© 2011 extreme telematics corp. 1 alien 2 /alien 2 expert plunger lift controller overview

© 2011 Extreme Telematics Corp.1

ALiEn2/ALiEn2 ExpertPlunger Lift Controller Overview


Agenda

• Overview• Configurations• Controller Operation


Overview


Highlights• Reliable Operation in Canada

– -40 ºC to +70 ºC Operating Temperature– Rechargeable Battery provides 8+ months Standby

Power

• CSA Certified– Class 1, Div 1, Groups C & D

• Features– Modbus Communication Interface – Time/Velocity Based Optimization– Pressure Based Optimization


Highlights• Rugged Design

– Steel enclosure with locking door– Easy to remove electronics module

• Easy to use Menu Based Interface– Arrows and numbers– Hot Keys

• Easy to Install– Flexible connections– Lots of space– Universal Mounting Bracket


Model Comparison

ALiEn2 ALiEn2 Expert

Battery 6V, 4.5 Ah 6V, 7.2 Ah

Standby Time 5+ months 8+ months

Valves 1 – 2 1 – 3

Input Devices PAS, LP PAS, LP, CP/DP

Timer Optimization Additional Included

Communications RS-485 Modbus 2 x RS-485 Modbus


Mounting

• Universal Mounting Bracket– Wall– Vertical/Horizontal Stud– Vertical/Horizontal Pipe


Solenoids

• Gas Connections– Supply gas side stamped IN– Valve side stamped CYL– Vent routed to the back

• Solenoid Service– Unscrew vent– Pull body up– Allows access to piston/spring


External Electrical

• Solar– 2 wire connection– Polarity matters

• Grounding– Lug supports up to 4 AWG

• Plunger Arrival Sensor (PAS)• Line Pressure• Casing Pressure/Differential Pressure


Plunger Arrival Sensor (PAS)

• Supported Sensors– ETC PAS

• Low Power• Rugged• Teck Cabled• Adjustable Sensitivity

– Most other 2/3 Wire sensors

• May be disabled if one not present


Line Pressure (LP)

• 2 Wire (Murphy) Switch– Tripped switch prevents controller

from opening the well– Automatically forces well to close

• 3 Wire Transducer– Shows numerical value for Line

Pressure– Allows for custom trip/reset points– Specific low power model from ETC

must be used.


Casing Pressure (CP)• 2 Wire (Murphy) Switch

– Tripped switch prevents controller from opening the well until Casing Pressure is high enough

– Automatically forces well to close on low Casing Pressure

• 3 Wire Transducer– Shows numerical value for Casing Pressure– Allows for custom trip/reset points– Use with LP for Casing-Line Differential– Enhanced optimization modes utilize the behaviour of

CP– Specific low power model from ETC must be used.


Differential Pressure (DP)

• 2 Wire (Murphy) Switch– Automatically forces well to close on low Differential

Pressure

• 3 Wire Sensor– Shows numerical value for Differential Pressure– Allows for custom trip/reset points– Use with LP and orifice plate settings to calculate flow– When using flow, daily production totals are summed.– Low Power 1151 or 3051CD from Rosemount must

be used if powered from plunger lift controller.


Outputs

• Programmable– Default Device Operation– Mimic Valve Operation– Alarm Call Out

• Connections– Uses the PWR pin from LP or CP/DP– Can only be used when connections not in

use by primary devices


COM Ports• RS485 2 Wire Differential• COM1 acts as a Modbus Slave• COM2 used as a Modbus Master or Pass Thru• Integrate with existing SCADA• Use web based access

– Zedi– MRL– Bentek

• IS Barrier required• COM1 used to upgrade the controller


User Interface


Screen Layout

State/Menu– Left hand side screen shows the current controller

state.– Scroll up or down to access other screens/menus

• Cycle Information• Current Date/Time

• Status– Right hand side screen scrolls through valve status

and device status automatically.


Menu Navigation

• Navigation Keys– Arrows move in and out of menus, used to

scroll up and down.– Select confirms a value or enters a menu– Cancel undoes an edit or moves backward

• Numeric Keys– Enter in numerical settings directly


Shortcut Keys• Close

– Starts the close portion of the cycle– Navigates back to the status screen

• Open– Starts the open (rise) portion of the cycle– Navigates back to the status screen

• Settings– Brings up the settings menu– A list of all timers and basic set points


Shortcut Keys• History

– Rise Time Log shows the last 25 plunger arrival times

– Cycle Log shows a detailed log of the last 25 cycles

– Daily Log shows a summary of the last 14 days plus the current day.

• Install– Takes the user to the install menu.


Install Menu• One Level of Sub Menus

– Date/Time - Set current date/time– System – Serial number, Firmware Version, and

Errors– Security – Installer/Operator passwords – Well Setup – Well information and velocities– Inputs – Configure Inputs– Outputs – Configure Outputs– Alarms – Fast Trip, Non-Arrival– Optimize – Optimization Mode, Input Behaviour– Modbus – Communication Settings


Configurations


Configurations

• Sales Valve– Factory default

Cas ing

S al es Val ve

cont r ol l er

Tubing

S al es l ine

Lubr icat or

Ar r ival sensor

DI


Configurations

• No Arrival Sensor

Cas ing

S al es Val ve

cont r ol l er

Tubing

S al es l ine

Lubr icat or


Configurations

• Top Valve

Cas ing

Val ve B

S al es Val ve

cont r ol l er

Tubing

S al es l ine

Lubr icat or

Ar r ivalsensor

cat cher


Configurations

• Flow Tee

Cas ing

S al es Val ve

cont r ol l er

TubingS al es l ine

Lubr icat or

Ar r ivalsensor

cat cher

Val ve B


Configurations

• Tank Valve

Cas ing

Val ve B

S al es Val ve

cont r ol l er

TubingS al es l ine

Lubr icat or

Ar r ivalsensor

Tank

cat cher


Configurations• Optimization: Pressure Switches

Cas ing

S al es Val ve

cont r ol l er

TubingS al es l ine

Lubr icat or

Ar r ival sensor

F

Fl ow swit ch

P

Line Pr essur eS wit ch

P

Cas ing Pr essur e S wit ch

LP

CP/DPCP


Configurations

• Optimization: Casing/Line Differential Pressure

Cas ing

S al es Val ve

cont r ol l er

TubingS al es l ine

Lubr icat or

Ar r ival sensor

P

Line Pr essur eS ensor

PCas ing P r essur e S ensor

LP

CP


Configurations

• Optimization: Differential Pressure

Cas ing

S al es Val ve

cont r ol l er

Tubing

S al es l ine

Lubr icat or

Ar r ival sensor

FDiff Pr essur e

sensor

AI


Configurations• Optimization: Flow Rate

Cas ing

S al es Val ve

cont r ol l er

TubingS al es l ine

Lubr icat or

Ar r ival sensor

FDiff Pr essur e

S ensor

P

L ine Pr essur eS ensor

LP

DP


Controller Operation


The Complete Cycle

Rise

cl ose

Afterfl owAf t er fl ow

Del ay

Non-Ar r ivalCl ose

Ext endedAf t er fl ow

Nor malar r ival

S t opped

Non-Ar r ival

Powerup

Cycl eS t ar t


The Complete Cycle• Rise

– Monitor arrival sensor– Sales Valve open.– Declare fast-trip if plunger

arrives early (fast-trip time).– Declare non-arrival when rise

time expires.– Switch to Tank Valve B when tank delay time expires.– Will not be shown if the arrival sensor is disabled.

Rise

cl ose


Del ay

Non-Ar r ivalCl ose


Nor malar r ival

S t opped

Non-Ar r ival

Powerup

Cycl eS t ar t


The Complete Cycle

• Afterflow Delay– Only entered if:

• Valve B enabled, AND• Afterflow delay time > 0

– Delays switching of valves tothe afterflow configuration

– Allows time for fluid slug to exitthe well-head.

Rise

cl ose


Del ay

Non-Ar r ivalCl ose


Nor malar r ival

S t opped

Non-Ar r ival

Powerup

Cycl eS t ar t


The Complete Cycle

• Afterflow– Only entered if Afterflow

time > 0– Valves:

• Sales: open• Valve B: configurable

– Exits when:• Afterflow or Max Open Timers expire, or• Line pressure “trips”

Rise

cl ose


Del ay

Non-Ar r ivalCl ose


Nor malar r ival

S t opped

Non-Ar r ival

Powerup

Cycl eS t ar t


The Complete Cycle• Extended Afterflow

– Entered if there are “extendedflow” devices enabled or timeroptimization is enabled

– Same valve settings asafterflow.

– Exits when:• Pressure or flow rate conditions change, or• Max Open timer expires, or• Line pressure “trips”, or• Extended Afterflow Timer expires (Timer Optimization)

Rise

cl ose

Afterfl owAf t er fl owDel ay

Non-Ar r ivalCl ose


Nor malar r ival

S t opped

Non-Ar r ival

Powerup

Cycl eS t ar t


The Complete Cycle• Close

– Entered following flow states.– Allows time for plunger to fall.– All valves closed.

Auto-catcher released.– Exits when:

• Min Close timer expires, AND• Pressure conditions change

– Line pressure switch or sensor

– Casing Pressure switch or sensor

– Casing/line pressure differential

Rise

cl ose


Ext endedCl ose


Nor malar r ival

S t opped

Non-Ar r ival

Powerup

Cycl eS t ar t


The Complete Cycle• Non-Arrival Close

– Entered when a “non-arrival”is declared.

– Allows extra time for pressureto build in the well-bore.

– All valves closed.Auto-catcher released.

– Exits when:• Non-Arrival close timer expires, AND• Pressure conditions change.

Rise

cl ose


Non-Ar r ivalCl ose


Nor malar r ival

S t opped

Non-Ar r ival

Powerup

Cycl eS t ar t


The Complete Cycle

• Stopped– Entered when:

• A number of consecutivenon-arrivals have occurred.

• A number of consecutivefast-trips have occurred.

• Low battery.

– All Valves closed.

Rise

cl ose


Non-Ar r ivalCl ose


Nor malar r ival

S t opped

Non-Ar r ival

Powerup

Cycl eS t ar t


Timer/Velocity Optimization

• Optimization Modes include:– Afterflow Optimization– Close Optimization– Close Then Afterflow Optimization


Timer/Velocity Optimization

• Set times manually or set well depth and desired velocities.

• Each plunger arrival is evaluated compared to the Target Rise Time.

• Modifies the Close and/or Afterflow times to get the plunger to arrive at the specified target time/velocity.


Target Rise Miss

• Early/Late Arrival– Early window is Target

Rise Time– Late window is Rise

Time – Target Rise Time

– Plunger misses are represented as a percentage

TargetRise

Rise Time

EarlyArrival

LateArrival


Afterflow Optimization

• Extended Afterflow Optimization– Miss percentage multiplied by Scale Factor and

subtracted from Extended Afterflow Percentage.– Actual time calculated from Extended Afterflow

Percentage and Remaining Flow Time

Rise Afterflow Extended Afterflow

Max Open

Adjust Based OnPlunger Arrival


Close Optimization

• Extended Close Optimization– Miss percentage multiplied by Scale Factor and

added to Extended Close Percentage.– Actual time calculated from Extended Close

Percentage and Remaining Flow Time.

Rise Afterflow Extended Close

Max Close

Adjust Based OnPlunger Arrival

Close


Close Then Afterflow

• Close Time is optimized first.

• When we run out of close time to optimize (either min or max is reached), Afterflow Time is then optimized.


Pressure Optimization

• Casing Pressure

• Casing-Line Differential Pressure

• Differential Pressure

• Flow Rate


Casing Pressure Optimization• Close Optimization

– Stay in close until Casing Pressure is high enough– Stay in close until Casing Line Differential is High Enough

• Extended Afterflow Optimization– Exit Extended Afterflow when Casing pressure has bottomed out

and then risen a predetermined amount.– Exit Extended Afterflow when the Rate of Change of Casing

Pressure slows Down and the Trip Delay timer expires.– Exit Extended Afterflow when Casing pressure drops below

specified set point.


Casing/Line Pressure Optimization

• Uses Casing – Line Differential Pressure

Line Pr essur e

Cas ing Pr essur e

Rise Cl ose

Af t er fl owTr ip Point

Cl oseTr ip Point

Monit or Act iveMonit orAct ive

Min-Cl oseTime


Af t er fl ow


Differential Pressure Optimization

• Extended Flow Optimization– Low Differential Pressure


Differential Pressure Optimization

Diff Pr essur e

RiseExt endedAf t er fl ow

Cl ose

Monit or Act ive Min-Cl ose Time

DP t r ippoint

0

Af t er fl ow


Flow Rate Optimization

• Sensors– Differential Pressure and Line Pressure– Analog Flow Sensor– Discrete Flow Sensor– Virtual Flow Sensor

• Automatically sums daily production values.


Flow Rate Calculations• Fixed parameters

– Optimize Menu • Gas temperature• Specific gravity• Meter run size • Orifice size• Max Differential Pressure (150 “WC by Default)

– Changes not applied until start of next cycle.

• Simplified gas flow calculations– AGA 3 Table Based (Not EUB compliant)– Process inaccuracies


Flow rate optimization cycle

L ine Pr essur e

Fl ow r at e

RiseExt endedAf t er fl ow

Cl ose

Monit or Act ive Min-Cl ose Time

Check l inepr essur e

Fl ow r at et r ip point

May get var iat ions as s l ugsof fl uid ar e del iver ed

0

Af t er fl ow

© 2011 extreme telematics corp. 1 alien 2 /alien 2 expert plunger lift controller overview

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