SET 24 Well x Load Factor



8000 Series Multi-Well Application

Command + ENTER With master selected (default)

Command + ENTER

With a slave (well) Scope

READ/SET 25 Well x Critical Flow K Factor

READ/SET 26 Well x Line Delay Time Interval

READ/SET 38 Well x Read Staging Mode

READ 39 Well x Alarm Status

READ 40 Well x Well Name/Group

SET 40 Well x Group #

SET 50 Select Master Controller

SET 51 Select Well 1








* Indicates commands that require an administrator PIN if the keypad is using the Walk Up Display security feature

Table 13.4 The SET command with 50 through 58 selects the master or a slave

13.3 The AutoCycle™ Program Keypad CommandsThe following table is a list of commands to monitor and configure the AutoCycle program using the keypad on a single-well controller. For most of the ACiC Hot Keys, the user can add 100 to the legacy command. Some hot keys have replacement commands for the same feature or function.

8000 Series AutoCycle Program8000 Series + ENTER Feature or Function ACiC Hot Keys

READ Firmware Version 60

READ/SET B ON Tank On (B Open Time) 31

READ/SET B 2 Tank Delay (B Delay Time) 30

READ 00 System Status (battery/solar voltages) 61

READ 10 Report Pages 1: Plunger Count and Tubing Cycles 2: Valve Counts and Tank Cycles 3-4: Time Totals 5: Accumulations

6-11: Plunger Run Times and History

51-58

SET 10 Clear the Totals 56

READ/SET 26 High Line Shut In Delay 77

READ/SET 100 Auto-Cycle Status: enabled/disabled n/aREAD/SET 101 Fast Time 01




READ/SET 102 Slow Time 02

READ/SET 103 Current On Time (A Open Time, Tubing On Time) 03

READ/SET 104 Current Off Time (Tubing Off Time, Close Time) 04

READ/SET 105 Minimum Off Time (Close Time) 05

READ/SET 106 Afterflow Time (Sales Time) 06

READ/SET 107 Minimum Afterflow Time (Sales Time) 07

READ/SET 108 Maximum Afterflow Time (Sales Time) 08

READ/SET 109 Off Time Decrease (-) for Fast Arrival 09

READ/SET 110 Afterflow Time (Sales Time) Increase (+) for Fast Arrival 10

READ/SET 111 Off Time increase (+) for Slow Arrival 11

READ/SET 112 Afterflow Time (Sales Time) decrease (-) for Slow Arrival 12

READ/SET 113 Off Time increase (+) for No Plunger Arrival 13

READ/SET 115 Initial Fast Plunger Arrival Count 15

READ/SET 116 Current Fast Plunger Arrival Count 16

READ/SET 117 Initial Good Plunger Arrival Count 17

READ/SET 118 Current Good Plunger Arrival Count 18

READ/SET 119 Initial Slow Plunger Arrival Count 19

READ/SET 120 Current Slow Plunger Arrival Count 20

READ/SET 121 Initial No Plunger Arrival Count 21

READ/SET 122 Current No Plunger Arrival Count 22

READ/SET 126 Maximum Off Time 26

READ/SET 127 Early Arrival Time 27

READ/SET 128 Initial Early Plunger Arrival Count 28

READ/SET 129 Current Early Plunger Arrival Count 29

READ/SET 144 Tubing Pressure-Line Pressure Adjustment for Fast Arrival n/a

READ/SET 145 Tubing Pressure-Line Pressure Adjustment for Slow Arrival n/a

READ/SET 146 Tubing Pressure-Line Pressure Adjustment for No Arrival n/a

READ/SET 147 Fluid Slug Adjustment for Fast Arrival n/a

READ/SET 148 Fluid Slug Adjustment for Slow Arrival n/a

READ/SET 149 Fluid Slug Adjustment for No Arrival n/a

READ/SET 162 Control Option Pages: 1: Afterflow on Slow Arrival: enable/disable 2: Plunger Arrival Adjustments: enable/disable 3: Proportional Adjustments: enable/disable 4: Early Plunger Arrival: enable/disable (120)

62

READ/SET 168 Open if Tubing Pressure-Line Pressure > than the set point 100

READ/SET 169 Open if Fluid Slug >= to the set point 101

READ/SET 170 Open if Casing Pressure >= to the set point 70

READ/SET 171 Open if Tubing Pressure >= to the set point 71

READ/SET 172 Close if Casing Pressure <= to the set point 72

READ/SET 173 Close if Tubing Pressure <= to the set point 73

READ/SET 174 Close if Differential Pressure <= to the set point 74READ/SET 176 Close if Line Pressure >= to the set point 76




READ/SET 178 Open Casing Pressure decrease (-) for Fast Arrival 78

READ/SET 179 Open Casing Pressure increase (+) for Slow Arrival 79

READ/SET 180 Open Arrival Casing Pressure increase (+) for No Plunger 80

READ/SET 181 Open Tubing Pressure decrease (-) for Fast Arrival 81

READ/SET 182 Open Tubing Pressure increase (+) for Slow Arrival 82

READ/SET 183 Open Tubing Pressure increase (+) for No Plunger Arrival 83

READ/SET 184 Close Casing Pressure decrease (-) for Fast Arrival 84

READ/SET 185 Close Casing Pressure increase (+) for Slow Arrival 85

READ/SET 186 Close Casing Pressure increase (+) for No Plunger Arrival 86

READ/SET 187 Close Tubing Pressure decrease (-) for Fast Arrival 87

READ/SET 188 Close Tubing Pressure increase (+) for Slow Arrival 88

READ/SET 189 Close Arrival Tubing Pressure increase (+) for No Plunger 89

READ/SET 190 Close Differential Pressure decrease (-) for Fast Arrival 90

READ/SET 191 Close Differential Pressure increase (+) for Slow Arrival 91

READ/SET 192 Close Arrival Differential Pressure increase (+) for No Plunger 92

READ/SET 193 Maximum Casing Pressure Shut in 93

READ/SET 194 Minimum Tubing Pressure Shut in 94

READ/SET 195 Maximum Tubing Pressure Shut in 95

* Indicates commands that require an administrator PIN if the keypad is using the Walk Up Display security feature

Table 13.5 8000 Series Commands for the AutoCycle Program

The following ACiC Hot Keys are obsolete.

• Synch Mode (23)

• Flow Time (24)

• Plunger Catch Mode (25)

• Tank Cycles (57)

• TTL Tank On/Gauge Readings (58)

• Set Password (63)

• Low Differential Pressure Delay (75) Use pressure overrides

• H-L Delay (77)

• Recovery Off Time (102)

• Shared Flow Mode (119)

• Initial Recovery Count (121)

• Current Recovery Count (122)

• Reset To Minimum Afterflow (123)


120 Monitoring Tank Levels

14 Monitoring Tank LevelsThe 8800™ Site Manager or 8400™ controllers can monitor and respond to devices that measure levels in the tanks of a well system. The tank management devices can connect directly to the master controller, a slave controller, or a remote IO device. The location depends on the well site and the needs of the well system.

Figure 14.1 The WellVision application includes Tank Level Management

14.1 Understanding the Tank Management SystemThe Tank Management System requires two types of configuration: the system and the tank. For the system, the user specifies the frequency the controller polls for information about the tanks and the values in the information that initiate warnings or shut-in of the well. For the tanks, the user specifies the Modbus addresses for the devices that provide the tank information, identifies the dimensions of the tanks, and specifies the values that initiate a warning or shut in.

14 .1 .1 System Settings

The controller’s communications with the tanks are critical to managing the tanks and preventing accidents. The user specifies the polling interval that set the frequency that the controller queries the devices. This interval is unique to the well site. The user needs to set this value at a level that can detect and respond to the warning and shut-in values before the tanks are too full. The rate of production determines the interval. If the interval is too short, the controller fills the logs with unnecessary entries that can hide significant trends. The extra entries also use memory unnecessarily. If the interval is too long, the controller might get data too late to respond to a shut-in condition. The delay might cause damage to equipment.

The System Setup tab, shown below, specifies the settings that apply to the management of all of the tanks. The following options are available in this tab:

• The Modbus address of the monitoring device

• The measuring system the user wants the controller to use for displaying and logging data

• How often the controller polls for data from the input devices


121Monitoring Tank Levels

• The voltage at which the unit alarm or shut-in for low battery and communication errors

• [Optional] Memory use estimate for determining how often to poll the device. Memory is a secondary factor; gas production rate is the primary.

• [Optional] Creating a sniff file to examine the RS-485 communications

Figure 14.2 The System Setup for Tank Management

14 .1 .2 Tank Settings

The PCS Ferguson Tank Management system can manage up to 24 tanks. Each row in the figure below represents one tank configuration. For each tank, the user identifies the communications for each device that provides input to the controller. On the Tank Setup tab, column 1 configures a name for the tank. Columns 2-6 configure the Modbus addresses to devices. Columns 7 and 8 identify the dimensions of the tank. Column 9 and 10 specify the levels raise an alarm or shut-in the well.

Figure 14.3 The system can manage up to 24 tanks



14 .1 .3 Alarms and Shut-Ins

The user can set alarm and automatic shut in conditions based on the tank level readings. For example, the figure below indicates that both the level of the tank and the number of communications error can raise a warning or shut-in the well.

Figure 14.4 Warnings and Shut-ins Window

The manager uses the values in the system settings and tank settings to calculate automatically the percentage of the tank that is full when the fluid level reaches the specified height. Based on the settings, the manager can initiate a warning or shut-in the well. The user can decide the source of the command to resume operations.

• Allow only a host command: Limits the ability to restart operations to commands from the host port. This option disallows the ability to use the keypad on the controller to start operations. The user must connect directly through the host port or remotely through the host port. This connection could be through the radio network or a cellular modem. The user needs to use the Resume Well Operation button available on the Status tab of PCS Ferguson Tank Management System.

• Allow the command from the host or the keypad: The user can start operations using a connection to the host port or keypad of the Walk Up Display.

• Allow the manager to resume operations automatically when the controller detects that the shut-in conditions have cleared: The user can choose this option to let the controller evaluate conditions and start operations when the conditions have returned to normal.

14 .1 .4 Polling Interval

The Polling Interval is specific to the well site. The user must set the interval to insure that the controller detects warnings or shut-ins promptly. An incorrect interval can result in delays in appropriate responses and possible safety or equipment issues.



However, the interval also affects the content of the data logs and the memory usage. The system uses datalogs 32 thru 55 for tanks 1 through 24. When the memory buffer is full, the controller writes over the oldest data. The number of data points is constant, but the number of days stored depends on the polling interval. The more frequent the polling rate, the log shows fewer days. This setting affects the history and the data available for monitoring trends. For more information about datalogs, see “” in the Guides section of the Help Documents.

If the system has a high number of tanks, a short poll interval can cause Modbus communication errors. A short poll interval might not allow enough time to poll the tanks before the next poll begins. If the user sets an interval of less than (<) five (5) minutes, a yellow warning appears to alert the user to possible Modbus communication errors.

14 .1 .5 The Tank Configuration File

After setting up the Tank Level Management system, the user can save the configuration to a .csv file. This file saves the values for both the system settings and for the individual tanks. The user can recover the configuration using this file. If the Modbus address has changed, the user must update that setting in the System Setup tab in order to read the tank information.

14.2 PreparationTo successfully setup and configure tank management, the well system needs the following in place and operational:

• Tanks piped to the wells

• Tank level measurement system such as OleumTech™ or iTank Level

• A configuration file (.csv) to import or manufacturer’s documentation

– Modbus information for

– Register

– Data type

– Function

• Tank height, diameter, and the maximum and minimum fluid levels

• PCS Ferguson 8000 Series Well Site SCADA™ Controllers

14.3 Task List for Tank ManagementThe user needs to complete the following tasks to configure the master controller to monitor and respond to tank levels.

Setup Tasks• Import an existing configuration file or configure communications and alarms for each tank

• For the Tank Management system, configure the communications and alarms

Monitoring Tasks• Check the status of the configuration

• Respond to warnings and shut in events



14.4 Configure TanksThe user needs to add the information for the tank to the PCS Ferguson Tank Management system. The system is available from the Status tab.

The system provides the user with features to complete the following tasks:

• Set up the configuration of the tanks

– By entering tank values directly

– By opening a WellVision file for tank configurations

– By importing from OleumTech or iTank Level

• Save the tank configurations to a file

• Clear the tank configurations

14 .4 .1 Importing an OleumTech or iLevel Tank configuration file

The manufacturer for the base unit might offer an existing configuration file. The user can import certain manufacturer’s files directly into the PCS Ferguson Tank Management system.

To import a tank system configuration1. In WellVision, connect to the controller.

2. On the Status tab, select the Oank Level button

3. On the Oank Setup tab of the PCS Ferguson Oank Management System window, select the Import iLevel or Nleum settings button.

4. In the Import dialog box, locate and select the .csv file for the tank configuration and then select the Npen button.

The values in the Tank Setup tab fill and remain highlighted in yellow. The user might need to complete the row for each tank if the .csv does not contain the dimension or alarm information. For more information, see “Configuring Tanks in the WellVision Application” for completing those columns.

5. Verify that the values are appropriate and then select the Set button.

6. [Optional] To save the configuration, select Save to File on the Oank Setup tab and complete the Save Settings dialog box.

14 .4 .2 Configuring Tanks in the WellVision Application

If the user does not have a configuration file to import, the user can add the tanks and communication information directly into the WellVision application.

To configure a tank, the user needs the following information:

• Tank name

• From the base unit documentation: Modbus registers for the gauges and probes in the tank.

• Tank dimensions: height and diameter

• Values for warnings and shut-ins



If the user knows the percentages for when to warn and when to shut-in, the application calculates the values for the level and the margin. If not, the user can enter the level or the margin to fill the percentage automatically.

To configure a tank manually in the WellVision application1. In WellVision, connect to the controller.

2. On the Status tab, select the Oank Level button

3. In the PCS Ferguson Tank Management System window, select the Oank Setup tab.

Figure 14.5 Each row represents a tank and associated inputs, dimensions, and alarm values

4. On the Oank Setup tab, enter a name in the Oank ame column.

5. In the columns, Oop Fluid Level – CNMMS TErrors, select the cell in the column to open the Modbus Setup dialog box and enter the Modbus Register information from the base unit for the probes and then select the NK button. Complete this step for each column.

Figure 14.6 The base unit documentation has the Modbus Register values

6. In the Oank Height and Oank Diameter columns, select the cell and enter the dimensions of the tank to open the dialog box for the column and then select the NK button.

NOTE The application uses these values to calculate the warning and shut-in values.



Figure 14.7 Tank Height

7. In the Warning and Shut-in columns, select the cell and enter the values for the maximum and minimum levels, and then select the NK button.

NOTE For the maximum values, the application automatically updates the other values the user enters a percentage or feet and inches.

Figure 14.8 The set up dialog box for a Warning and Shut-in are the same

8. After configuring the tanks, select the Set button to commit the changes.

14.5 Tank System ConfigurationThe user can configure the system settings before or after configuring the tank settings. The System Setup tab, shown below, offers the following features:

• The Modbus address of the monitoring device

• The measuring system the user wants the controller to use for displaying and logging data

• How often the controller polls data from the devices

• The voltage value that initiates an warning or shut-in for low battery

• The number of communication errors that initiate a warning or shut-in because the communications have become unreliable



• [Optional] Memory use estimate for determining how often the unit should be polled

• [Optional] Create a sniff file for the polling device to test

Figure 14.9 The System Setup tab offers configuration features

To configure the tank system1. On the System Setup tab, enter the Modbus address for the base unit.

2. Examine the remaining defaults for communications, warnings, and shut-in and then adjust to meet the needs of the well system.

3. [Optional] To use the Modbus Analyzer to examine the communications, select the number of test polls and then select Start the Oest Poll and Sniff button.

4. [Optional] If memory is a concern, select Memory Use TEstimate. For more information, see the section on Polling Interval earlier in this document.

14.6 Monitoring Levels in the TanksThe user can configure and monitor tank level devices in WellVision such as PCS Ferguson’s iTank or OleumTech.

14 .6 .1 Review Current Status

The user might want to review the status of the tanks. For example, the controller might be set to shut in a well in response to a tank level reading. The user can review the status of the tanks and resume operations, if appropriate.

To review the status of the tanks1. Open WellVision and connect to the controller.

2. On the Status tab, select the Oank Level button.



Figure 14.10 The Status tab

3. Examine the information.

4. To update the display, select the Refresh button.

5. If appropriate, select Resume Well Nperation button.

14 .6 .2 Review Tank Trends

The user can view a summary of the tanks the system is monitoring.

The Orend tab allows the user to complete the following tasks:

• Clear the trend data for all tank levels

• Upload the trend data from the tank level monitor



Figure 14.11 The Trend Tab

To view trend data for the tanks1. On the Orend tab, select Upload Orend Data.

2. In the Upload dialog box, select the box next to the dates the user wants to view and then select the Upload button.

The Status box displays the progress of the upload. Then the operation is complete, the user sees “DONE:” and a count of data points.

Figure 14.12 Upload window displays the available log files



3. Select the View data button to open the View Datalogs window with tabs for each log.

4. To close the window, select the Red X button.

14 .6 .3 Respond to Tank Level Alarms

If the controller detected levels that match the warning or shut-in values set in the configuration, the application raises a warning or closes the wells.

To respond to a tank level alarm1. Open WellVision and connect to the 8800 Site Manager or 8400 controller.

2. On the controller’s Status tab, select the Oank Level button to open to the Status tab of the Oank Management window.

Figure 14.13 The user can select in the column, Warning & Shut in, for the details

3. On the Status tab, select the alarm to open the Warning and Shut-in dialog box.

Figure 14.14 Warnings and Shut-ins Window



4. Examine the information and select Acknowledge, and then select the Close button.

For example, in the figure above, the controller detected that the tank’s fluid level matched the maximum in the configuration settings.

The type of alarm determines what the user might want to do.


132 Viewing Graphs of Well Performance

15 Viewing Graphs of Well PerformanceTo make optimization decisions, the user can examine graphs showing well performance over time. The controller uses the raw data from the input and output devices to generate a trend graph. A graph provides the user with practical information to make decisions about adjustments to the well program.

A few of the questions the user might have are:

• When did the well last open and how often has the well turned on in a day?

• Is the plunger arriving consistently?

• What are the basic flow rates?

• What are the pressures for casing, tubing, and line when the well opens?

• What setting for differential open pressure might improve production?

The user can get a quick view of performance and do an in-depth analysis with a Well Trending Graph.

15.1 PreparationThe user needs the following items to view a graph:

• Connection to a well or import of a Well Export File (.wxf) from a well

• Datalog uploaded to the computer

15.2 General Task ListA graph shows performance of a well over a time interval. The graph uses values from the datalog, Log1: Well Control. The WellVision application uses the log data to calculate values for additional data points on the graph. The following list describes the tasks the user might want to perform.

• View a basic graph of a well’s data

• View a summary of the data within a timeframe

• View the details within a timeframe

• View the raw data behind the graph and statistics

• Export the data to other formats

• Customize the graph window

• Configure the colors and content of the graph


133Viewing Graphs of Well Performance

15.3 View a Basic Well Trending GraphA graph shows performance of a well over a time interval. The graph uses values from the datalog, Log1: Well Control. The WellVision uses the log data to calculate values for additional data points on the graph. The user can view the calculated values in the Raw Data view.

To view a trending graph and choose a timeframe1. In the WellVision Main window, select a well and then select the Analyze button.

Figure 15.1 A graph shows data in Log 1: Well Control

– The data inputs are color-coded.

– The red letters indicate Reason Codes for changes from well program.

– To understand the symbols in the graph, select the Keys button on the toolbar and review the Mode Graph Key window and the Reason Code Key window.



Figure 15.2 The keys describe the symbols and colors in the graph

2. To show a specific date, select the Start Date button and then select a day from the Select Date dialog box.

NOTE The display shows only data from dates available on the computer. The user can view the Upload dialog box to check for files that are on the controller but not uploaded to the computer.

3. To scroll through the graph, select the arrow buttons.

• To scroll one grid view, select a single arrow button.

• To scroll one page view, select a double arrow.

4. To set the timeframe of Page View and Grid View, select the Zoom In button or Zoom Nut button to change the time interval.

NOTE To specify an interval, select from 1 hour to 30 days from the 12 Hours drop-down menu. This setting specifies the increments that the arrow buttons scroll the view.



Figure 15.3 The user can change time interval of the display

5. To add production to the graph, select the Daily Production button.

6. To print the graph, select the Print button on the toolbar.

15.4 View a Summary of Data within a TimeframeThe user might want to see the performance data summarized. The view in the Trend Graph window sets the timeframe of the data in the summary. The user can add lines to the graph using the Optional Traces feature.

To view a summary of the well’s performance1. In the WellVision Main window, select a well and then select the Analyze button.

2. To select the data to view, set the start date and zoom to the time interval the user wants to summarize.

3. On the toolbar, select the Statistics button to open a summary view of the data.



.

Figure 15.4 Calculations use raw data to show summary values for the select data

4. To close the window, select the Red X button.

5. [Optional] To add other information to the graph, select the Configure button to open the Configuration window and use the Optional Traces feature.

15.5 View Details and Calculations within a TimeframeThe user might want to analyze the pressure details within a timeframe. For example, if the user needs pressure details for choosing a value for the Differential Open Pressure set point, the user can examine the details using the Markers feature of the Well Trending Graph.

To examine details and calculate differentials within a timeframe1. In the WellVision Main window, select a well and then select the Analyze button.

2. Set the graph to show the timeframe that has the activity the user wants to analyze.

3. On the toolbar, select Markers to add the Makers table and Marker Lines to the graph.



Figure 15.5 The Markers table shows calculations using the marked data points

4. Select and position the markers around a pressure event.

5. Move the cursor to examine a specific position on the graph.

6. Examine the table and adjust the lines and cursor to change the results.

7. To examine the corresponding raw data, select the Oile button or Raw Data button.

Figure 15.6 Raw Data window shows a text version of the data points

8. To view values in the columns, scroll.

Column DescriptionDate Timestamp from the Well Trend log

Daily Production

Casing Pressure reading from the Well Trend log

Tubing Pressure reading from the Well Trend log

Line Pressure reading from the Well Trend log



Column DescriptionFlow Rate of the gas flow at that point in

time

Casing-Tubing Differential calculation

Casing-Line Differential calculation

Tubing-Line Differential calculation

%LF Load Factor Percentage calculation

Reason Condition met, see the Code Table

Mode Change in the plunger cycle

Valve Open or close of the Production Valve or Tank Valve

Plunger Arrival of the plunger detected

Valve open Time reading when that the valve opened

Travel Time Time calculation from the start of A OPEN mode to the plunger arrival

Last Close Time reading of last valve closure

Last Open Time reading at last valve open

* The Keys button opens lists that describe the values in this column.

Table 15.7 Value Descriptions

9. [Optional] To change the amount of data the view shows, select one of the following options.

• The TExpand All or Collapse All buttons

• From Well Control and Daily dropdown menu, select a scope.

– Well Control shows well program data without daily production data.

– Daily shows the total daily production for each day in the chosen interval.

– Daily and Well Control shows both with Daily production at the beginning of each days data.

10. To export the data, select from the following options:

• Save as a .csv file on the computer.

• Email to someone in the WellVision address book configured by the user.

• Save as a Microsoft Excel spreadsheet.


139Multiwell IO Worksheet

Appendix A: Multiwell IO WorksheetSample Well Name North Valley

Group Number Group 1

Modbus address 32

Input Source For…

Production Valve WC Local

Tank Valve WC Local

Sensor 101

Casing 101

Tubing 101

Line 101

Surface Casing 101

Gas Temperatures Disabled

Separator Temp Disabled

Shutin Switch 1 Disabled





Flow EFM Disabled

Read Today/Yesterday Accum from EFM No

Translator has Accumulation Tracking Support No

Assign Closed Flow to the “9th Well” No

Synchronize Well Cloc to the EFM No

Enable Sleep Control No

Oil Flow Meter Disabled

Water Flow Meter Disabled

Table A.1 Multi-Well ™IO Worksheet 1


140 Multiwell IO Worksheet

Well Name (1-4) WELL 1 WELL 2 WELL 3 WELL 4

Group Number

Modbus address

Input Source For…

Production Valve

Tank Valve

Sensor

Casing

Tubing

Line

Surface Casing

Gas Temperatures

Separator Temp

Shutin Switch 1

Shutin Switch 2

Shutin Switch 3

Shutin Switch 4

Shutin Switch 5

Flow EFM Read Today/Yesterday Accum from EFM yes/no yes/no yes/no yes/noTranslator has Accumulation Tracking Support yes/no yes/no yes/no yes/noAssign Closed Flow to the “9th Well” yes/no yes/no yes/no yes/noSynchronize Well Clock to the EFM yes/no

Enable Sleep Control yes/no yes/no yes/no yes/no

Oil Flow Meter

Water Flow Meter



141Multiwell IO Worksheet

Well Name (5-8) WELL 5 WELL 6 WELL 7 WELL 8

Group Number

Modbus address

Input Source For…

Production Valve

Tank Valve

Sensor

Casing

Tubing

Line

Surface Casing

Gas Temperatures

Separator Temp

Shutin Switch 1

Shutin Switch 2

Shutin Switch 3

Shutin Switch 4

Shutin Switch 5

Flow EFM Read Today/Yesterday Accum from EFM yes/no yes/no yes/no yes/noTranslator has Accumulation Tracking Support yes/no yes/no yes/no yes/noAssign Closed Flow to the “9th Well” yes/no yes/no yes/no yes/no

Enable Sleep Control yes/no yes/no yes/no yes/no

Oil Flow Meter

Water Flow Meter



142 Agency Compliance

Appendix B: Agency ComplianceRefer to details below regarding hazardous locations certification:

Manufacturer: PCS Ferguson 3771 Eureka Way Frederick, CO 80516 (720) 407-3550 www.doverals.com

Electrical Rating: 12Vdc, 100a

Ambient Temperature Rating: -40°C ≤ Ta ≤ 70°C

Enclosure Material: 5052-H32 Aluminu

Paint: Cardinal RD030

Table B.1 Hazardous Locations Certification

CAUOIN This equipment is suitable for installation in Class I, Division 2, Group C and D hazardous locations or nonhazardous locations only.

WAR I G Explosion Hazard. Do not connect or disconnect this equipment unless power has been removed or the area is known to be nonhazardous.

WAR I G Explosion Hazard. Substitution of components may impair suitability for Class I, Division 2 hazardous areas.

NOTE PCS Ferguson 8800 Series components must be connected to a power source (i.e. solar panel) rated 12V dc nominal, 26V dc maximum, open circuit; 8A nominal, 10.5A maximum short circuit and appropriately certified for the location. Power source is subject to investigation by the Local Authority Having Jurisdiction at the time of the installation.

NOTE Wiring to or from this equipment, which enters or leaves the system enclosure, must utilize wiring methods suitable for Class I, Division 2 Hazardous Locations as appropriate for the installation.