Data Sheet Wellhead Control Overview 2101129-AC X . - ABB

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Data Sheet2101129-ACINTRODUCTIONThis datasheet overviews various wellhead controlapplications and technologies supported by ABBTotalflow XSeries products that are regularly usedevery day.Many of these applications can be used individuallyor together, to provide many forms of wellheadautomation. With these applications, you are able toimplement such things as: Timer based and process based intermitting Production control with overrides Adaptive plunger lift control Nominations control Emergency shutdown control Reservoir / well test control Injection well control Simple math/logic with User Operators Complex math/logic using IEC61131Many of ABB Totalflow’s wellhead control schemesare implemented in two standard applications: Valve Control Plunger LiftAfter many years and thousands of wells, theseapplications have proven to provide a robust andmature base from which solutions can beimplemented, often without change.ABB Totalflow continues to adapt these applicationsand, if needed, can also adapt them to meet yourrequirements.Other types of custom math and control logic can beaccommodated using: User Operators IEC61131 Control LanguageVALVE CONTROLThis application fundamentally provides automaticfeedback control of Differential Pressure (DP), StaticPressure (SP), or Flow Rate for the purpose ofpositioning a control valve to maintain a desiredvalue.Wellhead Control OverviewXSeries ProductsApplicationAdditionally, other parameters (such as differentialpressure and static pressure) can be monitored foroverride conditions. If override conditions are metthe controller will maintain the override value until theoverride condition clears, after which the controllerwill revert to the primary control scheme. Thisfeature can be used, for example, to control a well’sproduction rate, as well as to help maintain pressureentering the gathering system. It can alsoautomatically shut-in a well when a compressor goesdown and then bring the well back on when thecompressor starts back up.Through configuration options it is also possible tointermit a well based either on simple timers or basedon more dynamic measurements of differential andstatic pressure.It is also possible to halt the control algorithm andmanually step the valve in either direction. The valvecan be moved in small increments or can beinstructed to ramp the valve to it’s full open or fullclosed position.CONTROLLER ALGORITHMThe control algorithm is best described as a ‘SingleSpeed Floating Algorithm’. This algorithm providesintegral action based on: The process variable’s difference from set point(error). The process variable’s range of control (span). The total possible valve travel time or (gain). The controller output is computed and appliedanytime the (error) term is outside a user defineddead band.CONTROLLER OUTPUTDigital Valve ActuatorA digital actuator, such as a stepper motor or an E/Pactuator is interfaced to the XSeries Valve Controllerusing two digital outputs and two digital inputs. Theoutputs are used to control the polarity and durationof the control signal. The inputs are used to detectvalve stops.

2101129-ACWellhead Control OverviewIn this scheme, the computed outputs from theController are (1) duration and (2) direction. Voltageis applied to the valve actuator for the computedduration in either the open or close direction. Thisoutput results in valve movement. The outputvoltage duration and direction, and the resulting valvemovement are such that the Process Variable ismaintained at a pre-determined user defined value(Set point).CONTROLLER OUTPUTAnalog Valve ActuatorAn analog actuator, such as an I/P actuator isinterfaced to the XSeries Valve Controller using a4-20 ma analog output. In this case, the analogoutput is used to control the percent open or closeposition of the valve.SUMMARY OF FEATURESNOMINATION APPLICATIONThe nomination application is used to deliver aspecified amount of volume over a specified period oftime. For example, if a delivery point is contracted todeliver an exact volume of gas over a month’s periodof time, then nominations is used to ensure thesetargets are met.The nomination application is implemented in theXSeries device. Once properly configured theapplication operates unattended, making sure yourrequirements are being met.The nomination application is implemented as asupervisory application, atop the valve controlapplication. As such, the nomination applicationcontinuously feeds new flow rate set points to thevalve control application in order to meet thenominated volume over the specified period of time. Single Speed Floating Algorithm providingintegral action feedback control of flow rate,differential or static pressure.All the while, the valve control application is honoringoverrides making sure to maintain the processvariable at set point. Even if valve control needs toshut in a well, due to a down compressor, the systemwill attempt to make up the nominated volumeautomatically, when the compressor comes back online. Continuous monitoring of override conditions forsecondary control needs.As shown here, there are three standard nominationperiods. Manual control of valve. Use of either two digital outputs or an analogoutput to interface to control valve actuator.Previous Period: Settings and results of the mostrecently completed nomination period. Appropriate valves and communication optionscan be powered from the same battery packsused for the XSeries device.Current Period: Settings and status of thecurrently active nomination period. Next Period: Settings for the upcomingnomination period. Control of wellhead pressure using downstreamstatic pressure by estimating pressure drop usingWeymouth equation. Intermitting logic based on either timers ordynamic inputs, such as differential pressure andstatic pressure. All control features can be accessed either locallywith PCCU32 or remotely with WinCCU, ABB’sSCADAvantage or TDS32 (non-ABB SCADAsystems).Valve Control is an option on all XSeriesproducts by simply adding the appropriate TFIOmodule or I/O daughter card.The following are features provided with ABBTotalflow’s standard Valve Control Application: 2All control features can be accessed either locallywith PCCU32 or remotely with WinCCU, ABB’sSCADAvantage or TDS32 (other SCADA systems).

2101129-ACWellhead Control OverviewPLUNGER LIFT APPLICATIONPLUNGER OPTIONSPlunger lift is often used on wells exhibitingproduction drop-off from fluid build-up and has beenshown to increase gas production and extend welllife. In one sense, plunger lift logic is merely anotherform of intermitter logic. However, superior plungerlogic has several common traitsThe fundamental goal of plunger lift logic is todetermine the optimum conditions for continuing toflow the well or continuing to shut-in the well bydeciding when to transition from flowing to shut-inand vice versa. Monitors dynamic parameters (pressures,differential pressures, flow rates and plungerarrival time) in order to predict the optimumconditions for continuing to flow or continuing toshut-in the well.Supports adaptive algorithms to dynamically tunethe control system to each unique well, withminimal oversight and unattended operation.Maintains data logger for engineering andoperations analysis.Can be configured and tuned either on-site usinglocal user interfaces or off-site, using remotecommunications.Is implemented in a software environment thatcan be readily adapted to new control algorithmsas state-of-the art evolves.Plunger applications, as implemented in ABBTotalflow’s XSeries products, have proven toexemplify all of these features. When integrated intoABB’s various host and SCADA systems, the user isprovided a complete, turnkey solution empoweringthe user to monitor, control and optimize the wholereservoir.As depicted here, several options are available fordeciding when to make these state transitions. Someof these options, and their associated step changecriteria, can be automatically adapted by the plungerapplication in order to achieve the theoreticaloptimum arrival time of the plunger.Open Conditions (with optional tuning) Timer expires1 (Tubing-Line) Limit (Tubing-Casing) LimitClose Conditions (with optional tuning) Timer expires1 Low DP timer expires Low flow rate timer expires (Tubing-Line) Limit (Tubing-Casing) Limit (Casing Limit)The plunger application also supports many detailsbeyond the scope of this overview; among which isthe support for a blow valve feature that also hasselectable options. Please contact Totalflow for amore detailed description of the plunger applications.The plunger application software is implemented inthe IEC61131 control language. This softwareenvironment allows for rapid and accuratemodification of the control algorithm, if the needshould arise.Plunger logic is an option on all XSeries products bysimply adding the appropriate TFIO module or I/Odaughter card and downloading the appropriateplunger application.1Timers are implemented as fixed duration switchesbetween open and close conditions, acting as overrideoperations, and are not included in any tuning logic.3

Wellhead Control Overview2101129-ACPLUNGER and VALVE CONTROLpressure or static pressure when the well is flowing.The flow line control valve can be a simpleopen/close valve or it can be a modulating controlvalve.When used in this way, the standard Valve Controland Nominations features are also made available.Taken together with the Plunger Application this canprovide a rich set of wellhead control schemes; allwith simple, straightforward options to any XSeriesdevice.When using a simple open/close valve a standardTFIO DIDO module is used for interfacing to thevalve.PLUNGER USER INTERFACE OPTIONSPCCU32 Tabular User Interface ScreenWhen using a modulating control valve a standardTFIO VCIO module is used for interfacing to thecontrol valve. In this case, both the PlungerApplication and the Valve Control application areintegrated so that the Valve Control applicationReport from Plunger Application Plug-InProperly configured, ABB Totalflow’s standardPCCU32 and WinCCU products support tabular userinterfaces to the plunger application, as depictedhere.An optional WinCCU plug-in is available that providesa more graphical user interface, as depicted here.This application can be used remotely viacommunications or locally at the site.In addition to these options, ABB’s SCADAvantage, astate-of-the-art, multi-protocol SCADA system canalso be interfaced to these and other XSeriesapplications. Plunger Lift Plug-In also supportsreporting as depicted here.GUI from Plunger Application Plug-Inprovides automatic control of flow rate, differential4Additionally, using Totalflow’s DDE/OPC driver(TDS32) or Totalflow’s Communications Library,other SCADA systems can be interfaced to these andother XSeries applications.

Wellhead Control OverviewPower and Productivityfor a Better World. ABB Inc.Totalflow Products7051 Industrial Blvd.Bartlesville, OK 74006Tel: (918) 338-4888Fax: (918) 338-4699(800) ww.abb.comABB Inc.Totalflow Products433 Northpark Central Dr., Ste. 100Houston, TX 77073Tel: (281) 869-5212Fax: (281) 869-5203(800) 442-3097For more information,please contact yourlocal ABB Totalflowrepresentative or visitour website.

state-of-the-art, multi-protocol SCADA system can also be interfaced to these and other XSeries applications. Plunger Lift Plug-In also supports reporting as depicted here. Additionally, using Totalflow’s DDE/OPC driver (TDS32) or Totalflow’s Communications Library, other SCADA systems can be interfaced to these and other XSeries applications.

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