State of The Art RPC REV01 PDF

State of the Art Rod Pump Controllers and
Instrumentation
Rod Pumping Systems Applications Course
Defining Production Optimization
op· ti· mi· za· tion (Ŏp΄tə-mĭ-zā′shən)
n. The procedure or procedures used to make a system or design as effective

or functional as possible
Increase production
– Lower mean failure rate
– Increase flow rate
– Maximize reservoir production
Lower costs
– Reduce down times
– Maximize human resource potential
– Doing more with less
© 2015 Weatherford. All rights reserved.

Automation vs Optimization
– Automation
• To manage the operation of a system or process with
electronic, mechanical, hydraulic or pneumatic
technology.
• “to operate without manual intervention”
• ATM automates the process of a bank teller.
– Optimization
• The systematic or continuous control of a system or
process to maximize (or minimize) the results.
• “to manage to a target or goal”
• “Variable speed function” continuously controls
around a setpoint.

Electric Motors
The Electric Motors used in the oil industry are induction asyncronous motors.
This type of motors have a rotor and a stator .
The speed is determined by:
Were “f” is the frequency, “s” is the slip and “p” is the number of magnetic
poles.

Challenges in Rod Lift Wells
A common rod pump application problem:
– Matching a well’s dynamic inflow to the rod pump system’s fixed
displacement
– The rate at which fluid enters the wellbore is constantly changing
due to
Reservoir pressure
Pressure in the Well assembly (fluid level)
– Displacement of the rod pump systems almost never exactly
matches the well’s ability to produce fluid
Under-produced well – rod pump system is undersized
Over-produced well – most common scenario, pump system is too large or
pumping too fast

Common Rod Pump Problems
Pump Off/Fluid Pound
• The condition when the displacement of the rod
pump system exceeds the inflow to the well
(Overproduced)
• During the upstroke, the pump does not completely
fill with fluid – but will almost always have some
degree of low pressure gas present in the pump
barrel
• During the down-stroke, the rod string and tubular
fluid behave as a free-falling body, accelerating
through the free space in the pump barrel
• “Fluid pound” occurs when the freefalling plunger
and tubular fluid column above reach the partially full
fluid level of the pump causing the valves to finally
open. The sudden stop can cause severe damage
to all rod lift components
Benefits of Fluid Pound Control
Extends time between failures of SRP components
– Damage caused by shock loading
– Reduces daily rod string cycles
10 SPM = 5,256,000 stroke per year
Average rod string life is 20,000,000 strokes
Average pump life is 5,000,000 strokes
25% runtime reduction extends life of rod string one year and pump three months
Reduces electrical consumption
Early detection of well problems (rod/tubing failure, pump
wear, high fluid level, etc.) using dynamometer analysis
Other Common RRL Problems
Almost half of all production related issues are found at the
pump
Pump Barrel Splits
Worn Plunger
Plunger pins breaking
Cracked traveling or standing valve cages
Split traveling or standing valve ball into two pieces
Top of pump worn causing leakage
Trash, paraffin, salts, H2S leading to etching or plugging of Standing and/or
Traveling valves
Foaming
Wrong pump for the well
Rod Failures

Optimization Solution for RRL
Rod Pump Controller
Principle form of automation for rod pump
system
Gathers load and position points to generate
dynamometers for detecting:
– Incomplete pump fillage
– Fluid pound
– Parted rods
– Pump wear
– High fluid level
– Excessive down-hole friction
By using a dynamometer it takes the
appropriate action to automatically start and
stop the well

How the RPOC does it
Principle tool for analyzing the
The Dynamometer Card operation of rod pumped wells
Gathers polished rod load and
B C position points throughout the
Rod Load (lbs)
stroke, and plots these points on a

graph
– This plot is referred to as a
A = BOS dynamometer card
C = TOS – The shape of this card is directly
related to changing down-hole
conditions and represents the work
A D of the down-hole pump
Position of Stroke (inches)
Rod Pump Controllers use the
dynamometer to detect changes
in pump fillage as well as identify
down-hole problems
© 2015 Weatherford. All rights reserved. 10
What a Rod Pump Controller(RPC) Does?
Provides a solution to the pump displacement vs. reservoir inflow
problem
Detects when the fluid available to the pump begins to drop and
– Takes the appropriate action to limit operation in fluid pound conditions:
– Shuts the well down for an adjustable idle time to allow the reservoir to
replenish the fluid available in the wellbore (Fixed Speed)
– Automatically restarts the pump at the end of the idle period and pumps until
the well beings to pound fluid again
Monitors wellhead instrumentation (temperature, pressure, vibration
switch, etc.) which can be used as data, or for control and/or alarming
Shuts the well down when down-hole problems are detected and alerts
operators to the condition

Dynamometer Card
Basics/Wave Equation

Surface Dynamometer Card
13
Downhole Dynamometer Card
14
The 1-D Damped Wave Equation
To know how much “actual work” is done
downhole requires a downhole
dynamometer.
A more efficient solution is to calculate the
position and load at the pump using the
surface position and load.
Because of elasticity and friction, the work
done at the surface is not directly translated
downhole.
This takes the form of stress waves traveling
along the string at the speed of sound.
The 1-D wave equation describes this
motion.
Solving using the wave equation calculates
the downhole card.
The “Gibbs” Method
The most commonly used method of calculating
downhole cards.
Uses the classical method of separation of variables,
which involves the splitting of the original partial
differential wave equation into two “ordinary
differential equations”.
Each ODE is solved and a product solution is formed
that satisfies the wave equation.
The polished-rod load and displacement vs. time
functions are approximated by Fourier Series.
16
The “Everitt-Jennings” Method
Uses finite difference method to solve directly the wave equation.
Each rod taper is segmented to a number of finite difference
elements.
Calculations progress from the surface to the downhole location
along the above number of finite difference elements.
Provides iteration on the net stroke and the damping factor to
ensure the best downhole card.
Computes “effective load” for downhole data.
Weatherford has “modified” the EJ method for efficiency and
specific functionality.
17
Modified Everitt-Jennings Method (MEJ)
The one dimensional damped wave equation models the
propagation of stress waves down the rod string:
The MEJ method is an algorithm for solving the wave equation

using finite differences
One of many advantages to using finite differences is that the
position, load and stress can be computed at any level down the
taper
The Everitt-Jennings method incorporates an iteration on the net
stroke and damping factor. Weatherford developed the MEJ
method in 2008
Other Everitt-Jennings Functionality
Downhole pump fillage is calculated from load or
position data.
Improved fluid level calculations.
Calculation of stress level on any individual rod in
the string.
19
Downhole Card Visualization
Load (Lbs.)
Load (Lbs.)
Full Pump Pump-Off
Net Pump Stroke (in.) Net Pump Stroke (in.)

Load (Lbs.)
Load (Lbs.)
Gas
Interference Tubing
or Movement
Compression
Net Pump Stroke (in.) Net Pump Stroke (in.)
0.2 © 2015 Weatherford. All rights reserved.

Rod
String
Tubing
Casing Fluid Top of Stroke

Level down-hole Pump Card
Maximum Fluid Load
Load (Lbs)
Tubing
Anchor
Pump Hold-
Pressure Down Full Pump
Above Pump
Plunger Barrel
Minimum Fluid Load
Fluid Load Pump Stroke (Inches)
Pump On PlungerPolished rod in the hole –
Plunger
bottom of stroke
Ball
Pressure
Below Traveling Valve
Plunger
Seat Ball
Standing Valve
F1-03
Seat Click Anywhere to Continue
Start of Upstroke
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
Pressure TV Closed (loads increase to maximum)

Below
Plunger
SV Open – Rods Support Fluid Column (load increases)
SV Closed – Tubing Supports Fluid Column (load)
F2-04 Click Anywhere ©to
2015Continue
Weatherford. All rights reserved.
Upstroke Completed
Pump moves up the hole
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
Pressure TV Closed (load @ maximum)

Below
Plunger
SV Open – Rods Support Fluid Column (load)
F3-05 Click Anywhere to Continue

Downstroke Begins
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
TV Closed Net Stroke (in.)

TV Will Open (loads decrease)
Pressure
Below
Plunger
SV Open – Rods Support Fluid Column
SV Will Close – Tubing Supports Fluid Column (load)
2015Continue
Pump Downstroke Completes
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Pump moves down
TV Open Net Stroke (in.)
(loads @ minimum)
Pressure
Below
Plunger

2015Continue
Pump Stroke Complete
Load (Lbs)
Tubing
Anchor
Pressure Full down-hole Pump Card
Above
Plunger
Net Stroke (in.)
Pressure
TV Open
Below TV Will Close
Plunger
F6-08 Click Anywhere to Continue

Rod Pump Visualization
down-hole Pump Card
Load (Lbs)
Tubing
Anchor
Pressure Pump-Off
Above (low pressure gas)
Plunger
Net Stroke (in.)
Pressure
Plunger
Fluid
Level Standing Valve
O1-16 Click Anywhere to Continue

Start of Upstroke
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
Pressure Traveling Valve Closed (load increases to maximum)

Below
Plunger
Standing Valve Will Open – Rods Support Fluid
Fluid
Level
Column
Standing Valve Closed – Tubing Supports Fluid
Column (load)
O2-17 Click Anywhere ©to
2015Continue
Upstroke Continues
Top of Pump Stroke
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Low Pressure Traveling Valve Closed Net Stroke (in.)

Gas
(loads @ maximum)
Pressure
Below
Plunger
Standing Valve Open – Rods Support Fluid Column
Fluid
Level
O3-18
Click Anywhere to Continue
Start Downstroke
Load (Lbs)
Tubing
Anchor
Pressure Traveling valve must contact
Above liquid before it can open
Plunger
Low Pressure Net Stroke (in.)

Gas
Traveling Valve Closed
Pressure
Below
Plunger
Fluid Standing Valve Closed – Tubing Supports Fluid Column
Level

O4-19
Downstroke (cont.)
Load (Lbs)
Tubing
Traveling valve
Anchor
opens late in the
Pressure downstroke
Above
Plunger
Traveling Valve Closed Net Stroke (in.)

Traveling Valve Open
Pressure (loads to minimum)
Below
Plunger
Fluid
Level Standing Valve Closed – Tubing Supports Fluid Column
O5-20
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
Pressure
Below Traveling Valve Open
Plunger
Fluid
(loads @ minimum)
O6-21
Click Anywhere ©to
2015Continue
Bottom of Pump Stroke
Load (Lbs)
Tubing
Anchor
Pressure
Pump Off Card
Above (low pressure gas)
Plunger
Net Stroke (in.)
Pressure
Below
Plunger Traveling Valve Closed
Fluid
O7-22
Click Anywhere to© 2015
Continue
Rod Pumping Visualization
Fluid
Level down-hole Pump Card
Load (Lbs)
Tubing
Anchor Gas
Pressure
Above
Interference
(high pressure gas)
Plunger
Net Stroke (in.)
Pressure
Plunger
Standing Valve
G1-09 Click Anywhere to©Continue

2015 Weatherford. All rights reserved.
Start of Upstroke
Fluid
Level
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
Pressure TV Closed
Below
Plunger
(loads increase to maximum)
SV Open – Rods Support Fluid Column (load increases)
G2-10 Click Anywhere to© 2015
Continue
Pump Upstroke Completes
Fluid
Level
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Net Stroke (in.)
Pressure TV Closed
Below
Plunger
G3-11 Click Anywhere to© 2015

Continue
Start of Downstroke
Fluid
Level
Load (Lbs)
Tubing
Anchor
Pressure
Above Gas below pump must be compressed before
Plunger traveling valve can open
Net Stroke (in.)

TV Closed
Pressure
Below
Plunger
SV Will Close – Tubing Supports Fluid Column (load)
G4-12
Downstroke (cont.)
Fluid
Level
Load (Lbs)
Tubing
Anchor
Pressure
Gas Compression
Above
Complete
Plunger
TV Closed Net Stroke (in.)

TV Will Open
Pressure
(loads decrease)
Below
Plunger
G5-13
Click Anywhere ©to
2015Continue
Fluid
Level
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger
Pump moves down
Net Stroke (in.)
Pressure
Plunger (loads @ minimum)
Standing Valve Closed – Tubing Supports Fluid
Column (load)
G6-14
Click Anywhere ©to
2015Continue
Bottom of Pump Stroke
Fluid
Level
Load (Lbs)
Tubing
Anchor
Pressure Gas Interference
Above Card
Plunger
Net Stroke (in.)
Pressure
Below
Standing Valve Closed – Tubing Supports
Fluid Column (load)
G7-15
Click Anywhere© 2015
to Weatherford.
Continue All rights reserved.
Rod Pump Visualization
Fluid down-hole Pump Card
No Level Tubing movement reduces effective pump stroke
Load (Lbs)
Tubing
Anchor
Pressure
Tubing
Above Movement
Plunger
Net Stroke (in.)
Pressure
Plunger
Standing Valve
T1-23 Click Anywhere ©to

2015Continue
Start of Upstroke
No
Load (Lbs)
Tubing
Anchor
Pressure
Above
Plunger Lost effective pump stroke
Net Stroke (in.)
Pressure
Below Traveling Valve Closed
Plunger (loads to maximum)
Standing Valve Closed – Tubing Supports Fluid Column
Tubing moves up due to rods now supporting the fluid load
T2-24 Click Anywhere to Continue
Upstroke Continues
Top of Pump Stroke
No Tubing
Load (Lbs)
Anchor
Pressure
Above
Plunger

(loads @ maximum)
Pressure
Below
Plunger
T3-25
Start Downstroke
No Tubing
Load (Lbs)
Anchor
Pressure
Above
Plunger
Pressure
Below
Plunger

Downstroke (cont.)
No Tubing
Load (Lbs)
Anchor
Pressure
Above
Plunger

Pressure (loads decrease to minimum)
Below
Plunger
Tubing moves down due to rods no longer supporting the fluid load
2015Continue
Downstroke Completes
No Tubing
Load (Lbs)
Anchor
Pressure
Above
Plunger
Pump moves down
Net Stroke (in.)
Pressure Traveling Valve Open

Below
Plunger (loads @ minimum)

Bottom of pump Stroke
No Tubing
Load (Lbs)
Anchor
Tubing Movement
Pressure
Above Card
Plunger
Net Stroke (in.)
Pressure

2015Continue
Card Shape Genesis

Downhole Card Examples



Card Exercise
Identify the potential source behind the below card
shapes:
PumpGas
Off
Possible
/Very
GasRotaflex
Pumped
Compression
Leak
Worn
Interference
Excessive /towards
Tag Excessive
Traveling
off
Load / Low
at BOS
Friction / Standing
TOS,
Cell Pump
Valve
Friction
NOT
SlightNormal
Fillage
Valve
Zeroed
PumpOff Card
Leak

Rod Pump Controller Basics
Principle form of automation for SRP
system
Gathers load and position points to
generate a dynamometer for detection of:
– Fluid pound
– Parted rods
– Pump wear
– High fluid level
– Excessive downhole friction
Takes appropriate action to start, stop, or
change speed (VSD) of the well
Key Features
Dyna- • Surface and downhole cards available every stroke

Cards in real time using MEJ calculations.
• Enhanced pump fill calculations
• 120 days production

History • 256 Events, including up to 5 surface
and downhole cards for each event
• 2 Digital in / 2 • 1 Pulse Input

Digital Out • RTD Input
Inputs • 2 Analog In • 2 Modbus
• 1 Analog Out Scan Ports
• SD Card for easy Upgrade

• Native Tank Level and FCU protocols
• Backlit and heated display
Additional
• Quick Guided Setup for easy startup
• Expandable I/O adds 6DI/6DO/6AI
• Touchscreen HMI option (Shown)

Controls from Surface or Downhole card for accurate control
Enhanced I/O Logic for control and data monitoring
Performance History – recaps last 12 days of stroke count, SPM, Avg. fillage, and if
equipped kwh usage and Regen
MEJ Calculation for accurate downhole data under multiple conditions on every
stroke
Manual Valve check ability with storage and remote data retrieval using SCADA
Intuitive user interface, “Quick Guided Setup” for easy startup and configuration
RS232/485 Serial and Ethernet w/out additional hardware needed
Modbus polling of remote devices w/out additional hardware
Multiple Host capability


RPC Sensor Technology
Polished Rod Load Cell WFT Inclinometer Wireless Load Cell Option
Installs on carrier bar to measure total Operating range of 10-30Vdc Optimal option for Rotaflex applications
rod string load where traditional cable installation is
not ideal due to the design and long
Based on wheatstone bridge technology Accurate up to (±0.05°) stroke of the pumping unit
providing rugged reliability and inclination
repeatability The Node transmits the load signal to
the Gateway which is wired into the
Capable of withstanding 200% shock Easy to install, magnetically RPOC as a direct wire replacement
loading
mounts to beam, utilizes Works with Intelligent Rod Rotator
Available in 30k,50k, and 80k ratings quick-connect cables
Approx. 1yr battery life
Fully Welded Stainless Steel
Construction Top of stroke not affected by
sensor placement

Polished Rod Load Cell
Installs between carrier bar and
polished rod clamp to measure total
rod string load at surface
Working Wheat Stone bridge sensor
provides output signal relative to
measured load and input excitation.
Capable of withstanding 200% shock
loading
Available in 30k,50k, and 80k ratings
Fully Welded Stainless Steel
Construction
Polished Rod Load Cell Installation

Continuous Position Inclinometer
Inclinometer based position measurement
Operating range of 10-30Vdc
Accurate up to (±0.05°) inclination
Easy to install, magnetically mounts to beam, utilizes quick-connect cables
Top of stroke not affected by sensor placement

Position Switch Sensor

Continuous Position Sensor
Dual Position
Sensor
Load & Position

Cables from
Controller
DPS (dual position Sensor)
Polished Rod
Load Cell
Sensor Cables
to Controller

Potentiometer

Auxiliary Boards
I/O Expansion Board
Provides the WellPilot with
• 6 Additional AI
• 6 Additional DI
• 6 Additional DO
and plugs directly on the main
board with no additional wiring
needed.
Lightning Protection Board

Designed to help protect the
CPU board from unwanted
voltage and current spikes that
may enter via the external
sensors that are attached.

Quick Guided Setup
Walks users through

necessary settings for
well
startup/commissioning
Allows quick access to
frequently used
settings
Easily accessible from
front Menu screen
<10 Screens to fully
program controller

Local RPC Interface

Local RPC Interface

Dynamometer Display

Fixed Speed Control
Fixed Speed – Pump Off Control
Pump fillage below set point, well goes idle Pump fillage above set point, well continues
running
Cycle Runtime History

Daily Runtime History

Alarm History
USE Up/Dn PgUp/PgDn OR ### TO SELECT

PRESS EXIT TO QUIT

Auxiliary IO and Dataloggers
- AUXILIARY I/O STATUS —
This image cannot currently be display ed.
ANALOG CHANNEL DIGITAL CHANNEL

AI 1 0.0 DIO 1(OUTPUT) OFF
AI 2 1.32 DIO 2(INPUT) OPEN
AI 3 0.0 DIO 3(INPUT) OPEN
AI 4 0.0 DIO 4(INPUT) CLOSED
Page 1/3 - DAILY LOGGER DATA —
AI 8 0.0 08/19/02@11:00:00
DIO 8(OUTPUT) OFF AM 120
08/18/02@11:00:00 AM 136
PRESS EXIT TO 08/17/02@11:00:00
QUIT AM 114
08/16/02@11:00:00 AM 68
08/15/02@11:00:00 AM 86
08/14/02@11:00:00 AM 99
08/13/02@11:00:00 AM 114
08/12/02@11:00:00 AM 136
08/11/02@11:00:00 AM 120
08/10/02@11:00:00 AM 114
Freeze channel: >1

Advanced Rod Pump Controller
Applications
Variable Speed Control
Advanced Well Testing Application
Integrated Fluid Level Measurement
Chemical Pump Management System
Local Sucker Rod & Gearbox Torque Calculation

Uses a Variable Frequency Drive to adjust the speed of a
SRP system to match displacement to well inflow
Limits stress on pumping unit, motor, rod string, and
downhole pump
Reduces power consumption
– Eliminates unnecessary well cycling
– Increases PF of electrical system
Reliable, efficient method of phase conversion
Dual-compartment cabinet provides electrical isolation of
high-voltage components
Isolated Low
Voltage Field
Compartment Standard VSD High-Voltage Regen VSD High-Voltage
Compartment Compartment

A complete package that builds on features and standard functionality of the RPOC.
Uses proven Yaskawa inverter rated at 28 years MTBF.
Nema 3R Enclosure
Optimizes the SPM based on the downhole pump fillage.
Safety oriented dual cabinet design. Wherein the dual cabinet has isolated low and high
voltage sections
Ideal for wells with variable inflow due to injection pressures or long lateral completions
Runs the well continuously to prevent problems with sand/solids accumulation and flowline
freezing
Is inherently a soft-starter, and can convert single-phase power to three-phase power.
Optimizes Rotaflex operation by decreasing speed during reversals (TOS & BOS) and increasing
during straight portions of the stroke
Can adjust SPM instantaneously based on load cell feedback in case of downhole issues such
as rods/pump sticking on upstroke or rods floating on the downstroke

WellPilot Regen VSD
LOW
High reliability HARMONIC
S
High efficiency POWER

FACTO
R
Low Harmonics
GREATER
EFFICIEN
CY
High Power Factor
POWER
Smaller Footprint REGENERATI
ON
Flexible programming COMPAC

T

WellPilot Regen VSD
VSD Pkg
Standard WFT
Differing from conventional drives, the Matrix Drive has no
DC link circuit with diode and main capacitor, thus resulting
higher efficiency
The Matrix Drive creates precise control of voltage and
frequency from 3ph AC power by connecting 9 bi-
directional switches like a matrix
Typical harmonics associated with charging and discharging
VSD
WFT U100 Regen
of DC link capacitors is not present with the Matrix drive.
The Matrix Drive can return power during regeneration
which can be re-used by loads connected to the same
power source
Harmonic countermeasure components; such as input AC
reactors, harmonic filter reactors, and capacitors, are not
necessary, which helps you save wiring, space, and energy
costs.
WellPilot Regen VSD
Isolated LV Safety Oriented Enclosure
Integrated WellPilot RPC
< 5% THD (IEEE.519)
Lack of braking system means less overall components
meaning less cost and complexity

WellPilot Variable Speed Packages
WellPilot VSD Package WellPilot Harmonic Filter VSD WellPilot Regen VSD
Isolated LV Safety Enclosure Isolated LV Safety Enclosure Isolated LV Safety Enclosure

Integrated WellPilot RPC Integrated WellPilot RPC Integrated WellPilot RPC
~ 40% THD ~ 6-12% THD < 5% THD (IEEE.519)
Dynamic Braking Unit used Dynamic Braking Unit used Motor generated power
to dissipate motor to dissipate motor passes back onto grid to
generated energy (waste) generated energy (waste) lessen overall loading
Requires either internally Lack of braking system
mounted OR externally means less overall
added individually enclosed components meaning less
harmonic filter to achieve cost and complexity
lower THD levels (additional
cost, labor, parts)

VSD Control Basics
POSITION
LOAD
If Min Fillage
set, once Fill < Setpoint Fill > Setpoint
violated takes Slows down in Speeds up in
appropriate steps to Min SPM steps to Max SPM
action
(Default= Idle)
VSD Tolerance (Deadband) No speed
change while fillage is between tolerances.

VSD Pump Fill Control - Speed Control
Pump Speed is based on the pump fill calculation and the pump fill setpoint
– There is a deadband on control to minimize speed changes around the setpoint
Operator sets the following

– Minimum Speed Minimum operating speed of the pumping unit
– Maximum Speed Maximum operating speed of the pumping unit
– Startup speed Speed that the pumping unit will start at
– Initial speed change Speed change when the pump fill goes outside of the deadband
– Minimum speed change Secondary speed changes after initial change
Minimum Pump fill

– If the pump fill continues to drop when operating at Minimum speed, there is a Minimum pump fill set point that has configurable actions
Go to Idle time , Off to reset, NO Action, Alarm
Skip control
– In wells that have erratic behavior, control can be extended over several strokes to minimize large speed changes
Intolerance time
– If the pump fill stays within the tolerance for a given time period, it will initiate a speed change to challenge the fill
STA
– Multiple speeds within the same stroke
Different up/downstroke speeds
Configurable for several different speeds in the same stroke
Rod Load Control

– Automatically adjusts pumping speed to maintain or limit rod load
Enhanced Speed Control Options
Speed Trim Adjust (STA) Rod Load Control (RLC)

• Set Different Speeds • Slows pumping system based
throughout stroke on rod load changes
• Slow rod velocity during • Limits stresses on system
TOS and BOS transition from:
• Slow downstroke for • Rod Float
heavy oil or Mark II • Wells with excessive
pumping units friction and/or high
• Maximize production in deviations
Rotaflex applications • Sticking pump
Rod Load Control

Advanced Well Testing
Daily gross fluid production calculated from downhole
pump fillage
Integration of water cut measurement for daily net oil
production
AGA3/AGA8 gas flow calculations

Stroke by stroke integration of

downhole pump fillage yields
accurate representation of
daily gross fluid production.

Integration of infrared technology enables accurate water cut measurement
at the wellhead
Does not require flow meter since RPC calculates gross fluid for each stroke
Improves visibility of well production by giving daily net oil production
values
Lowers capital costs by eliminating the need for costly, high maintenance
testing facilities
Water Cut
Meter © 2015 Weatherford. All rights reserved.
AGA3/AGA8 gas flow calculations integrated into rod
pump controller
Allows one device to control well and measure gross
fluid, net oil, and gas flow on a per well basis

Fluid Level Measurement
Integrates processing of fluid level gun signal into rod pump controller
Can make automatic and on-demand fluid level shots
Able to perform automated build-up analysis (optimizes idle time setting)

Chemical Management System
Control chemical injection pump
– Production rate
– Running state
Track chemical usage per day and run cycle
Monitor chemical tank levels
Alert operator when refills are required

Local Stress Calculations
Calculate rod stresses at multiple points per taper on every stroke
Configure calculation to analyze more points in high stress areas
– High failure rate tapers
– Areas near deviated well sections
Calculate gearbox torque on every stroke

Configure alarms and shut down limits for maximum allowable rod and gearbox stresses

Intelligent Rod Rotator
WFT Complete Intelligent Rotator
Internal rotation sensor
Built in anti-rotation mount
Common Sizes
– 20K (164)
– 40K (302)
WellPilot application in development
Upgrade Kit - Existing Rotators

Rotation sensor
Sensing magnet and strap
Mounting kit
Load Cell/Rotator cables
Questions???

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State of The Art RPC REV01 PDF

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What are some of the challenges in rod lift wells?

What are some of the challenges in rod lift wells?

What is the difference between automation and optimization?

What is the difference between automation and optimization?

State of the Art Rod Pump Controllers and

n. The procedure or procedures used to make a system or design as effective

© 2015 Weatherford. All rights reserved.

© 2015 Weatherford. All rights reserved.

© 2015 Weatherford. All rights reserved.

© 2015 Weatherford. All rights reserved.

© 2015 Weatherford. All rights reserved.

© 2015 Weatherford. All rights reserved.

stroke, and plots these points on a

© 2015 Weatherford. All rights reserved. 11

© 2015 Weatherford. All rights reserved.

The MEJ method is an algorithm for solving the wave equation

Net Pump Stroke (in.) Net Pump Stroke (in.)

0.2 © 2015 Weatherford. All rights reserved.

Casing Fluid Top of Stroke

Net Stroke (in.)

Pressure TV Closed (loads increase to maximum)

Pump moves up the hole

Net Stroke (in.)

Pressure TV Closed (load @ maximum)

F3-05 Click Anywhere to Continue

TV Closed Net Stroke (in.)

SV Closed – Tubing Supports Fluid Column (load)

F5-07 Click Anywhere ©to

Net Stroke (in.)

SV Closed – Tubing Supports Fluid Column (load)

F6-08 Click Anywhere to Continue

Net Stroke (in.)

O1-16 Click Anywhere to Continue

Net Stroke (in.)

Pressure Traveling Valve Closed (load increases to maximum)

Pump moves up the hole

Low Pressure Traveling Valve Closed Net Stroke (in.)

Low Pressure Net Stroke (in.)

Click Anywhere to Continue

Traveling Valve Closed Net Stroke (in.)

Net Stroke (in.)

Net Stroke (in.)

Net Stroke (in.)

G1-09 Click Anywhere to©Continue

Net Stroke (in.)

Net Stroke (in.)

G3-11 Click Anywhere to© 2015

Net Stroke (in.)

TV Closed Net Stroke (in.)

Net Stroke (in.)

Net Stroke (in.)

T1-23 Click Anywhere ©to

Net Stroke (in.)

Traveling Valve Closed Net Stroke (in.)

Traveling Valve Closed Net Stroke (in.)

T4-26 Click Anywhere to Continue

Traveling Valve Closed Net Stroke (in.)

Pressure Traveling Valve Open

T6-28 Click Anywhere to Continue