ABB Totalflow Plunger User Guide

TOTALFLOW Plunger Lift Control Users Guide
Application Part Number 2102890-001
User's Guide 2102890-001
Plunger Lift Control
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Table of Contents
Totalflow Hardware Requirements:........................................................................................ 3 I/O Requirements.......................................................................................................................... 3 Program Description................................................................................................................ 4 Overview....................................................................................................................................... 4 Plunger Lift Control...................................................................................................................... 4 General scheme...............................................................................................................4 Overview.........................................................................................................................6 Conditions to open the Production valve.............................................. 6 Conditions to close the Production valve............................................. 6 Conditions to open the Blow valve for helping plunger arrival.............. 7 Other options....................................................................................... 7 Blow valve cushion timer..................................................................... 7 Integrating with Valve Control.............................................................. 8 Turner Flow Rate Calculation............................................................... 8 Tuning.................................................................................................. 8 Operation........................................................................................................................ 9 State 0: Fail.......................................................................................... 9 State 1: Closing Valve.......................................................................... 9 State 2: Valve Closed.......................................................................... 9 State 3: Plunger Arriving...................................................................... 10 State 4: Blow Valve.............................................................................. 10 State 5: Plunger Arrived....................................................................... 11 State 6: Afterflow.................................................................................. 11 PCCU Screens.......................................................................................................................... 12 Plunger.......................................................................................................................................... 12 Plunger-Setup................................................................................................................................14 Plunger - States............................................................................................................................. 20 State 1 Closing Valve..................................................................................................... 23 State 2 Valve Closed.......................................................................................................25 State 3 Plunger Arriving................................................................................................. 48 State 4 Blow Valve........................................................................................................ 53 State 5 Plunger Arrived.................................................................................................. 60 State 6 Afterflow.............................................................................................................62 State 0 FAIL................................................................................................................... 81 Plunger - Statistics........................................................................................................................ 82 Misc................................................................................................................................ 82 Closed............................................................................................................................. 84 Plunger ...........................................................................................................................87 Flow................................................................................................................................ 90 Blow ...............................................................................................................................92 Slug ................................................................................................................................ 93 Register List............................................................................................................................. 95 Initial Set-Up.............................................................................................................................. 95 Flow Computer............................................................................................................................. 95 Plunger Lift Control...................................................................................................................... 95 Change Log:.............................................................................................................................. 96 Recommended Module Wiring - Direct I/O Option................................................................. 97
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Totalflow Hardware Requirements:

X series electronic board: xFC (P/N 2100204-xxx), or xRC (P/N 2100355-xxx) Flash: xFC (P/N 2102888-xxx) or xRC (P/N 2102889-xxx) Optional Valve Control module (P/N 2100412-xxx) Other IO modules as needed to meet IO requirements. Cables, connectors etc.
I/O Requirements
Input/Output (I/O) requirements shown below are specific to this application. Analog Inputs (AIs) Tubing pressure (optional) Line pressure (optional) Casing Pressure (optional) Plunger Input 1 (optional) Plunger Input 2 (optional) Hold Input (optional) Digital Inputs (DIs): Plunger arrival switch (Pulse Input) Open Push Button (optional) Close Push Button (optional) Restart from Plunger Fail (optional). DIs needed if valve control module is used. These IO points are part of that module. Full open status input Full closed status input Local lockout External event input
Digital Outputs (DOs) Close main valve (If valve control module is used, must be on that module). Open main valve (If valve control module is used, must be on that module) Close a Vent or Blow valve. (optional) Open a Vent or Blow valve. (optional) Close a Plunger Capture valve. (optional) Open a Plunger Capture valve. (optional)
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Program Description
Overview
This application is based on the IEC Plunger Lift application (2102217) however a number of additions have been made to the operation of the Plunger logic.

This application allows the user to control a plunger on a production well. Adaptive algorithms make adjustments in order to optimize plunger rise times and gas production. Plunger Lift is used to increase gas production by keeping liquids off the formation and/or reduce freeze-up. Generally speaking, it is used on wells that do not have enough constant down hole pressure to free flow into a gathering system.
General scheme
Steel plunger is inserted into the production tubing. Shut-in causes plunger to fall allowing fluid to collect above plunger. Different methods are used to decide how long to shut-in and flow well. Down hole pressure is used to lift the plunger and fluid to surface.
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Overview
The plunger logic is made up of a combination of previous plunger lift applications plus the addition of Turner Flow Rate logic. Additional close and open logic has been added. A general description of the Plunger Lift logic follows. Please note that the valve position relative to the meter determines which inputs are used for line pressure and tubing pressure. The valve position is specified as part of the setup for the plunger logic. If valve control is used as an integral part of the advanced plunger logic then the specification of the valve position must be done from the valve control set up screens. If valve control is not used, then the valve position is specified on the plunger logic set up screen. If the valve position is Downstream then: the line pressure is read from the input specified using the Ext Pressure AI, and the tubing pressure is read from the input specified using the AP Register and the value in the Baro Press Register is subtracted from it to calculate the tubing pressure in PSI. If the valve position is Upstream then: the line pressure is read from the input specified using the AP Register and the value in the Baro Press Register is subtracted from it to calculate the line pressure in PSI, and the tubing pressure is read from the input specified using the Ext Pressure AI. Conditions to open the Production valve If any one of the following conditions is TRUE and the valve is closed, then the valve will be commanded open. Those noted with (opt) are optionally enabled by user setup. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. (opt) Timer > Limit (opt) (Tubing pressure Line Pressure ) > Limit (opt) ( Casing Pressure Tubing Pressure) > Limit (opt) (Casing Pressure Line Pressure ) > Limit (opt) ((Casing Pressure Line Pressure ) > Limit) AND ((Tubing pressure Line Pressure ) > Limit) (opt) Load Ratio < Limit for a user specified time AND Casing Pressure greater than Line Pressure by user specified amount OR Load Ratio < Load Ratio Trip (opt) (Tubing pressure > Limit) OR (Tubing pressure < Limit) for user defined amount of time (opt) (Casing pressure > Limit) OR (Casing pressure < Limit) for user defined amount of time (opt) (Static pressure > Limit) OR (Static pressure < Limit) for user defined amount of time (opt) Slug Size > Limit (opt) (Input 1 > Limit) OR (Input 1 < Limit) for user defined consecutive minutes (opt) (Input 2 > Limit) OR (Input 2 < Limit) for user defined consecutive minutes (opt) Mandatory close timer > Mandatory close time. This is only used after a plunger non-arrival. (opt) Total Cycle time from valve open to valve open. (opt) Hold in closed state if status indicates (opt) Hold in closed state if pressure >= limit (opt) Hold in closed state during certain hours of the day. (opt) Using the Open Push Button. NOTE: This will open the valve even if the valve has just been closed and the plunger has not fallen to the bottom of the tubing.
Conditions to close the Production valve If any of the following conditions are TRUE and the controller is in after flow state, then the valve will be commanded closed. Those noted with (opt) are optionally enabled by user setup. (opt) Timer > Limit (opt) DP < Limit for user defined amount of time (opt) Flow Rate < Limit for user defined amount of time (opt) (Tubing Pressure Line Pressure) < Limit (opt) ( Casing Pressure Tubing Pressure) < Limit (opt) Casing Pressure < Limit (opt) (Flow Rate < (Turner flow * Turner Multiplier) AND ( ABS(Line pressure casing pressure) < User specified value) for user defined amount of time 8. (opt) Load Ratio < Limit for a user specified time 9. (opt) (Tubing pressure > Limit) OR (Tubing pressure < Limit) for user defined amount of time 10. (opt) (Casing pressure > Limit) OR (Casing pressure < Limit) for user defined amount of time 11. (opt) (Static pressure > Limit) OR (Static pressure < Limit) for user defined amount of time 12. (opt) Slug Size > Limit 13. (opt) (Input 1 > Limit) OR (Input 1 > Limit) for user defined amount of time User's Guide Plunger Lift Control 6 of 97 2102890-001 January 15, 2007 1. 2. 3. 4. 5. 6. 7.
14. (opt) (Input 2 > Limit) OR (Input 2 > Limit) for user defined amount of time 15. (opt) Using the Close Push Button. Conditions to open the Blow valve for helping plunger arrival If any of the following conditions are TRUE and the controller is waiting for plunger arrival, then the blow valve will be commanded open. This is a separate action from the existing blow valve state, which is activated by number of arrivals that exceed the maximum arrival time. These conditions will simply open the blow valve in an effort to help the plunger arrival. The controller will remain in the plunger arrival state. 1. 2. 3. 4. (opt) Casing Pressure < Setpoint (opt) Flow Rate < Setpoint for user defined amount of time (opt) DP < Setpoint (opt) Timer > Setpoint
Other options 1. Ignore conditions during the close valve state for a user set time. The plunger fall delay setting and the optional Plunger Drop detection logic provides this. 2. Set flow control rates and DP during the plunger arrival and after flow. Enabling the valve control option and selecting a valve open method provide this. Enabling this option requires that the Valve Control application be running with the Valve Control I/O module. 3. Auto tune pressure adjustment increment at a larger value if a plunger arrival failure should occur. This larger tuning value will be in effect only during the tuning that takes place immediately following the plunger arrival failure. 4. Automatically tune (if enabled) conditions that open and close the production valve (see section on Tuning). 5. Shutdown (fail) when battery voltage gets too low or if Pressure violates the Hi or Low Shutdown Limits (this is provided by the Safety System application). The Shutdown position of both the Main Valve and Blow Valve may be specified as either Open, Close or None. None will leave the valves in the position determined by the Plunger logic at the time the Shutdown is requested. 6. The user may specify how the Plunger Lift application begins its operation. It may be started either from the closed production valve position or from the open production valve position. This is specified in the startup mode parameter. 7. Blow valve cushion timer. When the cushion timer is enabled, if the plunger arrives during the blow valve state, then the afterflow state will leave the blow valve open for a predetermined time before closing the blow valve, opening the main valve, and starting the afterflow timer and checking conditional close parameters. 8. Allow the use of either two pulsed DOs or two latched DOs or a single latched DO for the operation of both the Main Sales Valve, the Blow Valve and the Plunger Capture valve. This selection is only valid for the Main Sales Valve if Valve Control is not used. 9. Allow the user to specify if a plunger is used or if the logic bypasses the check for plunger arrival. 10. Allow the specification of a Pressure that will cause the logic to hold in the Closed Valve state. This feature allows the logic to stop during gathering system problems. 11. Allow the user to optionally specify a time period where use of the Blow Valve is not allowed. 12. Allow the user to enable a plunger swabbing cycle. 13. Allow the use of a mandatory recovery time after a plunger non-arrival. Blow valve cushion timer When the cushion timer is enabled, if the plunger arrives during the blow valve state (4), then the afterflow state will leave the blow valve open for a predetermined time before closing the blow valve, opening the main valve, and starting the afterflow timer and checking conditional close parameters.
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Integrating with Valve Control When the Valve Controller Option is Enabled several things must be noted. First, when Reset VCBs is set to Reset, several default registers are different than when the Valve Controller Option is Disabled. Another difference is in using the Manual Main Valve Close and Open Commands on the Control tab. If Valve Controller Option is Enabled you may request that the Main Valve be either opened or closed in either the Plunger Controller Disabled or Manual state. This request is actually made to the Valve Control application. However to manually operate the Blow Valve the Plunger Controller must be in Manual. Once the Plunger Controller is set to Enabled the Valve Control screen displays the Control Method as Program Override. This indicates that another application is actually setting Valve Control parameters. Once the Valve Control Control Method is set to Program Override any Valve Control user entry fields may not have data entered, this includes use of the Step Closed/Open and Ramp Closed/Open buttons. If any Valve Control user entry fields require new data, the Plunger Controller must be set to either Disabled or Manual before any data may be entered. Turner Flow Rate Calculation The Turner Flow Rate Calculation provides the required volumetric flow rate across a known area (Tubing ID) to shear droplets of a liquid of known density and maintain those droplets in a vapor state until being released from the vapor state by surface processing equipment. In this application the resulting flow rate is adjusted by the Turner Multiplier (TRM) to obtain the finial shut-in rate. The pressure term in the equation can be selected to be equal to one of the following P = Tubing Pressure P = Casing Pressure - Static Pressure The velocity in ft/sec is calculated as follows for a liquid, primarily water. This calculation applies the 20% correction needed required to adjust for the difference between surface and bottom hole conditions.
Vg = 5.62(67-(P*0.0031)) (0.0031 * P)
The volumetric flow rate in MMCF/Day is obtained as follows
TR1 =
3.067 * P * Vg * AREA TEMP R0 * Z
Finally the volumetric rate is adjusted by the turner multiplier to obtain the shut-in flow rate.
TR=TR1 * TRM
Tuning The following open valve values are tuned based upon plunger arrival time: Tubing Line Pressure Limit Casing Tubing Pressure Limit Casing Line Pressure Limit Tubing Pressure Limit Casing Pressure Limit SP Pressure Limit Load Ratio Limit The following close valve values are tuned based upon plunger arrival times: Dp Limit Flow Rate Limit Tubing Line Pressure Limit Casing Tubing Pressure Limit Casing Pressure Limit Tubing Pressure Limit SP Pressure Limit Turner Flow Multiplier Load Ratio Limit User's Guide 2102890-001 Plunger Lift Control 8 of 97 January 15, 2007
Operation
The Plunger controller has 7 states, which are used to switch through the stages of logic. This section will explain the controller logic using these states. This logic is run only if Plunger Control is set to Enabled. If Plunger Control is changed from Enabled to Disabled during operation all state logic is stopped. Also please note that the current values for Sp, Dp, Flowrate (etc.) are updated when Plunger Control is set to Enabled or Manual. State 0: Fail This is a plunger-failed condition. This can only happen if the program has exhausted the number of plunger arrival attempts programmed by the user and the blow valve is disabled. This state is also used by the Safety System application to indicate a Safety System Failure. User may restart the Plunger Controller by telling the logic to restart or by using the reset button (DI). The restart request may be done with remote communications. State 1: Closing Valve This is the state where the controllerhas requested the valve to close. The controller will remain in this state waiting for one of the following events: The Plunger fall delay timer elapsed (opt) Open push button has been used (opt) Mandatory recovery time > Mandatory recovery timer (opt) Flow rate dropping below Valve Close Setpoint by a user defined time. If this option is enabled, none of the other options are used. After this timer expires the control valve will be considered to be full closed. The closed timer is now started and the state moves to 2. If Valve Close Check is enabled and the flow rate does not drop below the Valve Close Check Setpoint by the Valve Close Check Time Limit, a Valve Close Failure is set and the plunger logic remains in State 1. State 2: Valve Closed The valve is full closed waiting one of the following events (each may be individually selected): Close valve timer => Close Cycle parameter (Tubing pressure - Line pressure) > Tubing Line Delta (Casing pressure Line pressure) > Case Line Delta ((Casing Pressure Line Pressure) > Limit) AND (Tubing pressure Line Pressure ) > Limit) (Casing pressure Tubing Pressure) > Case Tube Delta Load Ratio < Load Ratio Limit AND Casing Pressure/Line Pressure difference is larger than a user specified amount for Load Ratio time Load Ratio < Load Ratio Trip Tubing pressure > Tubing Limit OR Tubing pressure < Tubing Limit for Tubing pressure time Static pressure > Static Limit OR Static pressure < Static Limit for Static pressure time Slug size > Slug Limit Input 1 > Input 1 Limit OR Input 1 < Input 1 Limit for Input 1 time Input 2 > Input 2 Limit OR Input 2 < Input 2 Limit for Input 2 time The Open push button has been used.
The control valve is then opened based on the setting of Open Valve Method parameter if the valve control option is enabled. The user can elect to either ramp the valve open or open the valve to control either Dp or Flow Rate. After opening the control valve the program computes the closed time, starts the plunger arrival timer and the state moves to 3. User's Guide 2102890-001 Plunger Lift Control 9 of 97 January 15, 2007
State 3: Plunger Arriving Monitor the following conditions while looking for plunger arrival or until the Maximum Arrival timer has been exceeded or until the Close push button has been used. These conditions will simply open the blow valve in an effort to help the plunger arrive. Each may be individually selected: Casing Pressure < Setpoint Flow Rate < Setpoint for user defined amount of time DP < Setpoint Timer > Setpoint
If the High Line Close option is enabled, wait for the amount of time specified by the High Line Open Time Limit and then determining if the line pressure is above the High Line Close Limit, if so close the valve and go to State 2 to wait for the High Line Close Time Limit and then re-open the valve. Else if the line pressure is below the High Line Close Limit continue monitoring plunger arrival. If the Maximum Arrival timer elapses (before the plunger arrives) the controller will: Increment Max. Arrivals Count by 1 Check to see if Mandatory Recovery is enabled. If true, set state = 1 (Ramp valve closed) Else, check to see if Max. Arrivals Count => Max. Arrivals Allowed. If true, determine if the user has enabled the Blow Value for use. Else, set state = 1 (Ramp valve closed) If the Blow Valve has been enabled then: Open the blow valve Start the blow valve open timer Move to state 4 If the Blow Valve has not been enabled then: Set production valve to the Fail Main Valve State Set the blow valve to the Fail Blow Valve State Move to state 0 (Failed condition) Controller can only be restarted by the user issuing a Reset Controller command (this may be done remotely). This action will move to either state 1 (Closing Valve) or state 6 (Afterflow) based upon the Startup Mode that has been selected. If the plunger arrives before the Maximum Arrival timer has elapsed then: If plunger arrival time < Fast Arrival time then: Tune open valve conditions to flow longer Tune close valve conditions to leave the valve closed less time Else if, plunger arrival time > Slow Arrival time then: Tune open valve conditions to flow less time Tune close valve conditions to leave the valve closed longer Else, If plunger arrival time falls within the Fast Arrival time and the Slow Arrival time or if plunger arrival time < Minimum Arrival time then: Do not tune any open or close valve conditions. Move to state 5
State 4: Blow Valve This state waits until the Blow Valve Curtail period has elapsed (if enabled) and then until either the plunger has arrived after the blow valve has been opened or until the Blow valve timer has exceeded the Maximum Blow time. If the plunger arrives before the Maximum Blow time then: Close Blow Valve Move to state 5 Else if the blow valve timer exceeds the Maximum Blow time then: Close Blow Valve User's Guide Plunger Lift Control 10 of 97 2102890-001 January 15, 2007
Move to state 1.
State 5: Plunger Arrived Once the plunger has arrived. Compute plunger arrival time (Minutes) Count number of normal, slow, fast, late and consecutive normal arrivals Compute plunger arrivals for current contract day Reset the Max. Arrival count = 0 If swabbing has been enabled and there are more swab runs to complete, Move to state 1 Else: Start after flow timer Give control of main control valve to standard valve controller if enabled by the user. Standard valve controller will start controlling valve based on previously programmed user settings (i.e. Auto DP, AP or Flow Rate). Move to state 6. State 6: Afterflow The controller will continue in this state until one of following occurs (each may be individually selected): After flow timer => Flow time. Flow rate is below the Flow Rate setpoint for the Flow Rate Lowtime Dp is below the Dp setpoint for the Dp Low time (Tubing pressure Line pressure) > Tube Line delta (Casing pressure Tubing pressure) > Case Tube delta Casing pressure < Casing Limit (Flow Rate < (Turner flow * Turner Multiplier) AND ( ABS(Line pressure casing pressure) < user specified value) for Turner Low time Load Ratio < Load Ratio close setpoint for Load Ratio Close Time Static pressure < Static setpoint OR Static pressure > Static setpoint for Static Time Tubing pressure < Tubing setpoint OR Tubing pressure > Tubing setpoint for Tubing Time Slug size > Slug size limit Input 1 < Input 1 setpoint OR Input 1 > Input 1 setpoint for Input 1 Time Input 2 < Input 2 setpoint OR Input 2 > Input 2 setpoint for Input 2 Time The Close push button is used. Once one of these conditions occurs the program computes the flow cycle time, starts the plunger fall delay timer and the state moves to 1.
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PCCU Screens
This section describes all the user interface screens that are displayed on the PCCU. These screens are defined in the file 2102890-001.ini and the ini file resides on the IniFiles subdirectory for PCCU. The PCCU screens are displayed in the Entry mode screen with a tree view display on the left hand side of the screen. The following sections list the tree view display names along with the screen or screens that appear in the right hand pane. Plunger
The Control tab contains the following values: Description Task Name Controller State Plunger Status Values List of values Normal = 0 Drop = 1 Fast = 2 Slow = 3 Late = 4 Hung = 5 Comments The task name may be entered here if desired. Represents the state of the plunger control logic. The values are: FAIL=0,Closing Valve=1,Valve Closed=2,Plunger Arriving=3,Blow Valve=4,Plunger Arrived=5,AfterFlow=6 Status of the plunger. Normal indicates that the plunger has returned between the fast and slow set points, no adjustment of setpoints is needed. Drop indicates that during the Valve Closing state the plunger drop has been determined either by using the valve close detection logic or that the plunger fall delay has expired. Fast indicates that the plunger has returned in less time than the fast arrival time; setpoints will be adjusted by decrementing the tuning values from the setpoints. Slow indicates that the plunger has not returned within the time set by the slow arrival time; setpoints will be adjusted by incrementing the setpoint values by the tuning values. Late Plunger Lift Control 12 of 97 January 15, 2007
indicates that the plunger has not returned before the Max Arrival time. Hung indicates that the plunger has not arrived by the time Blow Valve is opened (or Max Arrivals Allowed has been counted); setpoints will be adjusted by incrementing the setpoint values by the tuning values if the Blow Valve is not used. The Control tab continued: Description Cycle Status Values Running = 0 Maintenance = 1 Catch = 2 Disabled = 3 BV Curtail = 4 Manual = 5 Comments Operational status of the plunger logic. Running indicates that the plunger logic is enabled and it is performing checking of open and close parameters and monitoring plunger arrival times. Maintenance indicates that Cycles to Maintenance has been set to a value greater than zero and the total cycle count is equal to or greater than the Cycles to Maintenance value (indicator only). Catch indicates that plunger catch mode has been enabled and the logic is in Closing Valve waiting for plunger catch mode to be disabled. Disabled indicates that the plunger is disabled. BV Curtail indicates that Blow Valve Curtailment is in use and that the logic is waiting for the Curtail end hour to pass, then the statues will move to Running. Manual indicates that the plunger is in manual. Inputs are being read and valve may be opened and closed by using the manual valve commands, but no other logic is running. Disable prevents the logic from running. Manual allows manual operation of both the Main and Blow valves and it allows the input values to read. Enable initializes the logic from the Startup Mode and begins operation. This initializes the logic to the startup mode. This command may only be used if Plunger control is Disabled, Manual or if the State is FAIL. This the date and time when the last Reset Controller command was issued. Clear the counters used to track the count of arrivals and arrival types. Plunger Control must be in manual, then Force Close may be used to manually close the main valve. Plunger Control must be in manual, then Force Open may be used to manually open the main valve. The state of the main valve. This will reflect the operation of the Plunger logic which is the last command sent to the valve or, if Valve Control is enabled, the state of the valve from the TFIO Valve Control Module. Plunger control must be in manual, then Force Close may be used to manually close the blow valve Plunger control must be in manual, then Force Open may be used to manually open the blow valve. Last command sent to the blow valve Last command sent to Capture valve Plunger control must be in manual, then Force Capture may be used to manually close the capture valve Plunger control must be in manual, then Force Release may be used to manually open the capture valve
Plunger Control
Disable, Manual, Enabled normal, Reset Date and Time No, Yes auto, Force Close auto, Force Open Closed, Open
Reset Controller Reset Date/Time Reset Plunger Counters Manual Main Valve Close Manual Main Valve Open Main Valve State
Manual Blow Valve Close Manual Blow Valve Open Blow Valve State Capture Valve State Manual Capture Valve=Catch
Manual Capture Valve=Release
auto, Force Close auto, Force Open Closed, Open Release, Capture auto, Force Capture auto, Force Release
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Plunger-Setup
The following table lists the user entries that are available on this screen.
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The General Setup tab contains the following values: Description Plunger Control Values Disable, Manual, Enabled 1 Closing Valve, 6- Afterflow, Previous state Disabled, Enabled Comments Disable prevents the logic from running. Manual allows manual operation of both the Main and Blow valves and it allows the input values to read. Enable initializes the logic from the Startup Mode and begins operation. Set this to the state of the value to start the Plunger or Intermitter logic. Using 1 Closing valve will start the logic in state 1 Valve Closing. Using 6 Afterflow will start the logic in state 6 Afterflow. Enables and disables the continuous adjustment of all setpoints (including the Turner multiplier). When Enabled is selected the process is optimized, Disabled uses the last values. If the plunger fails to arrive before the Max Arrival Time, multiply any tuning by this value. The length of the tubing from the stop to the arrival sensor, used to calculate the lift velocity The INNER diameter of the well tubing used to calculate the Turner Flow Rate. Setting this value to Reset sets all register address values to defaults. If Valve Control is enabled, the TFIO Valve Control module (address 0) is used for the DOs for the Main Valve, otherwise the TFIO DI/DO module (address 0) is used. This will also find the first instance of the AGA3 tube to use as the application slot number for the registers that are normally used from a measurement tube. Setting this value to Reset sets all user entered values (other than register values) to pre-defined defaults.
Startup Mode
Optimization
Plunger Fail Factor Tune Tubing Length Tubing ID Reset VCBs
Any floating point value Any floating point value Any floating point value No, Reset
Reset Values
No, Reset
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The Valve Setup screen is as follows:
The following table lists the user entries that are available on this screen.
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The Valve Setup tab contains the following values: Description Valve Position Values Downstream, Upstream Comments This is valve position relative to the meter. Selecting Downstream indicates that the line pressure is read from the input specified using the Ext Pressure AI and the tubing pressure is calculated from the input specified using the AP Register and the value specified using the Baro Pressure Register is subtracted from it. If Valve Controller Option is Enabled, this selection is set from the Valve Control screens. This is the amount of time to energize the open and close DOs to either open or close the main, blow and capture valves. This setting specifies the number of digital outputs used for the Main (Sales) valve. If Latch-One output is specified then only the Main Open DO is used to open and close the valve. This is the DO register address of the DO used to Open the Main Valve (only when Valve Control is not used). This is the DO register address of the DO used to Close the Main Valve (only when Valve Control is not used). This setting specifies the number of digital outputs used for the Blow (Vent) valve. If Latch-One output is specified then only the Blow Open DO is used to open and close the valve. This is the DO register address of the DO used to Open the Blow Valve. This is the DO register address of the DO used to Close the Blow Valve. This setting specifies the number of digital outputs used for the Capture valve. If Latch-One output is specified then only the Release DO is used to open and close the valve. This is the DO register address of the DO used to release the plunger This is the DO register address of the DO used to catch the plunger Selecting Enabled uses the Valve Control application to control the valve during Plunger Arriving and Afterflow. Selects the operation of Valve Control during Plunger Arriving and Afterflow. This is the register address of the Valve Control command word 1 register. This is only used if Valve Control is Enabled. This value must come from the Valve Control application if it is used. This is the register address of the Valve Control Features 1 register. This is only used if Valve Control is Enabled. This value must come from the Valve Control application if it is used. This is the register address of the Valve Control Full Closed DI. This is only used if Valve Control is Enabled. This value must come from the Valve Control application if it is used. Used to discount the casing pressure input for wells using a packer where no valid casing pressure is available. No indicates that the well has a valid casing pressure input that can be used for the Turner flow and Load Ratio calculations. Yes indicates that the well utilizes a packer and no valid casing pressure is available. Yes will disable the use of the Load Ratio to open the valve and it will also force the selection of Tube for the Turner Mode and will not use the difference between and casing and line pressure to determine when to close the valve. 17 of 97 January 15, 2007
Valve Time Main Valve Type Main Open DO Main Close DO Blow Valve Type Blow Open DO Blow Close DO Capture Valve Type Capture Release DO Capture Catch DO Valve Controller Option Open Valve Method VCI Cmd1 Register`
A value is seconds Latch-One output Latch-Two output Pulse-Two output Any register value Any register value Latch-One output Latch-Two output Pulse-Two output Any register value Any register value Latch-One output Latch-Two output Pulse-Two output Any register value Any register value Disabled, Enabled Ramp, AutoDP, AutoFR, AutoSP Any register value
VC Features 1 Register
Any register value
VC Full Closed DI Packer Well
Any register value No Yes
The Input Setup screen is as follows:
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The Input Setup tab contains the following values: Description AP Register DP Register Flow Rate Register Volume Register Values Any register value Any register value Any register value Any register value Comments This is the register address of the value that will be used for AP. Generally this value comes from an AGA3 measurement tube. This is the register address of the value that will be used for DP. Generally this value comes from an AGA3 measurement tube. This is the register address of the value that will be used for Flow Rate. Generally this value comes from an AGA3 measurement tube. This is the register address of the value that will be used for the accumulated volume. This value is used in calculating the current run volume. Generally this value comes from an AGA3 measurement tube and it is accumulated there. This is the register address of the value that will be used for the temperature. This value is used in calculating the Turner Flow Rate. Generally this value comes from an AGA3 measurement tube. This is the register address of the value that will be used for the compressibility. This value is used in calculating the Turner Flow Rate. Generally this value comes from an AGA3 measurement tube. This is the register address of the value that will be used for the barometric pressure. This value is used in calculating the static pressure from the AP. Generally this value comes from an AGA3 measurement tube. This is the register address of the value that will be used for casing pressure. This is the register address of the value that will be used for either tubing or line pressure. The Valve Location determines how this input value is used. This it the register address of the value used to hold the plunger logic in the closed state. This is the register address of Input 1. This value may be used to determine when to open and/or when to close the main valve. This is the register address of Input 2. This value may be used to determine when to open and/or when to close the main valve. Selects whether a plunger is being used or the logic will act as an intermitter. I/O indicates that an external I/O point is used to detect the arrival of the plunger. Intermit indicates NO arrival sensor is used to signal the start of Afterflow. This is the register address of the Pulse Input used to detect Plunger Arrival. This is the register address of the date and time when contract hour last occurred. Generally this value comes from an AGA3 measurement tube. This is the register address of the digital input connected to the Reset Plunger Controller button. This is the register address of the digital input connected to the Close Main Valve push button. This is the register address of the digital input connected to the Open Main Valve push button.
Tf Register
Any register value
Z factor
Any register value
Baro Press Register
Any register value
Casing Pressure AI Ext Pressure AI Hold AI Register Input 1 Register Input 2 Register Detection type
Any register value Any register value Any Register value Any register value Any register value I/O, Intermit
Plunger Arrival PI Contract Hour Update Restart Button Register Close Button Open Button
Any register value Any register value Any register value Any register value Any register value
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Plunger - States This is the Plunger States screen from PCCU. Note that there are numerous screens that contain the Plunger Logic information. Each tab will be described separately.
20 of 97 January 15, 2007
The States tab contains the following values: Description Plunger Control Values Disable, Manual, Enabled List of values A value of hr:min:sec A value of hr:min:sec Normal = 0 Drop = 1 Fast = 2 Slow = 3 Late = 4 Hung = 5 Comments Disable prevents the logic from running. Manual allows manual operation of both the Main and Blow valves and it allows the input values to read. Enable initializes the logic from the Startup Mode and begins operation. Represents the state of the plunger control logic. The values are: FAIL=0,Closing Valve=1,Valve Closed=2,Plunger Arriving=3,Blow Valve=4,Plunger Arrived=5,AfterFlow=6 This is a copy of the current state timer This is a copy of the current state maximum timer Status of the plunger. Normal indicates that the plunger has returned between the fast and slow set points, no adjustment of setpoints is needed. Fast indicates that the plunger has returned in less time than the fast arrival time; setpoints will be adjusted by decrementing the tuning values from the setpoints. Slow indicates that the plunger has not returned within the time set by the slow arrival time; setpoints will be adjusted by incrementing the setpoint values by the tuning values. Late indicates that the plunger has not returned before the Max Arrival time. Hung indicates that the plunger has not arrived by the time Blow Valve is opened (or Max Arrivals Allowed has been counted); setpoints will be adjusted by incrementing the setpoint values by the tuning values if the Blow Valve is not used. Operational status of the plunger logic. Running indicates that the plunger logic is enabled and it is performing checking of open and close parameters and monitoring plunger arrival times. Maintenance indicates that Cycles to Maintenance has been set to a value greater than zero and the total cycle count is equal to or greater than the Cycles to Maintenance value (indicator only). Catch indicates that plunger catch mode has been enabled and the logic is in Closing Valve waiting for plunger catch mode to be disabled. Disabled indicates that the plunger is disabled. BV Curtail indicates that Blow Valve Curtailment is in use and that the logic is waiting for the Curtail end hour to pass, then the statues will move to Running. Manual indicates that the plunger is in manual. Inputs are being read and valve may be opened and closed by using the manual valve commands, but no other logic is running.
Controller State State Timer Max State Timer Plunger Status
Cycle Status
Running = 0 Maintenance = 1 Catch = 2 Disabled = 3 BV Curtail = 4 Manual = 5
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The States tab continued: Description Main Valve State Values Closed, Open Comments The state of the main valve. This will reflect the operation of the Plunger logic which is the last command sent to the valve or, if Valve Control is enabled, the state of the valve from the TFIO Valve Control Module. Last command sent to the blow valve Last command sent to Capture valve Current reason that the main valve opened. Elapsed time since valve was commanded closed and fall delay expired. The amount of time of the last closed cycle The last reason that the main valve was closed. The amount of time that the well has been flowing. This value is equal to the plunger arrival timer plus the after flow timer. The amount of time of the last flow cycle The total number of the times the logic has gone thru the Closing Valve state since the last reset plunger counters was used.
Blow Valve State Capture Valve State Current Open Reason Closed Timer Last Close Cycle Current Close Reason Flow Cycle Timer Last Flow Cycle Total Cycles
Closed, Open An enumerated list A value of hr:min:sec A value of hr:min:sec An enumerated list A value of hr:min:sec A value of hr:min:sec An integer value
22 of 97 January 15, 2007
State 1 Closing Valve This is the State 1 Closing Valve screen from PCCU.
23 of 97 January 15, 2007
The 1 Closing Valve tab contains the following values: Description Controller State Main Valve State Values List of values Closed, Open Comments Represents the state of the plunger control logic. The values are: FAIL=0,Closing Valve=1,Valve Closed=2,Plunger Arriving=3,Blow Valve=4,Plunger Arrived=5,AfterFlow=6 The state of the main valve. This will reflect the operation of the Plunger logic which is the last command sent to the valve or, if Valve Control is enabled, the state of the valve from the TFIO Valve Control Module. Status of the plunger. Normal indicates that the plunger has returned between the fast and slow set points, no adjustment of setpoints is needed. Drop indicates that during the Valve Closing state the plunger drop has been determined either by using the valve close detection logic or that the plunger fall delay has expired. Fast indicates that the plunger has returned in less time than the fast arrival time; setpoints will be adjusted by decrementing the tuning values from the setpoints. Slow indicates that the plunger has not returned within the time set by the slow arrival time; setpoints will be adjusted by incrementing the setpoint values by the tuning values. Late indicates that the plunger has not returned before the Max Arrival time. Hung indicates that the plunger has not arrived by the time Blow Valve is opened (or Max Arrivals Allowed has been counted); setpoints will be adjusted by incrementing the setpoint values by the tuning values if the Blow Valve is not used. Operational status of the plunger logic. Running indicates that the plunger logic is enabled and it is performing checking of open and close parameters and monitoring plunger arrival times. Maintenance indicates that Cycles to Maintenance has been set to a value greater than zero and the total cycle count is equal to or greater than the Cycles to Maintenance value (indicator only). Catch indicates that plunger catch mode has been enabled and the logic is in Closing Valve waiting for plunger catch mode to be disabled. Disabled indicates that the plunger is disabled. BV Curtail indicates that Blow Valve Curtailment is in use and that the logic is waiting for the Curtail end hour to pass, then the statues will move to Running. Manual indicates that the plunger is in manual. Inputs are being read and valve may be opened and closed by using the manual valve commands, but no other logic is running. Time to wait before declaring valve closed and beginning to check for valve open conditions. Elapsed time since valve close command was issued. Enabled indicates that flow is used to verify valve close. Current flow rate Valve close is verified when the flow rate falls below this value. The amount of time the flow rate has to fall below the Valve Close Setpoint before a Valve Close failure is declared. Amount of time that flow rate has not fallen below the Valve Close Check Setpoint. Status of the Valve Close Check.
Plunger Status
Normal = 0 Drop = 1 Fast = 2 Slow = 3 Late = 4 Hung = 5
Cycle Status
Running = 0 Maintenance = 1 Catch = 2 Disabled = 3 BV Curtail = 4 Manual = 5
Plunger Fall DelayLimit Fall Timer Option Valve Close Check Flow Rate In Valve Close Check Setpoint Valve Close Time Limit Valve Close Check Timer Valve Close Failure
A value of hr:min:sec A value of hr:min:sec Disabled, Enabled A floating point value Any floating point value A value of hr:min:sec A value of hr:min:sec No Yes
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State 2 Valve Closed This is the State 2 Valve Closed tab from PCCU.
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The 2 Valve Closed tab contains the following values: Description Controller State Main Valve State Plunger Status Values Closed, Open Normal = 0 Drop = 1 Fast = 2 Slow = 3 Late = 4 Hung = 5 Running = 0 Maintenance = 1 Catch = 2 Disabled = 3 BV Curtail = 4 Manual = 5 A value of hr:min:sec A value of hr:min:sec A value of hr:min:sec None = 0 TIMER = 1 ONCE = 2 RECOVERY = 3 CNT = 4 PRESSURE = 5 HIGH = 6 TOD = 7 TOTAL = 8 CATCH = 9 Comments See previous. See previous. See previous.
Cycle Status
See previous.
State Timer Max State Timer Closed Timer Hold Reason
This is a copy of the current state timer This is a copy of the current state maximum timer Elapsed time since valve was commanded closed and fall delay expired. Indicates the reason that the logic is held in the closed state.
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The 2 Valve Closed tab continued: Description Current Open Reason Values None = 0 TIMER = 1 DP = 2 FR = 3 TUBE-LINE = 4 CASE-LINE = 5 CASE = 6 SP = 9 TUBE = 10 AI1 = 11 AI2 = 12, LOAD = 13 NOW = 14 CT_TL = 15 LR_TIME = 16 LINE = 17 AFTER = 18, C_L = 19 CL_TL = 20 SLUG = 21 Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Values Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled A value of hr:min:sec Disabled, Enabled Disabled, Enabled Comments Last reason the valve was opened.
Option Closed Timer Option Tube-Line Open Option Case-Line Open Option C-L & T-L Open Option Case-Tube Open Option C-T & T-L Open Option Load Ratio Description Option Tubing Pressure Open Option Casing Pressure Open Option Static Pressure Open Option Slug Size Open Option Input 1 Open Option Input 2 Open Option Total Cycle Time Hold Once Time Limit Option Hold Ext Option Hold Pressure
Use timer to open valve Use tubing pressure/line pressure difference to open valve. Use casing pressure/line pressure difference to open valve. Use casing/line pressure difference AND tube/line difference to open valve. Use casing pressure/tube pressure difference to open valve Use casing pressure/tubing pressure difference AND tubing pressure/line pressure difference to open valve. Enables the use of the Load Ratio to open the valve. Comments Enables the use of Tubing pressure to determine when to open the valve. Enables the use of Casing pressure to determine when to open the valve. Enables the use of Static Pressure to determine when to open the valve. Enables the use of Slug Size to determine when to open the valve. Enables the use of Input 1 to determine when to open the valve. Enables the use of Input 2 to determine when to open the valve. Enables the option of using an amount of time between valve open to valve open to operate the well If a value other than 00:00:00 is entered, this enables the option of delaying the well operation once for a single amount of time Enables the option of holding closed until Ext enables Use Hold Input to hold in closed valve state
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The 2 Valve Closed tab continued: Description Option High Line Close Option Hold Time of Day Option Mandatory Recovery Time Option Plunger Catch Mode Values Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Comments Enables the checking of line pressure shortly after opening to determine if the valve should be closed again Enables the option operating the well during certain hours of the day. Enables the mandatory recovery time option. This option runs after a plunger non-arrival to allow the well pressure to recover. Enables the plunger catch mode option.
Plunger State 2 Valve Closed - Timer This is the State 2 Valve Closed Timer tab from PCCU.
The Timer tab contains the following values: Description Controller State Main Valve State Plunger Status Values Closed, Open Normal = 0 Drop = 1 Fast = 2 Slow = 3 Late = 4 Hung = 5 Running = 0 Maintenance = 1 Catch = 2 Disabled = 3 BV Curtail = 4 Manual = 5 A value of hr:min:sec Comments See previous. See previous. See previous.
Cycle Status
See previous.
Closed Timer
Elapsed time since valve was commanded closed and fall delay expired. Plunger Lift Control 28 of 97 January 15, 2007
The Timer tab continued: Description Option Closed Timer Close Cycle Limit Values Disabled, Enabled A value of hr:min:sec Comments Use timer to open valve Time to keep valve closed before commanding valve open.
Plunger State 2 Valve Closed Tube-Line This is the State 2 Valve Closed Tube-Line tab from PCCU.
The Tube-Line tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Tube-Line Open Option Tube-Line Open Limit Tube-Line Tube Line Open Tune Tube Line Open Min Values Comments See previous. See previous. See previous. See previous. Use tubing pressure/line pressure difference to open valve. If (tubing line pressure) > this limit, then open valve Difference of tubing and line pressure Amount to tune the open limit value. Minimum value to tune the open limit value to.
Disabled, Enabled Any floating point value A floating point value Any floating point value Any floating point value
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The Tube-Line tab continued: Description Plunger Fail Factor Tune Option CT T-L Open Values Any floating point value Disabled, Enabled Comments If plunger fails, multiply the next tuning by this value Use casing pressure/tubing pressure difference AND tubing pressure/line pressure difference to open valve.
Plunger State 2 Valve Closed Case-Line This is the State 2 Valve Closed Case-Line screen from PCCU.
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The Case-Line tab contains the following values: Description Values Controller State Main Valve State Plunger Status Cycle Status Option Case-Line Open Disabled, Enabled Case Line Open Limit Case-Line Case-Line Open Tune Case-Line Open Min Tune Plunger Fail Factor Tune Option C-L & T-L Open Any floating point value A floating point value Any floating point value Any floating point value Any floating point value Disabled, Enabled
Comments See previous. See previous. See previous. See previous. Use difference between casing and line pressure to open main valve If (casing line) > this limit, then open valve Difference between casing and line pressure Amount to tune the open limit value. Minimum value to tune the open limit value to. If plunger fails, multiply the next tuning by this value Use casing/line AND tubing/line to open the main valve.
Plunger State 2 Valve Closed Case-Tube This is the State 2 Valve Closed Case-Tube screen from PCCU.
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The Case-Line tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Case-Tube Open Case-Tube Action Case-Tube Case-Tube Open Limit Case-Tube Open Limit Tune Case-Tube Open Limit Min Plunger Fail Factor Tune Values Comments See previous. See previous. See previous. See previous. Use difference between casing and tubing pressure to open main valve Select how Case-Tube pressure will open main valve Difference of casing and tubing pressure Any floating point value Any floating point value Any floating point value Any floating point value Amount to tune Minimum Case-Tube Limit can not be tuned below If plunger fails, multiply the next tuning by this factor.
Disabled, Enabled Lo Open Hi Open
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Plunger State 2 Valve Closed Load Ratio This is the State 2 Valve Closed Load Ratio screen from PCCU.
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The Load Ratio tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Load Ratio option Packer Well Load Ratio Values Comments See previous. See previous. See previous. See previous. Enables the use of the Load Ratio to open the valve. Used to discount the casing pressure input for wells using a packer where no valid casing pressure is available. Yes will disable the use of the Load Ratio to open the valve. Current value of the Load Ratio. It is calculated by the following formula: Load Ratio = (Casing Pressure Tubing Pressure) / (Casing Pressure Static Pressure). If the Load Ratio is above this value for the Load Ratio time AND the Casing Pressure => Line Pressure * Casing-Line Multiplier, the valve can be opened. If the Load Ratio falls below this value, restart the Load Ratio timer. Amount of time that the Load Ratio needs to exceed the Load Ratio Setpoint AND the Casing Pressure => Line Pressure * Casing-Line Multiplier before the valve is opened. Amount of time that the Load Ratio has exceeded the Load Ratio Setpoint AND the Casing Pressure is greater than Line pressure * Casing-Line Multiplier. The value of the Load Ratio when the Load Ratio timer was last reset. If the Load Ratio exceeds this value, open the valve regardless of the Load Ratio timer. Tune the Load Ratio close setpoint by this amount. Minimum value to tune the Load Ratio close setpoint to. Maximum value to tune the Load Ratio close setpoint to. If plunger fails, multiply the next tuning by this factor. This value is used to determine if there is enough differential between Casing Pressure and Line Pressure to allow the plunger to arrive. This is a value that is multiplied by the Line Pressure and then the result is compared to the Casing Pressure. The Casing Pressure must be greater than or equal to the result before the main valve is opened. Tune Casing-Line Open Mult Limit by this amount Do not tune Casing-Line Mult Limit below this value. Do not tune Casing-Line Mult Limit above this value.
Disabled, Enabled No Yes A floating point value Any floating point value A value of hr:min:sec A value of hr:min:sec A floating point value Any floating point value Any floating point value Any floating point value Any floating point value Any floating point value A floating point value
Load Ratio Setpoint
Load Ratio Time Load Ratio Timer Last Load Ratio Load Ratio Trip Load Ratio Close Tune Load Ratio Close Min Load Ratio Close Max Plunger Fail Factor Tune Casing-Line Multiplier
Case-Line Mult Tune Case-Line Mult Min Case-Line Mult Max
A floating point value A floating point value A floating point value
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Plunger State 2 Valve Closed Tube This is the State 2 Valve Closed Tube screen from PCCU.
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The Tube tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Tubing Pressure option Tubing Pressure In Tubing Action Values Comments See previous. See previous. See previous. See previous. Enables the use of Tubing pressure to determine when to open the valve. Current value of the Tubing pressure Selecting Lo Open will open the valve when Tubing pressure goes below the Tubing Setpoint for the Tubing pressure time. Selecting Hi Open will open the valve when Tubing pressure goes above the Tubing Setpoint for the Tubing pressure time. This is the test value used to begin the Tubing open timer. Tubing pressure must be above/below this value for Tubing open time before the valve is opened. The amount of time that the Tubing pressure must either go above or fall below the Tubing Open Limit before the valve opens. Amount of time that Tubing pressure has been above/below the Tubing Open Limit. If the Tubing pressure falls within the limit test, this is reset. Amount to tune Tube Open Limit Do not tune Tube Open Limit below this value If plunger fails, multiply the next tuning by this factor.
Disabled, Enabled A floating point value Lo Open, Hi Open
Tubing Open Limit Tubing Open Time Tubing Open Timer Tube Open Tune Tube Open Min Tune Plunger Fail Factor Tune
Any floating point value A value of hr:min:sec A value of hr:min:sec Any floating point value Any floating point value Any floating point value
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Plunger State 2 Valve Closed Case This is the State 2 Valve Closed Case screen from PCCU.
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The Case tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Casing Pressure option Casing Pressure In Casing Action Values Comments See previous. See previous. See previous. See previous. Enables the use of Casing pressure to determine when to open the valve. Current value of the Casing pressure Selecting Lo Open will open the valve when Casing pressure goes below the Casing Setpoint for the Casing pressure time. Selecting Hi Open will open the valve when Casing pressure goes above the Casing Setpoint for the Casing pressure time. This is the test value used to begin the Casing open timer. Casing pressure must be above/below this value for Tubing open time before the valve is opened. The amount of time that the Casing pressure must either go above or fall below the Casing Open Limit before the valve opens. Amount of time that Casing pressure has been above/below the Casing Open Limit. If the Casing pressure falls within the limit test, this is reset. Amount to tune Case Open Limit Do not tune Case Open Limit below this value If plunger fails, multiply the next tuning by this factor.
Disabled, Enabled A floating point value Lo Open, Hi Open
Casing Open Limit Casing Open Time Casing Open Timer Case Open Tune Case Open Min Tune Plunger Fail Factor Tune
Any floating point value A value of hr:min:sec A value of hr:min:sec Any floating point value Any floating point value Any floating point value
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Plunger State 2 Valve Closed SP This is the State 2 Valve Closed Sp screen from PCCU.
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The SP tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Static Pressure option SP In Static Pressure Action Values Comments See previous. See previous. See previous. See previous. Enables the use of static pressure to determine when to open the valve. Static pressure calculated from AP. Selecting Lo Open will open the valve when Static pressure goes below the Sp Setpoint for the Sp pressure time. Selecting Hi Open will open the valve when Static pressure goes above the Sp Setpoint for the Sp pressure time. This is the test value used to begin the Sp open timer. Static pressure must be above/below this value for Static open time before the valve is opened The amount of time that the Static pressure must either go above or fall below the Static Pressure Open Limit before the valve opens. Amount of time that Static pressure has been above/below the Sp Open Limit. If the Static pressure falls within the limit test, this is reset. Amount to tune SP Open Limit Do not tune SP Open Limit below this value If plunger fails, multiply the next tuning by this factor.
Disabled, Enabled A floating point value Lo Open Hi Open Any floating point value A value of hr:min:sec A value of hr:min:sec Any floating point value Any floating point value Any floating point value
SP Open Limit SP Open Time SP Open Timer SP Open Tune SP Open Min Plunger Fail Factor Tune
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Plunger State 2 Valve Closed Slug This is the State 2 Valve Closed Slug screen from PCCU.
The Slug tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option slug Size Open Slug Size Slug Size Open Limit Fluid Gradient Values Comments See previous. See previous. See previous. See previous. Option use slug size to open main valve Slug size is the difference between casing and tubing pressure divided by a fluid gradient. Slug size must be above this value before the valve is opened. Slug size constant (default is 0.433)
Disabled, Enabled A floating point value A floating point value A floating point value
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Plunger State 2 Valve Closed Inputs This is the State 2 Valve Closed Inputs screen from PCCU.
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The Inputs tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Input 1 option Input 1 In Input 1 Open Limit Input 1 Open Time Input 1 Open Timer Input 2 option Input 2 In Input 2 Open Limit Input 2 Open Time Input 2 Open Timer Values Comments See previous. See previous. See previous. See previous. Enables the use of Input 1 to determine when to open the valve. Current value of Input 1 This is the test value used to begin the Input 1 open timer. Input 1 must be above/below this value for Input 1 open time before the valve is opened The amount of time that Input 1 must either go above or fall below the Input 1 Open Limit before the valve opens. Amount of time that Input 1 has been above/below the Input 1 Open Limit. If Input 1 falls within the limit test, this is reset. Enables the use of Input 2 to determine when to open the valve. Current value of Input 2 This is the test value used to begin the Input 2 open timer. Input 2 must be above/below this value for Input 2 open time before the valve is opened The amount of time that Input 2 must either go above or fall below the Input 2 Open Limit before the valve opens. Amount of time that Input 2 has been above/below the Input 2 Open Limit. If Input 2 falls within the limit test, this is reset.
Disabled, Enabled A floating point value Any floating point value A value of hr:min:sec A value of hr:min:sec Disabled, Enabled A floating point value Any floating point value A value of hr:min:sec A value of hr:min:sec
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Plunger State 2 Valve Closed Hold Timers This is the State 2 Valve Closed Hold Timers screen from PCCU.
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The Hold Timers tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Hold Once Time Limit Option Total Cycle Time Total Cycle Timer Total Cycle Time Limit Mandatory Time Mandatory Close Time Hold External Option Hold External Status Values Comments See previous. See previous. See previous. See previous. Hold in Closed one time for this amount of time. Then open valve and proceed to Plunger Arriving State. Enables the use of a timer that runs from Valve Open to Valve Open Current value of the Total Cycle Timer Total Cycle Time Limit value Enabled indicates that mandatory recovery time option is enabled. This option runs after a plunger non-arrival to allow the well pressure to recover. Allow the valve to remain closed for this amount of time. Enabled indicates that this option is used to hold in closed state until an external application clears the hold. If HOLD, stay in closed state until ok.
A value of hr:min:sec Disabled, Enabled A value of hr:min:sec A value of hr:min:sec Disabled, Enabled A value of hr:min:sec Disabled, Enabled Ok, HOLD
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Plunger State 2 Valve Closed Hold Pressure This is the State 2 Valve Closed Hold Pressure screen from PCCU.
The Hold pressure tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Hold Pressure Hold Value Hold Limit Values Comments See previous. See previous. See previous. See previous. Use Hold Valueto hold in closed valve state Value used to determine if logic should remain in the closed state. This is read from the Hold Pressure AI The value that will cause the plunger cycle to hold in the Closed Valve state. If the Hold Input is above this value, the logic will hold the plunger down until the value is below the Hold Plunger pressure. This feature allows the logic to stop during gathering system problems. Use line pressure to re-close valve during plunger arriving state Amount of time to hold valve closed after valve has been opened but then closed due to high line pressure during plunger arriving state.
Disabled, Enabled A floating point value Any floating point value
Option High Line Close High Line Closed Time Limit
Disabled, Enabled A value of hr:min:sec
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Plunger State 2 Valve Closed Time of Day This is the State 2 Valve Closed Time of Day screen from PCCU.
The Time of Day tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Hold Time of Day Time of day Hold Time of Day Start 1 Hold Time of Day End 1 Hold Time of Day Start 2 Hold Time of Day End 2 Hold Time of Day Start 3 Hold Time of Day End 3 Values Comments See previous. See previous. See previous. See previous. Enables option to disable well production during certain hours of the day. Current time of day The time of day at which hold will begin The time of day at which hold will end The time of day at which hold will begin The time of day at which hold will end The time of day at which hold will begin The time of day at which hold will end
Disabled, Enabled A time value in hr:min:sec A time value in hr:min:sec A time value in hr:min:sec A time value in hr:min:sec A time value in hr:min:sec A time value in hr:min:sec A time value in hr:min:sec
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The Time of Day tab continued: Description Values Hold Time of Day Start 4 A time value in hr:min:sec Hold Time of Day End 4 A time value in hr:min:sec Hold TOD Status
Comments The time of day at which hold will begin The time of day at which hold will end A status that indicates the state of the Time of Day Hold. No indicates that Time of Day Hold is not in effect. Yes indicated that Time of Day Hold is in effect.
State 3 Plunger Arriving This is the State 3 Plunger Arriving Timers screen from PCCU.
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The Timers tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Detection type Values Comments See previous. See previous. See previous. See previous. Selects whether a plunger is being used or the logic will act as an intermitter. I/O indicates that an external I/O point is used to detect the arrival of the plunger. Intermit indicates that NO arrival sensor is used to signal the start of Afterflow. Amount of time for the last plunger arrival Elapsed time since valve was commanded open. Maximum amount of time to wait on plunger arrival. If the plunger does not arrive before this time either open the Blow Valve (if enabled) or go back to State 1 Closing Valve. The Plunger Fail Factor is used for tuning. If the plunger arrives slower than this, the status is set to slow and tuning is used (for the enabled options if Optimization is enabled). If the plunger arrives before this, the status is set to fast and tuning is used (for the enabled options if Optimization is enabled). If the plunger arrives faster than this time, dont tune. Number of times the plunger can arrive after the Max Arrival Time before either opening Blow Valve or going to FAIL state. The count of consecutive arrival times that have been greater than the Max Arrival Time. This value is reset if the plunger arrival time is less than the Max Arrival Time.
I/O, Intermit
Last Plunger Arrival Arrival Timer Max
A time value in hr:min:sec A time value in hr:min:sec A time value in hr:min:sec A time value in hr:min:sec A time value in hr:min:sec A time value in hr:min:sec Any integer value An integer value
Slow Fast Min Max Arrivals Allowed Max Arrival Count
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Plunger State 3 Plunger Arriving High Line This is the State 3 Plunger Arriving High Line screen from PCCU.
The High Line tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option High Line Close Line Pressure In High Line Close Limit High Line Open Time Limit Values Comments See previous. See previous. See previous. See previous. Enables the option to monitor the line pressure after opening and possibly close valve again if line pressure is too high. Current value of line pressure If the line pressure is above this limit after hgh line open limit time, then close the valve. Time to wait before checking for high line pressure to determine if the main valve should be closed.
Disabled, Enabled A floating point value Any floating point value A time value in hr:min:sec
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Plunger State 3 Plunger Arriving Blow Valve Help This is the State 3 Plunger Arriving Blow Valve Help screen in PCCU.
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The Blow Valve Help tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Blow Valve State Plunger Arrival Blow Valve Timer Option Plunger Arrival Blow Valve Time Limit Flow Rate Blow Valve Option Flow Rate In Flow Rate Blow Valve Limit Flow Rate Blow Valve Time Limit Flow Rate Blow Valve Timer Case Blow Valve Option Casing Pressure In Case Blow Valve Open Limit DP Blow Valve Option DP In DP Blow Valve Limit Values Comments See previous. See previous. See previous. See previous. The current state of the Blow Valve Enable the use of the Blow Valve to help the plunger to arrive if the plunger has not arrived after a specified time. Time to wait after valve has been opened. If plunger has not arrived by this time, open Blow Valve. Enable the use of Flow Rate to determine if the Blow Valve should be opened to help the plunger to arrive. Current Flow Rate If Flow Rate falls below this limit for Flow Rate Blow Valve Low Time Limit, then open Blow Valve to help plunger to arrive Flow must remain below the Flow Rate Blow Valve Limit for this amount of time, and then the Blow Valve will be opened to help the plunger to arrive. Elapsed time that Flow Rate has been below the Flow Rate Blow Valve Limit. Enable to use of casing pressure to open the Blow Valve to help the plunger to arrive. Current Casing Pressure If casing pressure falls below this limit, open the Blow Valve to help the plunger to arrive. Enable the use of DP to open the Blow Valve to help the plunger to arrive. Current DP If DP falls below this limit, then open the Blow Valve to help the plunger to arrive.
Closed, Open Disabled, Enabled A time value in hr:min:sec Disabled, Enabled A floating point value Any floating point value A time value in hr:min:sec A time value in hr:min:sec Disabled, Enabled A floating point value Any floating point value Disabled, Enabled A floating point value Any floating point value
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State 4 Blow Valve This is the State 4 Blow Valve screen from PCCU.
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The Blow Valve tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Fail Blow Valve State Values Comments See previous. See previous. See previous. See previous. This specifies the operation of the Blow Valve during the Plunger Failure (or Safety System) operation. None indicates that no action if performed by the Blow Valve when the FAIL State is activated. Close indicates the Blow Valve will close when the FAIL State is activated. Open indicates that Blow Valve will open when the FAIL State is activated. Enable the use of the Blow Valve to help the plunger to arrive if the plunger has not arrived after a specified time. Enable the use of Flow Rate to determine if the Blow Valve should be opened to help the plunger to arrive. Enable to use of casing pressure to open the Blow Valve to help the plunger to arrive. Enable the use of DP to open the Blow Valve to help the plunger to arrive. Enable the use of the Blow Valve when the plunger fails to arrive before the max arrival time Selects whether the venting of the well is disabled during certain hours of the day. Enable blow valve cushion logic. This logic causes the main valve to close while the blow valve is open. Once the plunger arrives, the main valve is opened and the blow valve also remains open for a specified time before closing.
None, Close, Open
Option 3-BV Help Plunger Arrival Time Option 3-Flow Rate BV Option 3-BV Case Option 3-BV DP Option 4-BV State Option 4-BV Curtail Option 6-BV Cushion
Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled
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Plunger State 4 Blow Valve- BV 3 Plunger Arriving This is the State 4 Blow Valve BV 3 Plunger Arriving screen from PCCU.
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The BV3 Plunger Arriving tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Plunger Arrival BV Timer Plunger Arrival Blow Valve Time Limit Option Flow Rate Blow Valve Flow Rate In Flow Rate Blow Valve Limit Flow Rate Blow Valve Time Limit Flow Rate Blow Valve Timer Option Case Blow Valve Casing Pressure In Case Blow Valve Open Limit Option DP Blow Valve DP In DP Blow Valve Limit Values Comments See previous. See previous. See previous. See previous. Enable the use of the Blow Valve to help the plunger to arrive if the plunger has not arrived after a specified time. Time to wait after valve has been opened. If plunger has not arrived by this time, open Blow Valve. Enable the use of Flow Rate to determine if the Blow Valve should be opened to help the plunger to arrive. Current Flow Rate If Flow Rate falls below this limit for Flow Rate Blow Valve Low Time Limit, then open Blow Valve to help plunger to arrive Flow must remain below the Flow Rate Blow Valve Limit for this many consecutive minutes, and then the Blow Valve will be opened to help the plunger to arrive. Elapsed time that Flow Rate has been below the Flow Rate Blow Valve Limit. Enable to use of casing pressure to open the Blow Valve to help the plunger to arrive. Current Casing Pressure If casing pressure falls below this limit, open the Blow Valve to help the plunger to arrive. Enable the use of DP to open the Blow Valve to help the plunger to arrive. Current DP If DP falls below this limit, then open the Blow Valve to help the plunger to arrive.
Disabled, Enabled A time value in hr:min:sec Disabled, Enabled A floating point value Any floating point value A time value in hr:min:sec A floating point value Disabled, Enabled A floating point value Any floating point value Disabled, Enabled A floating point value Any floating point value
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Plunger State 4 Blow Valve- BV 4 Blow Valve State This is the State 4 Blow Valve BV 4 Blow Valve State screen from PCCU.
The BV 4 Blow Valve State tab contains the following values: Description Controller State Main Valve State Blow Valve State Plunger Status Cycle Status Option BV State Blow Time Max Blow Timer Option BV Curtail Curtail Start Curtail End Curtail Wait Values Closed, Open Disabled, Enabled Any floating point value in minutes A time value in hr:min:sec Disabled, Enabled Any integer value between 0 and 23, default is 21. Any integer value between 0 and 23, default is 7. No, Yes Comments See previous. See previous. Current state of the Blow Valve See previous. See previous. Enable the use of the Blow Valve when the plunger fails to arrive The maximum amount of time to wait for plunger arrival (stay in Blow Valve state) before going back to State 1 Closing Valve. Elapsed time that Blow Valve has been opened. Selects whether the venting of the well is disabled during certain hours of the day. The hour at which curtailment will begin The hour at which curtailment will end. The status of the curtailment.
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Plunger State 4 Blow Valve- BV 6 Afterflow This is the State 4 Blow Valve BV 6 Afterflow screen from PCCU.
The BV 6 Afterflow tab contains the following values: Description Controller State Main Valve State Blow Valve State Plunger Status Cycle Status Option BV Cushion Values Closed, Open Disabled, Enabled Comments See previous. See previous. Current state of the Blow Valve See previous. See previous. Enable blow valve cushion logic. This logic causes the main valve to close while the blow valve is open. Once the plunger arrives, the main valve is opened and the blow valve also remains open for a specified time before closing. Only used when the Blow Valve Cushion Option is enabled. This is the amount of time to wait after plunger arrival to close the Blow Valve. Elapsed time since the plunger arrived and Blow Valve Cushion Option is enabled.
BV Cushion Time Limit BV Cushion Timer
A time value in hr:min:sec A time value in hr:min:sec
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Plunger 4 Blow Valve- Statistics This is the 4 Blow Valve Statistics screen from PCCU.
The Statistics tab contains the following values: Description Controller State Main Valve State Blow Valve State Plunger Status Cycle Status Blow Count Blow Time 0 Blow Time 1 Blow Time 2 Blow Time 3 Blow Time 4 Blow Date/Time 0 Blow Date/Time 1 Blow Date/Time 2 Blow Date/Time 3 Blow Date/Time 4 Values Closed, Open An integer value A time value in hr:min:sec Comments See previous. See previous. Current state of the Blow Valve See previous. See previous. Number of times the Blow Valve has been opened. The last five amount of time that the Blow Valve was opened. This value is the amount of time that the Blow Valve was open until either the plunger arrived or until the Blow Valve timer expired. The last five dates and times the Blow Valve was opened.
A date and time
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State 5 Plunger Arrived This is the 5 Plunger Arrived screen from PCCU.
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The 5 Plunger Arrived tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status First Run Setting First Run Count Plunger Swab Swab Runs Setpoint Swab Run Completed Swab Now Reset Plunger Counters Normal Consecutive Arrivals Normal Count Fast Count Late Count Slow Count Cycles before Maintenance Values Comments See previous. See previous. See previous. See previous. If the count of initial consecutive arrivals slower than the Slow Arrival Time must be larger than this before going to the Afterflow state. Count of the number of initial consecutive arrivals that are slower than the Slow Arrival Time. Enable the use of the plunger to swab. When set to Enable, the plunger will begin tripping on the next cycle repeating the drop phase on the next arrival The number of swab runs to complete. The number of swab runs completed in the current swab cycle. This value is reset to zero upon completion Selecting Yes will cause the swabbing process to begin immediately during Afterflow. Clear the counters used to track the count of arrivals and arrival types. The total number of consecutive arrivals that have fallen within the normal window created by the slow and fast arrival times. This value is reset by the reset plunger counters. The total number of normal arrivals since the last reset plunger counters was used. The total number of fast arrivals since the last reset plunger counters was used The total number of late arrivals since the last reset plunger counters was used The total number of slow arrivals since the last reset plunger counters was used The total number of cycles before the Maintenance message is displayed in the cycle status. The total cycles counter is reset when the reset plunger counters is used. A value of zero will disable this function. The total number of the time the logic has gone thru the Closing Valve state since the last reset plunger counters was used.
Any integer value A integer value Disabled, Enabled Any integer value An integer value No, Yes No, Yes An integer value An integer value An integer value An integer value An integer value Any integer value
Total Cycles
An integer value
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State 6 Afterflow This is the 6 - Afterflow screen from PCCU.
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The 6 Afterflow tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status State Timer Max State Timer Option Plunger Catch Mode Values Comments See previous. See previous. See previous. See previous. This is a copy of the current state timer This is a copy of the current state maximum timer Selects if the logic enters the catch mode at cycle end. Selecting Enabled will stop the logic at cycle end and display the Catch message in the cycle status. This allows the catch pin to be extended and left unattended to catch the plunger and close the main valve (sales valve). Selecting Disabled will cause the next cycle to start. The current accumulated run volume. This value begins accumulation when the main value is opened and the accumulation is complete when the Valve Closed state begins. This was the reason that the valve was closed the last time.
A time value in hr:min:sec A time value in hr:min:sec Disabled, Enabled
Current Run Volume Current Close Reason
A floating point value None = 0 TIMER = 1 DP = 2 FR = 3 TUBE-LINE = 4 CASE-LINE = 5 CASE = 6 TURNER = 7, SWAB = 8 SP = 9 TUBE = 10 AI1 = 11 AI2 = 12, LOAD = 13 NOW = 14 CT_TL = 15 LR_TIME = 16 LINE = 17 AFTER = 18, C_L = 19 CL_TL = 20 SLUG = 21 Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled
Option Flow Time Close Option Afterflow Timer Close Option Turner FR Close Option Load Ratio Close
Enables the option to use the flow timer to determine when to close the main valve Enables the option to use the afterflow timer to determine when to close the main valve Enables the use of the Turner flow rate to determine when to close the valve. Enables the use of Load Ratio to close the valve.
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The 6 Afterflow tab continued: Description Option DP Close Option Flow Rate Close Option Tube-Line Close Option Case-Tube Close Option Case Close Option SP Close Option Tubing Close Option Line Close Option Slug Close Option Input 1 Close Option Input 2 Close Values Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Disabled, Enabled Comments Enables the use of DP to close the valve Enables the use of flow rate to close the valve. Enables the use of the difference between tubing pressure and line pressure to determine when to close the valve. Enables the use of the difference between casing pressure and tubing pressure to determine when to close the valve. Enables the use of casing pressure to determine when to close the valve. Enables the use of static pressure to determine when to close the valve. Enables the use of tubing pressure to determine when to close the valve. Enables the use of line pressure to determine when to close the valve. Enables the use of slug size to determine when to close the valve. Enables the use of Input 1 to determine when to close the valve. Enables the use of Input 2 to determine when to close the valve.
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Plunger 6-Afterflow Timers This is the 6 - Afterflow Timers screen from PCCU.
The Timers tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Flow Time Close Flow Cycle Time Limit Flow Cycle Timer Option AfterFlow Timer Close After Flow Time Limit After Flow Timer Values Comments See previous. See previous. See previous. See previous. Enables the option to use the flow timer to determine when to close the main valve Amount of time to keep the main valve open before closing. The amount of time that the well has been flowing. This value is equal to the plunger arrival timer plus the after flow timer. Enables the option to use the afterflow timer to determine when to close the main valve Amount of time to keep the valve open after plunger arrival. The amount of time the well has been flowing after plunger arrival.
Disabled, Enabled A time value in hr:min:sec A time value in hr:min:sec Disabled, Enabled A time value in hr:min:sec A time value in hr:min:sec
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Plunger 6-Afterflow Turner This is the 6 - Afterflow Turner screen from PCCU.
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The Turner tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Turner Flow Rate Values Comments See previous. See previous. See previous. See previous. The flow rate at which the gas stream will carry fluids in the well casing/tubing to the surface. The product of the Turner Rate multiplier and the Turner Flow Rate is the shut-in or closing flow rate. The calculation used for the Turner Flow Rate follows. See the Plunger Operation Overview section for the description of the Turner Flow Rate calculation. This is value that will be used to determine if the valve should close. This value is the result of the following equation: Turner Flow Rate * Turner Multiplier. Current flow rate. This is the velocity required to carry droplets of liquid out of the well. This is the area of the tubing. This is the difference between the casing pressure and the line pressure. Current line pressure. Current casing pressure.
A floating point value
Turner FR Multiplied Flow Rate In Critical Velocity Area of tubing Case-Line In Line Pressure Casing Pressure In
A floating point value A floating point value A floating point value in ft/sec A floating point value in sq ft. A floating point value A floating point value A floating point value
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The Turner tab continued: Description Tubing Pressure In SP In Tf In Last Lift Velocity Values A floating point value A floating point value A floating point value A floating point value Comments Current tubing pressure Current static pressure Current temperature This is the last lift velocity calculated after the last plunger arrival. This is calculated when a non-zero value is entered for the Tubing length. The calculation is: Lift velocity (ft/min) = Tubing length (feet) / Plunger arrival time (min). Enables the use of the Turner flow rate to determine when to close the valve. Used to discount the casing pressure input for wells using a packer where no valid casing pressure is available. No indicates that the well has a valid casing pressure input that can be used for the Turner flow. Yes indicates that the well utilizes a packer and no valid casing pressure is available. Yes will force the selection of Tube for the Turner Mode. Selects if Tubing pressure or the difference between Casing and Static pressure are used to calculate the Turner Flow Rate. The difference between the line pressure and the casing pressure must be less than this value before the valve can be closed. This test value is only used on wells that are not Packer wells. The length of the tubing from the stop to the arrival sensor, used to calculate the lift velocity The INNER diameter of the well tubing used to calculate the Turner Flow Rate. The time that is applied as a delay after plunger arrival before the evaluation flag is raised. This provides a fixed time after plunger arrival in which the critical flow rate is not evaluated. This allows for wells that continue to unload after arrival and allow the flow rate to drop below the critical rate while unloading for a fixed time. The time that has elapsed after plunger arrival. When this value becomes equal to the Evaluation Time, the Evaluation flag is set to ON. This indicates the status of the evaluation of the critical flow. Off indicates that the logic is not currently using the flow rate to determine drop and that either the state is not in Afterflow or that the current mode of operation does not use the Turner flow rate option. Consecutive amount of time that the flow rate has been below Turner Flow Rate * Turner Rate multiplier (see above regarding Packer Well selection). This timer is reset if the flow rate goes above the Turner Flow Rate * Turner Rate multiplier. The amount of time that the flow rate is below the Turner Flow Rate * Turner Rate multiplier AND (only for Packer Well = No) when the line pressure/casing pressure difference is less than the Line-Casing test value, that will allow the logic to close the valve and begin the drop cycle.
Option Turner FR Close Packer Well
Disabled, Enabled No, Yes
Turner Mode Line-Casing Test value
Tube, Case-SP A floating point value Any floating point value Any floating point value A time value in hr:min:sec
Tubing Length Tubing ID Evaluation Time Limit
Evaluation Timer Evaluation Flag
A time value in hr:min:sec Off On
Turner Low Timer
Turner Low Time Limit
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The Turner tab continued: Description Turner Rate multiplier Values Comments The value that is multiplied against the calculated Turner unloading rate to determine the flow rate at which the valve will be closed. The multiplier is a value of zero of higher. Examples would be 0.1 (which is 10% of the calculated Turner flow rate) or 1.25 (which is 125% of the calculated Turner flow rate). This is the amount that will be decremented from the Turner multiplier when the plunger arrival is fast. This amount will be added to the Turner multiplier when the plunger is slow, late or hung. If plunger fails, multiply the next tuning by this factor. The lower limit of the Turner multiplier. If the process decrements the value below the minimum value the Turner multiplier will be set to the Min value The upper limit of the Turner multiplier. If the process increments the value above the maximum value the Turner multiplier will be set to the Max value values.
Turner Close Tune
Any floating point value Any floating point value Any floating point value Any floating point value
Plunger Fail Factor Tune Turner Multiplier Min Turner Multiplier Max
Plunger 6-Afterflow LR This is the 6 - Afterflow LR screen from PCCU.
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The LR tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Load Ratio Close Load Ratio Load Ratio Close Limit Load Ratio Close time Load Ratio Close timer Plunger Fail Factor Tune Load Ratio Close Tune Load Ratio Close Min Load Ratio Close Max Values Comments See previous. See previous. See previous. See previous. Enables the use of Load Ratio to close the valve. The current value of the Load Ratio. If Load Ratio is below this value for Load Ratio close time, close the valve. Consecutive amount of time that Load Ratio must be below the Load Ratio setpoint before the valve is closed. Elapsed time the Load Ratio has been below the Load Ratio close setpoint. If plunger fails, multiply the next tuning by this factor. Tune Load Ratio Close by this amount Do not tune Load Ratio Close below this value. Do not tune Load Ratio Close above this value.
Disabled, Enabled A floating point value A floating point value A time value in hr:min:sec A time value in hr:min:sec Any floating point value Any floating point value Any floating point value Any floating point value
Plunger 6-Afterflow DP This is the 6 - Afterflow DP screen from PCCU.
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The DP tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option DP Close DP In DP Limit DP Low Time DP Low Timer DP Limit Tune DP Limit Min Values Comments See previous. See previous. See previous. See previous. Enables the use of DP to close the valve Current DP If DP is below this value for DP Low Time, close the valve Consecutive amount of time that DP must be below the DP Setpoint before the valve is closed. Elapsed time that DP has been below the DP Setpoint. Amount to tune the DP Limit. Do not tune DP Limit below this value.
Disabled, Enabled A floating point value Any floating point value A time value in hr:min:sec A time value in hr:min:sec Any floating point value Any floating point value
Plunger 6-Afterflow FR This is the 6 - Afterflow FR screen from PCCU.
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The FR tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Flow Rate Close Flow Rate In Flow Rate Limit Flow Rate Low Time Limit Flow Rate Low Timer FR Limit Tune FR Limit Min Values Comments See previous. See previous. See previous. See previous. Enables the use of flow rate to close the valve. Current flow rate. If flow rate is below this value for Flow Rate Low Time, close the valve. Consecutive amount of time that flow rate must be below the Flow Rate Limit before the valve is closed. Elapsed time that flow rate has been below the Flow Rate Limit. Amount to tune the Flow Rate Limit. Do not tune FR Limit below this value.
Disabled, Enabled A floating point value Any floating point value A time value in hr:min:sec A time value in hr:min:sec Any floating point value Any floating point value
Plunger 6-Afterflow T-L This is the 6 - Afterflow T-L screen from PCCU.
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The T-L tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Tube-Line Close Tube-Line Tube-Line Close Limit Tube Line Close Tune Tube Line Close Min Values Comments See previous. See previous. See previous. See previous. Enables the use of the difference between tubing pressure and line pressure to determine when to close the valve. The difference between tubing and line pressure. If the difference between tubing and line pressure is less than this value, close the valve. Amount to tune the tubing pressure/line pressure difference. Do not tune the tubing pressure/line pressure difference below this value..
Disabled, Enabled A floating point value Any floating point value Any floating point value Any floating point value
Plunger 6-Afterflow C-T This is the 6 - Afterflow C-L screen from PCCU.
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The C-T tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Case-Tube Close Case Tube Case-Tube Close Limit Case Tube Close Tune Case Tube Close Min Values Comments See previous. See previous. See previous. See previous. Enables the use of the difference between casing pressure and tubing pressure to determine when to close the valve. The difference between casing and tubing pressure. If the difference between casing and tubing pressure is less than this value, close the valve. Amount to tune the casing pressure/tubing pressure difference. Do not tune the casing pressure/tubing pressure difference below this value.
Plunger 6-Afterflow Tube This is the 6 - Afterflow Tube screen from PCCU.
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The Tube tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Tubing Close Tubing Pressure In Tubing Close Action Values Comments See previous. See previous. See previous. See previous. Enables the use of tubing pressure to determine when to close the valve. Current tubing pressure Selecting Lo Close will close the valve when tubing pressure goes below the Tubing Close Limit for the Tubing Close Time. Selecting Hi Close will close the valve when tubing pressure goes above the Tubing Close Limit for the Tubing Close Time. This is the test value used to begin the Tubing Close Timer. The amount of time that the static pressure must either go above or fall below the Tubing Close Limit before the valve closes. Amount of time that tubing pressure has been outside of the Tubing Close Limit. If the tubing pressure falls within the limit test, this is reset. Amount to tune the Tube Close Limit Do not tune Tube Close Limit below this value
Disabled, Enabled A floating point value Lo Close, Hi Close
Tubing Close Limit Tubing Close Time Limit Tubing Close Timer Tube Close Tune Tube Close Min Tune
Any floating point value A time value in hr:min:sec A time value in hr:min:sec A floating point value A floating point value
Plunger 6-Afterflow Case This is the 6 - Afterflow Case screen from PCCU.
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The Case tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Case Close Casing Pressure In Case Close Limit Case Close LimitTune Case Close Min Values Comments See previous. See previous. See previous. See previous. Enables the use of casing pressure to determine when to close the valve. Current casing pressure If casing pressure falls below this value, close the valve. Amount to tune the close casing pressure. Do not tune close casing limit below this value.
Plunger 6-Afterflow SP This is the 6 - Afterflow SP screen from PCCU.
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The SP tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option SP Close SP In SP Action Values Comments See previous. See previous. See previous. See previous. Enables the use of static pressure to determine when to close the valve. Current static pressure Selecting Lo Close will close the valve when static pressure goes below the SP Close Limit for the SP Close Time. Selecting Hi Close will close the valve when static pressure goes above the SP Close Limit for the SP Close Time. This is the test value used to begin the SP Close Timer. The amount of time that the static pressure must either go above or fall below the SP Close Limit before the valve closes. Amount of time that Static pressure has been outside of the Sp Close Limit. If the Static pressure falls within the limit test, this is reset. Amount to tune SP close limit Do tune SP close limit below this value.
SP Close Limit SP Close Time Limit SP Close Timer SP Close Tune SP Close Min Tune
Any floating point value A time value in hr:min:sec A time value in hr:min:sec
Plunger 6-Afterflow Slug This is the 6 - Afterflow Slug screen from PCCU.
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The Slug tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Slug Size Close Slug Size Slug Size Close Limit Fluid Gradient Values Comments See previous. See previous. See previous. See previous. Enable the use of slug size to close valve. Current slug size Slug size must be below this value before the valve is opened. Slug Size constant (default = 0.433)
Disabled, Enabled Any floating point value Any floating point value Any floating point value
Plunger 6-Afterflow Inputs This is the 6 - Afterflow Inputs screen from PCCU.
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The Inputs tab contains the following values: Description Controller State Main Valve State Plunger Status Cycle Status Option Input 1 Close Input 1 In Input 1 Action Values Comments See previous. See previous. See previous. See previous. Enables the use of Input 1 to determine when to close the valve. Current Input 1 value Selecting Lo Close will close the valve when Input 1 goes below the Input 1 Close Limit for the Input 1 Close Time. Selecting Hi Close will close the valve when Input 1 goes above the Input 1 Close Limit for the Input 1 Close Time. This is the test value used to begin the Input 1 Close Timer. The amount of time that Input 1 must either go above or fall below the Input 1 Close Limit before the valve closes. Amount of time that Input 1 has been outside of the Input 1 Close Limit. If the tubing pressure falls within the limit test, this is reset. Enables the use of Input 2 to determine when to close the valve. Current Input 2 value Selecting Lo Close will close the valve when Input 2 goes below the Input 2 Close Limit for the Input 2 Close Time. Selecting Hi Close will close the valve when Input 2 goes above the Input 2 Close Limit for the Input 2 Close Time. This is the test value used to begin the Input 2 Close Timer. The amount of time that Input 2 must either go above or fall below the Input 2 Close Limit before the valve closes. Amount of time that Input 2 has been outside of the Input 2 Close Limit. If the tubing pressure falls within the limit test, this is reset.
Input 1 Close Limit Input 1 Close Time Limit Input 1 Close Timer Option Input 2 Close Input 2 In Input 2 Action
Any floating point value A time value in hr:min:sec A time value in hr:min:sec Disabled, Enabled A floating point value Lo Close, Hi Close
Input 2 Close Limit Input 2 Close TimeLimit Input 2 Close Timer
Any floating point value A time value in hr:min:sec A time value in hr:min:sec
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Plunger 6-Afterflow Blow This is the 6 - Afterflow Blow screen from PCCU.
The Blow tab contains the following values: Description Controller State Main Valve State Blow Valve State Plunger Status Cycle Status Current Run Volume After Flow Timer Option BV Cushion Values Closed, Open A floating point value A floating point value in minutes Disabled, Enabled Comments See previous. See previous. Current state of the Blow Valve See previous. See previous. The current accumulated run volume. This value begins accumulation when the main value is opened and the accumulation is complete when the Valve Closed state begins. The amount of time the well has been flowing after plunger arrival. Enable blow valve cushion logic. This logic causes the main valve to close while the blow valve is open. Once the plunger arrives, the main valve is opened and the blow valve also remains open for a specified time before closing. Only used when the Blow Valve Cushion Option is enabled. This is the amount of time to wait after plunger arrival to close the Blow Valve. Elapsed time since the plunger arrived and Blow Valve Cushion Option is enabled.
Blow Valve Cushion Time Limit Blow Valve Cushion Timer
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State 0 FAIL The 0 FAIL screen is as follows:
The 0 FAIL tab contains the following values: Description StateMachine Plunger Status Cycle Status Current Fail Reason Values Comments See previous. See previous. See previous. This value indicates the current reason why the FAIL state is activated
Current Fail Date/ Time Fail Main Valve State
None=0, Plunger NonArrival=1, DI x = 3, AI x LOW = 4, AI x HIGH = 5, REMOTE = 6, DISABLE = 7, RESET = 8 A date and time None, Close, Open
Fail Blow Valve State
None, Close, Open
This is the time and date when the FAIL State was entered. This specifies the operation of the Main Valve during the Plunger Failure (or Safety System) operation. None indicates that no action if performed by the Main Valve when the FAIL State is activated. Close indicates the Main Valve will close when the FAIL State is activated. Open indicates that Main Valve will open when the FAIL State is activated. This specifies the operation of the Blow Valve during the Plunger Failure (or Safety System) operation. None indicates that no action if performed by the Blow Valve when the FAIL State is activated. Close indicates the Blow Valve will close when the FAIL State is activated. Open indicates that Blow Valve will open when the FAIL State is activated.
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Plunger - Statistics Misc This is the Plunger Lift Statistics Misc screen from PCCU. Note that there are several screens that contain the Plunger Lift information. Each tab will be described separately.
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The Misc tab contains the following values: Description Current State State Timer Max State Timer Total Cycles Plunger Arrival In Hold? Values State expressed as a string A time value in hr:min:sec A time value in hr:min:sec An integer value A 32-bit integer value NO, YES Comments This is the current state of the plunger logic This is a copy of the current state timer This is a copy of the current state maximum timer The total number of the time the logic has gone thru the Closing Valve state since the last reset plunger counters was used. This is the value of the PI that is connected to the plunger arrival sensor This indicates the calibration state of the input values. YES indicates one or more input values are being calibrated and therefore the current input values are not being used to determine if the Safety System should be activated. This value will change from YES to NO as soon as the calibrate screen is closed. Current AP Current DP Current temperature Current flow rate Current accumulated volume Current calculated compressibility factor Current barometric pressure Current line pressure Current tubing pressure Current casing pressure Current value of Hold Input. Current value of Input 1 Current value of Input 2 The date and time when the contract hour was last crossed. The amount of time that this application has been executing for today. This is the part number of the Plunger application. This the current state of the Plunger controller.
AP In DP In Tf In Flow Rate In Volume Z factor Baro Press LinePressure Tubing Pressure In Casing Pressure In Hold Input Input 1 In Input 2 In LastCntrctHrUpdt LogTime Version Current State
A floating point value A floating point value A floating point value A floating point value A floating point value A floating point value A floating point value A floating point value A floating point value A floating point value A floating point value A floating point value A floating point value A date and time A time value in hr:min:sec A string value A string value
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Closed This is the Plunger Lift Statistics Closed Times screen from PCCU.
The Closed Times tab contains the following values: Description Close Cycle Average ClosedTimeToday ClosedTimeYest ClosedTodayTotal Close Cycle[0] Close Cycle[1] Close Cycle[2] Close Cycle[3] Close Cycle[4] Close Cycle[5] Close Cycle[6] Close Cycle[7] Close Cycle[8] Close Cycle[9] Values A time value in hr:min:sec A floating point value in percent A floating point value in percent A time value in hr:min:sec A time value in hr:min:sec Comments This is the average of the last ten closed cycle times The percent of time for today that the valve was closed. The percent of time for yesterday that the valve was closed. The total amount of time that the valve has been closed for today. The last ten close cycle times along with last ten close reasons..
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Plunger Statistics Closed Closed-Casing This is the Plunger Lift Statistics Closed-Casing screen from PCCU.
The Closed-Casing tab contains the following values: Description CsngPress0 CsngPress1 CsngPress2 CsngPress3 CsngPress4 CsngPress5 CsngPress6 CsngPress7 CsngPress8 CsngPress9 Values A floating point value Comments The last ten casing pressures taken at the end of the Closed Valve State (just before valve was opened).
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Plunger Statistics Closed Closed-Tubing This is the Plunger Lift Statistics Closed-Tubing screen from PCCU.
The Closed-Tubing tab contains the following values: Description TbngPress0 TbngPress1 TbngPress2 TbngPress3 TbngPress4 TbngPress5 TbngPress6 TbngPress7 TbngPress8 TbngPress9 Values A floating point value Comments The last ten tubing pressures taken at the end of the Closed Valve State (just before valve was opened).
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Plunger This is the Plunger Lift Statistics Plunger Status screen from PCCU.
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The Plunger Stats tab contains the following values: Description Normal Count Consecutive Normal Arrivals Fast Count Slow Count Late Count Current Fail Date/ Time Plunger Status[0] Plunger Status[1] Plunger Status[2] Plunger Status[3] Plunger Status[4] Plunger Status[5] Plunger Status[6] Plunger Status[7] Plunger Status[8] Plunger Status[9] Values An integer value An integer value An integer value An integer value An integer value A date and time A list of values Comments The total number of normal arrivals since the last reset plunger counters was used. The total number of consecutive arrivals that have fallen within the normal window created by the slow and fast arrival times. This value is reset by the reset plunger counters. The total number of fast arrivals since the last reset plunger counters was used The total number of slow arrivals since the last reset plunger counters was used The total number of late arrivals since the last reset plunger counters was used This is the time and date when the FAIL State was entered. The last ten states of the plunger. Normal indicates that the plunger has returned between the fast and slow set points, no adjustment of setpoints is needed. Fast indicates that the plunger has returned in less time than the fast arrival time; setpoints will be adjusted by decrementing the tuning values from the setpoints. Slow indicates that the plunger has not returned within the time set by the slow arrival time; setpoints will be adjusted by incrementing the setpoint values by the tuning values. Late indicates that the plunger has not returned before the Max Arrival time. Hung indicates that the plunger has not arrived by the time Blow Valve is opened (or Max Arrivals Allowed has been counted); setpoints will be adjusted by incrementing the setpoint values by the tuning values if the Blow Valve is not used.
Plunger Statistics Plunger Plunger-Arrivals This is the Plunger Lift Statistics Plunger Arrivals screen from PCCU.
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The Plunger Arrivals tab contains the following values: Description PlungArrivalYest PlngArrivalToday PlngAriveAvg PlngArive0 PlngArive1 PlngArive2 PlngArive3 PlngArive4 PlngArive5 PlngArive6 PlngArive7 PlngArive8 PlngArive9 Values An integer value An integer value A time value in hr:min:sec A time value in hr:min:sec Comments The number of plunger arrivals yesterday. The number of plunger arrivals today. The average of the last ten plunger arrival times. The last ten plunger arrival times and date/times
Plunger Statistics Plunger Plunger Non-Arrivals This is the Plunger Lift Statistics Plunger Non-Arrivals screen from PCCU.
The Plunger Non-Arrivals tab contains the following values: Description Non-Arrival 0 Non-Arrival 1 Non-Arrival 2 Non-Arrival 3 Non-Arrival 4 Non-Arrival 5 Non-Arrival 6 Non-Arrival 7 Non-Arrival 8 Non-Arrival 9 Values A date and time Comments The last ten dates and times when the plunger did not arrive before the Max Arrival Time
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Flow This is the Plunger Lift Statistics Flow Cycle screen from PCCU.
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The Flow Cycle tab contains the following values: Description CycleStatus Values Running = 0 Maintenance = 1 Catch = 2 Disabled = 3 BV Curtail = 4 Manual = 5 An integer value A floating point value in percent A floating point value in percent A time value in hr:min:sec A time value in hr:min:sec Comments This shows the status that has been determined through the operation of the cycle.
Total Cycles FlowTimeToday FlowTimeYest FlowCycleAvg FlowCycle0 FlowCycle1 FlowCycle2 FlowCycle3 FlowCycle4 FlowCycle5 FlowCycle6 FlowCycle7 FlowCycle8 FlowCycle9
The total number of the time the logic has gone thru the Closing Valve state since the last reset plunger counters was used. The percent of time for today that the valve was not closed. The percent of time for yesterday that the valve was not closed. The average of the last ten flow cycle times. The last ten flow cycles times and close reasons
Plunger Statistics Flow Run volume This is the Plunger Lift Statistics Flow Run Volume screen from PCCU.
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The Run Volume tab contains the following values: Description Run Volume average Run Volume Run Volume Run Volume Run Volume Run Volume Run Volume Run Volume Run Volume Run Volume Run Volume Blow This is the Plunger Lift Statistics Blow Blow Valve screen from PCCU. Values A floating point value A floating point value Comments The average of the last ten run volumes. The last ten run volumes.
The Blow Valve tab contains the following values: Description Blow Count Blow Time 0 Blow Time 1 Blow Time 2 Blow Time 3 Blow Time 4 Blow Date/Time 0 Blow Date/Time 1 Blow Date/Time 2 Blow Date/Time 3 Blow Date/Time 4 User's Guide 2102890-001 Values An integer value A time value in hr:min:sec Comments Number of times the Blow Valve has been opened. The last five amount of times that the Blow Valve was opened.
A date and time
The last five dates and times the Blow Valve was opened.
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Slug This is the Plunger Lift Statistics Slug Slug Open screen from PCCU.
The Slug Open tab contains the following values: Description Slug Open Size [1] Slug Open Size [2] Slug Open Size [3] Slug Open Size [4] Slug Open Size [5] Slug Open Size [6] Slug Open Size [7] Slug Open Size [8] Slug Open Size [9] Slug Open Size [10] Values A floating point value in gallons Comments Last 10 slug sizes at open.
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Plunger Statistics Slug Slug Close This is the Plunger Lift Statistics Slug Slug Close screen from PCCU.
The Slug Close tab contains the following values: Description Slug Close Size [1] Slug Close Size [2] Slug Close Size [3] Slug Close Size [4] Slug Close Size [5] Slug Close Size [6] Slug Close Size [7] Slug Close Size [8] Slug Close Size [9] Slug Close Size [10] Values A floating point value in gallons Comments Last 10 slug sizes at close.
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Register List
The register list for this application may be found in document PlungerRegistersRevAA.doc
Initial Set-Up Flow Computer

Program the XFC or XRC and calibrate internal transducers using Totalflows installation and operations manual

All plunger configuration and operations can be done locally using Totalflows PCCU (version 4.5 or newer) or remotely using Totalflows WinCCU software (version 6.3 or newer) thru the Remote Configuration option. Insure matching PCCU and WinCCU configuration file for the Plunger Lift application (2102890-xxx.INI) is installed. Activate Entry Mode of PCCU (icon or Operate/Communications/Entry). Set Plunger Lift configuration items. Plunger/Setup Valve Control or Direct I/O If Valve Control, set Open Valve Method I/O locations (Use Reset VCBs = Reset or manually enter values) Set Valve Position (Upstream or Downstream) Set Valve Time Set Startup Mode (Main Valve = Close/Open) States/Closing Valve Plunger Fall Delay States/Valve Closed (when to open) Timer (Optional) Tube-Line (Optional) Case-Tube (Optional) Case-Tube & Tube-Line (Optional) States/Plunger Arriving Arrival Times (Max, Slow, Fast, Min) Max Arrivals Allowed Blow Valve Help (timer, FR low, Case Low, DP Low) States/Blow Valve Blow Time Max Blow Cushion States/Plunger Arrived First Run Setting States/Afterflow (when to close) Blow Cushion (Flow Time, DP low, FR Low, Tube-Line, Case-Tube, Case) States/Fail
Fail Actions for the main valve of for the blow valve. Once configuration is complete the configuration files may be saved to save the user settings for cold start. Set Valve Control configuration items if valve control is used. Enable (or Manual) Plunger control (Plunger/Setup) User's Guide 2102890-001 Plunger Lift Control 95 of 97 January 15, 2007
Change Log:
Version: 001 Initial release
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Recommended Module Wiring - Direct I/O Option
J4 J3
1 1
2 3 4 2 3 4 Vbatt
C L O S E
BLOW
O P E N
J1 J2
1 1
2 3 4 2 3 4
C L O S E Plunger Arrival Switch
MAIN
O P E N
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ABB Totalflow Plunger User Guide

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ABB Totalflow Plunger User Guide

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TOTALFLOW Plunger Lift Control Users Guide

Application Part Number 2102890-001

User's Guide 2102890-001

Plunger Lift Control

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Totalflow Hardware Requirements:

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Plunger Lift Control

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Plunger Lift Control

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Plunger Lift Control

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Plunger Lift Control

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3.067 * P * Vg * AREA TEMP R0 * Z

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Plunger Lift Control

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User's Guide 2102890-001

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Plunger Lift Control

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Plunger Fail Factor Tune Tubing Length Tubing ID Reset VCBs

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Plunger Lift Control

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The Valve Setup screen is as follows:

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Plunger Lift Control

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Any register value

VC Full Closed DI Packer Well

Any register value No Yes

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Plunger Lift Control

The Input Setup screen is as follows:

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Plunger Lift Control

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Any register value

Any register value

Baro Press Register

Any register value

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Plunger Lift Control

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Controller State State Timer Max State Timer Plunger Status

Running = 0 Maintenance = 1 Catch = 2 Disabled = 3 BV Curtail = 4 Manual = 5

User's Guide 2102890-001

Plunger Lift Control