abb totalflow plunger user guide

TOTALFLOW®

Plunger Lift ControlUser’s Guide

ApplicationPart Number 2102890-001

User's Guide Plunger Lift Control 1 of 972102890-001 January 15, 2007

Table of Contents

Totalflow Hardware Requirements:........................................................................................ 3I/O Requirements.......................................................................................................................... 3

Program Description................................................................................................................ 4Overview.......................................................................................................................................4Plunger Lift Control...................................................................................................................... 4

General scheme...............................................................................................................4Overview.........................................................................................................................6

Conditions to open the Production valve.............................................. 6Conditions to close the Production valve............................................. 6Conditions to open the Blow valve for helping plunger arrival..............7Other options....................................................................................... 7Blow valve cushion timer..................................................................... 7Integrating with Valve Control.............................................................. 8Turner Flow Rate Calculation............................................................... 8Tuning.................................................................................................. 8

Operation........................................................................................................................ 9State 0: Fail.......................................................................................... 9State 1: Closing Valve.......................................................................... 9State 2: Valve Closed.......................................................................... 9State 3: Plunger Arriving...................................................................... 10State 4: Blow Valve.............................................................................. 10State 5: Plunger Arrived....................................................................... 11State 6: Afterflow.................................................................................. 11

PCCU Screens.......................................................................................................................... 12Plunger.......................................................................................................................................... 12Plunger-Setup................................................................................................................................14Plunger - States............................................................................................................................. 20

State 1 Closing Valve..................................................................................................... 23State 2 Valve Closed.......................................................................................................25State 3 Plunger Arriving................................................................................................. 48 State 4 Blow Valve........................................................................................................ 53State 5 Plunger Arrived.................................................................................................. 60State 6 Afterflow.............................................................................................................62State 0 FAIL................................................................................................................... 81

Plunger - Statistics........................................................................................................................ 82Misc................................................................................................................................ 82Closed............................................................................................................................. 84Plunger ...........................................................................................................................87Flow................................................................................................................................ 90Blow ...............................................................................................................................92Slug ................................................................................................................................ 93

Register List............................................................................................................................. 95

Initial Set-Up.............................................................................................................................. 95Flow Computer............................................................................................................................. 95Plunger Lift Control...................................................................................................................... 95

Change Log:.............................................................................................................................. 96

Recommended Module Wiring - Direct I/O Option................................................................. 97


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 RequirementsInput/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).

DI’s 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)


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.

Plunger Lift ControlThis 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.


OverviewThe 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 valveIf 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. (opt) Timer > Limit2. (opt) (Tubing pressure – Line Pressure ) > Limit3. (opt) ( Casing Pressure – Tubing Pressure) > Limit4. (opt) (Casing Pressure – Line Pressure ) > Limit5. (opt) ((Casing Pressure – Line Pressure ) > Limit) AND ((Tubing pressure – Line Pressure ) > Limit)6. (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 Trip7. (opt) (Tubing pressure > Limit) OR (Tubing pressure < Limit) for user defined amount of time8. (opt) (Casing pressure > Limit) OR (Casing pressure < Limit) for user defined amount of time9. (opt) (Static pressure > Limit) OR (Static pressure < Limit) for user defined amount of time10. (opt) Slug Size > Limit11. (opt) (Input 1 > Limit) OR (Input 1 < Limit) for user defined consecutive minutes12. (opt) (Input 2 > Limit) OR (Input 2 < Limit) for user defined consecutive minutes13. (opt) Mandatory close timer > Mandatory close time. This is only used after a plunger non-arrival.14. (opt) Total Cycle time from valve open to valve open.15. (opt) Hold in closed state if status indicates16. (opt) Hold in closed state if pressure >= limit17. (opt) Hold in closed state during certain hours of the day.18. (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 valveIf 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.

1. (opt) Timer > Limit2. (opt) DP < Limit for user defined amount of time3. (opt) Flow Rate < Limit for user defined amount of time4. (opt) (Tubing Pressure – Line Pressure) < Limit5. (opt) ( Casing Pressure – Tubing Pressure) < Limit6. (opt) Casing Pressure < Limit7. (opt) (Flow Rate < (Turner flow * Turner Multiplier) AND ( ABS(Line pressure – casing pressure) < User specified

value) for user defined amount of time8. (opt) Load Ratio < Limit for a user specified time9. (opt) (Tubing pressure > Limit) OR (Tubing pressure < Limit) for user defined amount of time10. (opt) (Casing pressure > Limit) OR (Casing pressure < Limit) for user defined amount of time11. (opt) (Static pressure > Limit) OR (Static pressure < Limit) for user defined amount of time12. (opt) Slug Size > Limit13. (opt) (Input 1 > Limit) OR (Input 1 > Limit) for user defined amount of time


14. (opt) (Input 2 > Limit) OR (Input 2 > Limit) for user defined amount of time15. (opt) Using the Close Push Button.

Conditions to open the Blow valve for helping plunger arrivalIf 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. (opt) Casing Pressure < Setpoint2. (opt) Flow Rate < Setpoint for user defined amount of time3. (opt) DP < Setpoint4. (opt) Timer > Setpoint

Other options1. 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 timerWhen 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.


Integrating with Valve ControlWhen 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 CalculationThe 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 PressureP = 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)) ¼

(0.0031 * P)½ The volumetric flow rate in MMCF/Day is obtained as follows

TR1 = 3.067 * P * Vg * AREATEMP R0 * Z

Finally the volumetric rate is adjusted by the turner multiplier to obtain the shut-in flow rate.

TR=TR1 * TRMTuningThe 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


OperationThe 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.


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


• 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.


PCCU ScreensThis 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 Values CommentsTask Name The task name may be entered here if desired.Controller State List of values 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

Plunger Status Normal = 0Drop = 1Fast = 2Slow = 3Late = 4Hung = 5

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.

The Control tab continued:

Description Values CommentsCycle Status Running = 0

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

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.

Plunger Control Disable, Manual, Enabled

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.

Reset Controller normal, Reset 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.

Reset Date/Time Date and Time This the date and time when the last Reset Controller command was issued.

Reset Plunger Counters No, Yes Clear the counters used to track the count of arrivals and arrival types.

Manual Main Valve Close auto, Force Close Plunger Control must be in manual, then Force Close may be used to manually close the main valve.

Manual Main Valve Open auto, Force Open Plunger Control must be in manual, then Force Open may be used to manually open the main valve.

Main Valve State Closed, Open 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.

Manual Blow Valve Close auto, Force Close Plunger control must be in manual, then Force Close may be used to manually close the blow valve

Manual Blow Valve Open auto, Force Open Plunger control must be in manual, then Force Open may be used to manually open the blow valve.

Blow Valve State Closed, Open Last command sent to the blow valveCapture Valve State Release, Capture Last command sent to Capture valveManual Capture Valve=Catch auto,

Force CapturePlunger control must be in manual, then Force Capture may be used to manually close the capture valve

Manual Capture Valve=Release auto,Force Release

Plunger control must be in manual, then Force Release may be used to manually open the capture valve


Plunger-Setup

The following table lists the user entries that are available on this screen.


The General Setup tab contains the following values:

Description Values CommentsPlunger Control Disable, Manual,

EnabledDisable 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.

Startup Mode 1 Closing Valve, 6- Afterflow,Previous state

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.

Optimization Disabled, Enabled 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.

Plunger Fail Factor Tune Any floating point value

If the plunger fails to arrive before the Max Arrival Time, multiply any tuning by this value.

Tubing Length Any floating point value

The length of the tubing from the stop to the arrival sensor, used to calculate the lift velocity

Tubing ID Any floating point value

The INNER diameter of the well tubing used to calculate the Turner Flow Rate.

Reset VCBs No, Reset 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.

Reset Values No, Reset Setting this value to Reset sets all user entered values (other than register values) to pre-defined defaults.


The Valve Setup screen is as follows:

The following table lists the user entries that are available on this screen.


The Valve Setup tab contains the following values:

Description Values CommentsValve Position Downstream,

UpstreamThis 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.

Valve Time A value is seconds This is the amount of time to energize the open and close DOs to either open or close the main, blow and capture valves.

Main Valve Type Latch-One outputLatch-Two outputPulse-Two output

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.

Main Open DO Any register value This is the DO register address of the DO used to Open the Main Valve (only when Valve Control is not used).

Main Close DO Any register value This is the DO register address of the DO used to Close the Main Valve (only when Valve Control is not used).

Blow Valve Type Latch-One outputLatch-Two outputPulse-Two output

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.

Blow Open DO Any register value This is the DO register address of the DO used to Open the Blow Valve.

Blow Close DO Any register value This is the DO register address of the DO used to Close the Blow Valve.

Capture Valve Type Latch-One outputLatch-Two outputPulse-Two output

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.

Capture Release DO Any register value This is the DO register address of the DO used to release the plunger

Capture Catch DO Any register value This is the DO register address of the DO used to catch the plunger

Valve Controller Option Disabled, Enabled Selecting Enabled uses the Valve Control application to control the valve during Plunger Arriving and Afterflow.

Open Valve Method Ramp, AutoDP, AutoFR, AutoSP

Selects the operation of Valve Control during Plunger Arriving and Afterflow.

VCI Cmd1 Register` Any register value 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.

VC Features 1 Register Any register value 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.

VC Full Closed DI Any register value 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.

Packer Well NoYes

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.


The Input Setup screen is as follows:


The Input Setup tab contains the following values:

Description Values CommentsAP Register Any register value This is the register address of the value that will be used for

AP. Generally this value comes from an AGA3 measurement tube.

DP Register Any register value This is the register address of the value that will be used for DP. Generally this value comes from an AGA3 measurement tube.

Flow Rate Register Any register value This is the register address of the value that will be used for Flow Rate. Generally this value comes from an AGA3 measurement tube.

Volume Register Any register value 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.

Tf Register Any register value 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.

Z factor Any register value 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.

Baro Press Register Any register value 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.

Casing Pressure AI Any register value This is the register address of the value that will be used for casing pressure.

Ext Pressure AI Any register value 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.

Hold AI Register Any Register value This it the register address of the value used to hold the plunger logic in the closed state.

Input 1 Register Any register value 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.

Input 2 Register Any register value 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.

Detection type I/O, Intermit 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.

Plunger Arrival PI Any register value This is the register address of the Pulse Input used to detect Plunger Arrival.

Contract Hour Update Any register value This is the register address of the date and time when contract hour last occurred. Generally this value comes from an AGA3 measurement tube.

Restart Button Register Any register value This is the register address of the digital input connected to the Reset Plunger Controller button.

Close Button Any register value This is the register address of the digital input connected to the Close Main Valve push button.

Open Button Any register value This is the register address of the digital input connected to the Open Main Valve push button.


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.


The States tab contains the following values:

Description Values CommentsPlunger Control Disable, Manual,

EnabledDisable 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.

Controller State List of values 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

State Timer A value of hr:min:sec

This is a copy of the current state timer

Max State Timer A value of hr:min:sec

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.

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



The States tab continued:

Description Values CommentsMain Valve State Closed, Open 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.

Blow Valve State Closed, Open Last command sent to the blow valveCapture Valve State Last command sent to Capture valveCurrent Open Reason An enumerated list Current reason that the main valve opened.Closed Timer A value of

hr:min:secElapsed time since valve was commanded closed and fall delay expired.

Last Close Cycle A value of hr:min:sec

The amount of time of the last closed cycle

Current Close Reason An enumerated list The last reason that the main valve was closed.Flow Cycle Timer A value of

hr:min:secThe amount of time that the well has been flowing. This value is equal to the plunger arrival timer plus the after flow timer.

Last Flow Cycle A value of hr:min:sec

The amount of time of the last flow cycle

Total Cycles An integer value The total number of the times the logic has gone thru the Closing Valve state since the last reset plunger counters was used.


State 1 Closing Valve

This is the State 1 Closing Valve screen from PCCU.


The 1 – Closing Valve tab contains the following values:

Description Values CommentsController State List of values 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

Main Valve State Closed, Open 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.



Plunger Fall DelayLimit A value of hr:min:sec

Time to wait before declaring valve closed and beginning to check for valve open conditions.

Fall Timer A value of hr:min:sec

Elapsed time since valve close command was issued.

Option Valve Close Check Disabled, Enabled Enabled indicates that flow is used to verify valve close.Flow Rate In A floating point

valueCurrent flow rate

Valve Close Check Setpoint Any floating point value

Valve close is verified when the flow rate falls below this value.

Valve Close Time Limit A value of hr:min:sec

The amount of time the flow rate has to fall below the Valve Close Setpoint before a Valve Close failure is declared.

Valve Close Check Timer A value of hr:min:sec

Amount of time that flow rate has not fallen below the Valve Close Check Setpoint.

Valve Close Failure NoYes

Status of the Valve Close Check.


State 2 Valve Closed

This is the State 2 Valve Closed tab from PCCU.


The 2 – Valve Closed tab contains the following values:

Description Values CommentsController State See previous.Main Valve State Closed, Open See previous.Plunger Status Normal = 0

Drop = 1Fast = 2Slow = 3Late = 4Hung = 5

See previous.


See previous.

State Timer A value of hr:min:sec


Max State Timer A value of hr:min:sec


Closed Timer A value of hr:min:sec

Elapsed time since valve was commanded closed and fall delay expired.

Hold Reason None = 0TIMER = 1ONCE = 2RECOVERY = 3CNT = 4PRESSURE = 5HIGH = 6TOD = 7TOTAL = 8CATCH = 9

Indicates the reason that the logic is held in the closed state.


The 2 – Valve Closed tab continued:

Description Values CommentsCurrent Open Reason None = 0

TIMER = 1DP = 2FR = 3TUBE-LINE = 4CASE-LINE = 5CASE = 6SP = 9TUBE = 10AI1 = 11AI2 = 12,LOAD = 13NOW = 14CT_TL = 15LR_TIME = 16LINE = 17AFTER = 18,C_L = 19CL_TL = 20SLUG = 21

Last reason the valve was opened.

Option Closed Timer Disabled, Enabled Use timer to open valveOption Tube-Line Open Disabled, Enabled Use tubing pressure/line pressure difference to open valve.Option Case-Line Open Disabled, Enabled Use casing pressure/line pressure difference to open valve.Option “C-L” & T-L” Open Disabled, Enabled Use casing/line pressure difference AND tube/line difference to

open valve.Option Case-Tube Open Disabled, Enabled Use casing pressure/tube pressure difference to open valveOption “C-T & T-L” Open Disabled, Enabled Use casing pressure/tubing pressure difference AND tubing

pressure/line pressure difference to open valve.Option Load Ratio Disabled, Enabled Enables the use of the Load Ratio to open the valve.Description Values CommentsOption Tubing Pressure Open Disabled, Enabled Enables the use of Tubing pressure to determine when to

open the valve.Option Casing Pressure Open Disabled, Enabled Enables the use of Casing pressure to determine when to

open the valve.Option Static Pressure Open Disabled, Enabled Enables the use of Static Pressure to determine when to open

the valve.

Option Slug Size Open Disabled, Enabled Enables the use of Slug Size to determine when to open the valve.

Option Input 1 Open Disabled, Enabled Enables the use of Input 1 to determine when to open the valve.

Option Input 2 Open Disabled, Enabled Enables the use of Input 2 to determine when to open the valve.

Option Total Cycle Time Disabled, Enabled Enables the option of using an amount of time between valve open to valve open to operate the well

Hold Once Time Limit A value of hr:min:sec

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

Option Hold Ext Disabled, Enabled Enables the option of holding closed until Ext enablesOption Hold Pressure Disabled, Enabled Use Hold Input to hold in closed valve state


The 2 – Valve Closed tab continued:

Description Values CommentsOption High Line Close Disabled, Enabled Enables the checking of line pressure shortly after opening to

determine if the valve should be closed againOption Hold Time of Day Disabled, Enabled Enables the option operating the well during certain hours of

the day.Option Mandatory Recovery Time

Disabled, Enabled Enables the mandatory recovery time option. This option runs after a plunger non-arrival to allow the well pressure to recover.

Option Plunger Catch Mode Disabled, Enabled Enables the plunger catch mode option.

Plunger – State 2 Valve Closed - TimerThis is the State 2 Valve Closed Timer tab from PCCU.

The Timer tab contains the following values:

Description Values CommentsController State See previous.Main Valve State Closed, Open See previous.Plunger Status Normal = 0

Drop = 1Fast = 2Slow = 3Late = 4Hung = 5

See previous.


See previous.

Closed Timer A value of hr:min:sec

Elapsed time since valve was commanded closed and fall delay expired.


The Timer tab continued:

Description Values CommentsOption Closed Timer Disabled, Enabled Use timer to open valveClose Cycle Limit A value of

hr:min:secTime to keep valve closed before commanding valve open.

Plunger – State 2 Valve Closed – Tube-LineThis is the State 2 Valve Closed Tube-Line tab from PCCU.

The Tube-Line tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Tube-Line Open Option Disabled, Enabled Use tubing pressure/line pressure difference to open valve.Tube-Line Open Limit Any floating point

valueIf (tubing – line pressure) > this limit, then open valve

Tube-Line A floating point value

Difference of tubing and line pressure

Tube Line Open Tune Any floating point value

Amount to tune the open limit value.

Tube Line Open Min Any floating point value

Minimum value to tune the open limit value to.


The Tube-Line tab continued:

Description Values CommentsPlunger Fail Factor Tune Any floating point

valueIf plunger fails, multiply the next tuning by this value

Option CT T-L Open Disabled, Enabled Use casing pressure/tubing pressure difference AND tubing pressure/line pressure difference to open valve.

Plunger – State 2 Valve Closed – Case-LineThis is the State 2 Valve Closed Case-Line screen from PCCU.


The Case-Line tab contains the following values:Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Case-Line Open Disabled, Enabled Use difference between casing and line pressure to open main

valveCase Line Open Limit Any floating point

valueIf (casing – line) > this limit, then open valve

Case-Line A floating point value

Difference between casing and line pressure

Case-Line Open Tune Any floating point value

Amount to tune the open limit value.

Case-Line Open Min Tune Any floating point value

Minimum value to tune the open limit value to.


If plunger fails, multiply the next tuning by this value

Option C-L & T-L Open Disabled, Enabled Use casing/line AND tubing/line to open the main valve.

Plunger – State 2 Valve Closed – Case-TubeThis is the State 2 Valve Closed Case-Tube screen from PCCU.


The Case-Line tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Case-Tube Open Disabled, Enabled Use difference between casing and tubing pressure to open

main valveCase-Tube Action Lo Open

Hi OpenSelect how Case-Tube pressure will open main valve

Case-Tube Difference of casing and tubing pressureCase-Tube Open Limit Any floating point

valueCase-Tube Open Limit Tune Any floating point

valueAmount to tune

Case-Tube Open Limit Min Any floating point value

Minimum Case-Tube Limit can not be tuned below


If plunger fails, multiply the next tuning by this factor.


Plunger – State 2 Valve Closed – Load RatioThis is the State 2 Valve Closed Load Ratio screen from PCCU.


The Load Ratio tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Load Ratio option Disabled, Enabled Enables the use of the Load Ratio to open the valve.Packer Well No

YesUsed 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.

Load Ratio A floating point value

Current value of the Load Ratio. It is calculated by the following formula:Load Ratio = (Casing Pressure – Tubing Pressure) / (Casing Pressure – Static Pressure).

Load Ratio Setpoint Any floating point value

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.

Load Ratio Time A value of hr:min:sec

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.

Load Ratio Timer A value of hr:min:sec

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.

Last Load Ratio A floating point value

The value of the Load Ratio when the Load Ratio timer was last reset.

Load Ratio Trip Any floating point value

If the Load Ratio exceeds this value, open the valve regardless of the Load Ratio timer.

Load Ratio Close Tune Any floating point value

Tune the Load Ratio close setpoint by this amount.

Load Ratio Close Min Any floating point value

Minimum value to tune the Load Ratio close setpoint to.

Load Ratio Close Max Any floating point value

Maximum value to tune the Load Ratio close setpoint to.



Casing-Line Multiplier A floating point value

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.

Case-Line Mult Tune A floating point value

Tune Casing-Line Open Mult Limit by this amount

Case-Line Mult Min A floating point value

Do not tune Casing-Line Mult Limit below this value.

Case-Line Mult Max A floating point value

Do not tune Casing-Line Mult Limit above this value.


Plunger – State 2 Valve Closed – TubeThis is the State 2 Valve Closed Tube screen from PCCU.


The Tube tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Tubing Pressure option Disabled, Enabled Enables the use of Tubing pressure to determine when to

open the valve.Tubing Pressure In A floating point

valueCurrent value of the Tubing pressure

Tubing Action Lo Open, Hi Open 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.

Tubing Open Limit Any floating point value

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.

Tubing Open Time A value of hr:min:sec

The amount of time that the Tubing pressure must either go above or fall below the Tubing Open Limit before the valve opens.

Tubing Open Timer A value of hr:min:sec

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.

Tube Open Tune Any floating point value

Amount to tune Tube Open Limit

Tube Open Min Tune Any floating point value

Do not tune Tube Open Limit below this value




Plunger – State 2 Valve Closed – CaseThis is the State 2 Valve Closed Case screen from PCCU.


The Case tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Casing Pressure option Disabled, Enabled Enables the use of Casing pressure to determine when to

open the valve.Casing Pressure In A floating point

valueCurrent value of the Casing pressure

Casing Action Lo Open, Hi Open 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.

Casing Open Limit Any floating point value

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.

Casing Open Time A value of hr:min:sec

The amount of time that the Casing pressure must either go above or fall below the Casing Open Limit before the valve opens.

Casing Open Timer A value of hr:min:sec

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.

Case Open Tune Any floating point value

Amount to tune Case Open Limit

Case Open Min Tune Any floating point value

Do not tune Case Open Limit below this value




Plunger – State 2 Valve Closed – SPThis is the State 2 Valve Closed Sp screen from PCCU.


The SP tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Static Pressure option Disabled, Enabled Enables the use of static pressure to determine when to open

the valve.

SP In A floating point value

Static pressure calculated from AP.

Static Pressure Action Lo OpenHi Open

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.

SP Open Limit Any floating point value

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

SP Open Time A value of hr:min:sec

The amount of time that the Static pressure must either go above or fall below the Static Pressure Open Limit before the valve opens.

SP Open Timer A value of hr:min:sec

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.

SP Open Tune Any floating point value

Amount to tune SP Open Limit

SP Open Min Any floating point value

Do not tune SP Open Limit below this value




Plunger – State 2 Valve Closed – SlugThis is the State 2 Valve Closed Slug screen from PCCU.

The Slug tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option slug Size Open Disabled, Enabled Option – use slug size to open main valveSlug Size A floating point

valueSlug size is the difference between casing and tubing pressure divided by a fluid gradient.

Slug Size Open Limit A floating point value

Slug size must be above this value before the valve is opened.

Fluid Gradient A floating point value

Slug size constant (default is 0.433)


Plunger – State 2 Valve Closed – InputsThis is the State 2 Valve Closed Inputs screen from PCCU.


The Inputs tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Input 1 option Disabled, Enabled Enables the use of Input 1 to determine when to open the

valve.Input 1 In A floating point

valueCurrent value of Input 1

Input 1 Open Limit Any floating point value

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

Input 1 Open Time A value of hr:min:sec

The amount of time that Input 1 must either go above or fall below the Input 1 Open Limit before the valve opens.

Input 1 Open Timer A value of hr:min:sec

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.

Input 2 option Disabled, Enabled Enables the use of Input 2 to determine when to open the valve.

Input 2 In A floating point value

Current value of Input 2

Input 2 Open Limit Any floating point value

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

Input 2 Open Time A value of hr:min:sec

The amount of time that Input 2 must either go above or fall below the Input 2 Open Limit before the valve opens.

Input 2 Open Timer A value of hr:min:sec

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.


Plunger – State 2 Valve Closed – Hold TimersThis is the State 2 Valve Closed Hold Timers screen from PCCU.


The Hold Timers tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Hold Once Time Limit A value of

hr:min:secHold in Closed one time for this amount of time. Then open valve and proceed to Plunger Arriving State.

Option Total Cycle Time Disabled, Enabled Enables the use of a timer that runs from Valve Open to Valve Open

Total Cycle Timer A value of hr:min:sec

Current value of the Total Cycle Timer

Total Cycle Time Limit A value of hr:min:sec

Total Cycle Time Limit value

Mandatory Time Disabled, Enabled Enabled indicates that mandatory recovery time option is enabled. This option runs after a plunger non-arrival to allow the well pressure to recover.

Mandatory Close Time A value of hr:min:sec

Allow the valve to remain closed for this amount of time.

Hold External Option Disabled, Enabled Enabled indicates that this option is used to hold in closed state until an external application clears the hold.

Hold External Status Ok, HOLD If HOLD, stay in closed state until ok.


Plunger – State 2 Valve Closed – Hold PressureThis is the State 2 Valve Closed Hold Pressure screen from PCCU.

The Hold pressure tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Hold Pressure Disabled, Enabled Use Hold Valueto hold in closed valve stateHold Value A floating point

valueValue used to determine if logic should remain in the closed state. This is read from the Hold Pressure AI

Hold Limit Any floating point value

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.

Option High Line Close Disabled, Enabled Use line pressure to re-close valve during plunger arriving state

High Line Closed Time Limit A value of hr:min:sec

Amount of time to hold valve closed after valve has been opened but then closed due to high line pressure during plunger arriving state.


Plunger – State 2 Valve Closed – Time of DayThis is the State 2 Valve Closed Time of Day screen from PCCU.

The Time of Day tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Hold Time of Day Disabled, Enabled Enables option to disable well production during certain hours

of the day.Time of day A time value in

hr:min:secCurrent time of day

Hold Time of Day Start 1 A time value in hr:min:sec

The time of day at which hold will begin

Hold Time of Day End 1 A time value in hr:min:sec

The time of day at which hold will end










The Time of Day tab continued:Description Values CommentsHold Time of Day Start 4 A time value in

hr:min:secThe time of day at which hold will begin



Hold TOD Status 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.


The Timers tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Detection type I/O, Intermit 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.

Last Plunger Arrival A time value in hr:min:sec

Amount of time for the last plunger arrival

Arrival Timer A time value in hr:min:sec

Elapsed time since valve was commanded open.

Max A time value in hr:min:sec

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.

Slow A time value in hr:min:sec

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).

Fast A time value in hr:min:sec

If the plunger arrives before this, the status is set to fast and tuning is used (for the enabled options if Optimization is enabled).

Min A time value in hr:min:sec

If the plunger arrives faster than this time, don’t tune.

Max Arrivals Allowed Any integer value Number of times the plunger can arrive after the Max Arrival Time before either opening Blow Valve or going to FAIL state.

Max Arrival Count An integer value 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.


Plunger – State 3 Plunger Arriving– High LineThis is the State 3 Plunger Arriving – High Line screen from PCCU.

The High Line tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option High Line Close Disabled, Enabled Enables the option to monitor the line pressure after opening

and possibly close valve again if line pressure is too high.Line Pressure In A floating point

valueCurrent value of line pressure

High Line Close Limit Any floating point value

If the line pressure is above this limit after hgh line open limit time, then close the valve.

High Line Open Time Limit A time value in hr:min:sec

Time to wait before checking for high line pressure to determine if the main valve should be closed.


Plunger – State 3 Plunger Arriving– Blow Valve HelpThis is the State 3 Plunger Arriving – Blow Valve Help screen in PCCU.


The Blow Valve Help tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Blow Valve State Closed, Open The current state of the Blow ValvePlunger Arrival Blow Valve Timer Option

Disabled, Enabled Enable the use of the Blow Valve to help the plunger to arrive if the plunger has not arrived after a specified time.

Plunger Arrival Blow Valve Time Limit

A time value in hr:min:sec

Time to wait after valve has been opened. If plunger has not arrived by this time, open Blow Valve.

Flow Rate Blow Valve Option Disabled, Enabled Enable the use of Flow Rate to determine if the Blow Valve should be opened to help the plunger to arrive.

Flow Rate In A floating point value

Current Flow Rate

Flow Rate Blow Valve Limit Any floating point value

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 Rate Blow Valve Time Limit


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.

Flow Rate Blow Valve Timer A time value in hr:min:sec

Elapsed time that Flow Rate has been below the Flow Rate Blow Valve Limit.

Case Blow Valve Option Disabled, Enabled Enable to use of casing pressure to open the Blow Valve to help the plunger to arrive.

Casing Pressure In A floating point value

Current Casing Pressure

Case Blow Valve Open Limit Any floating point value

If casing pressure falls below this limit, open the Blow Valve to help the plunger to arrive.

DP Blow Valve Option Disabled, Enabled Enable the use of DP to open the Blow Valve to help the plunger to arrive.

DP In A floating point value

Current DP

DP Blow Valve Limit Any floating point value

If DP falls below this limit, then open the Blow Valve to help the plunger to arrive.


State 4 Blow Valve

This is the State 4 Blow Valve screen from PCCU.


The Blow Valve tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Fail Blow Valve State None, Close, Open 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.

Option 3-BV Help – Plunger Arrival Time


Option 3-Flow Rate BV Disabled, Enabled Enable the use of Flow Rate to determine if the Blow Valve should be opened to help the plunger to arrive.

Option 3-BV Case Disabled, Enabled Enable to use of casing pressure to open the Blow Valve to help the plunger to arrive.

Option 3-BV DP Disabled, Enabled Enable the use of DP to open the Blow Valve to help the plunger to arrive.

Option 4-BV State Disabled, Enabled Enable the use of the Blow Valve when the plunger fails to arrive before the max arrival time

Option 4-BV Curtail Disabled, Enabled Selects whether the venting of the well is disabled during certain hours of the day.

Option 6-BV Cushion Disabled, Enabled 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.


Plunger – State 4 Blow Valve- BV 3 – Plunger ArrivingThis is the State 4 Blow Valve – BV 3 – Plunger Arriving screen from PCCU.


The BV3 – Plunger Arriving tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Plunger Arrival BV Timer


Plunger Arrival Blow Valve Time Limit


Time to wait after valve has been opened. If plunger has not arrived by this time, open Blow Valve.

Option Flow Rate Blow Valve Disabled, Enabled Enable the use of Flow Rate to determine if the Blow Valve should be opened to help the plunger to arrive.


Current Flow Rate

Flow Rate Blow Valve Limit Any floating point value

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 Rate Blow Valve Time Limit


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.

Flow Rate Blow Valve Timer A floating point value

Elapsed time that Flow Rate has been below the Flow Rate Blow Valve Limit.

Option Case Blow Valve Disabled, Enabled Enable to use of casing pressure to open the Blow Valve to help the plunger to arrive.


Current Casing Pressure

Case Blow Valve Open Limit Any floating point value

If casing pressure falls below this limit, open the Blow Valve to help the plunger to arrive.

Option DP Blow Valve Disabled, Enabled Enable the use of DP to open the Blow Valve to help the plunger to arrive.


Current DP

DP Blow Valve Limit Any floating point value

If DP falls below this limit, then open the Blow Valve to help the plunger to arrive.


Plunger – State 4 Blow Valve- BV 4 – Blow Valve StateThis 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 Values CommentsController State See previous.Main Valve State See previous.Blow Valve State Closed, Open Current state of the Blow ValvePlunger Status See previous.Cycle Status See previous.Option BV State Disabled, Enabled Enable the use of the Blow Valve when the plunger fails to

arriveBlow Time Max Any floating point

value in minutesThe maximum amount of time to wait for plunger arrival (stay in Blow Valve state) before going back to State 1 Closing Valve.

Blow Timer A time value in hr:min:sec

Elapsed time that Blow Valve has been opened.

Option BV Curtail Disabled, Enabled Selects whether the venting of the well is disabled during certain hours of the day.

Curtail Start Any integer value between 0 and 23, default is 21.

The hour at which curtailment will begin

Curtail End Any integer value between 0 and 23, default is 7.

The hour at which curtailment will end.

Curtail Wait No, Yes The status of the curtailment.


Plunger – State 4 Blow Valve- BV 6 – AfterflowThis is the State 4 Blow Valve – BV 6 – Afterflow screen from PCCU.

The BV 6 – Afterflow tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Blow Valve State Closed, Open Current state of the Blow ValvePlunger Status See previous.Cycle Status See previous.Option BV Cushion Disabled, Enabled 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.

BV Cushion Time Limit A time value in hr:min:sec

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.

BV Cushion Timer A time value in hr:min:sec

Elapsed time since the plunger arrived and Blow Valve Cushion Option is enabled.


Plunger –4 Blow Valve- StatisticsThis is the 4 Blow Valve – Statistics screen from PCCU.

The Statistics tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Blow Valve State Closed, Open Current state of the Blow ValvePlunger Status See previous.Cycle Status See previous.Blow Count An integer value Number of times the Blow Valve has been opened.Blow Time 0Blow Time 1Blow Time 2Blow Time 3Blow Time 4


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.

Blow Date/Time 0Blow Date/Time 1Blow Date/Time 2Blow Date/Time 3Blow Date/Time 4

A date and time The last five dates and times the Blow Valve was opened.


State 5 Plunger Arrived

This is the 5 Plunger Arrived screen from PCCU.


The 5 –Plunger Arrived tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.First Run Setting Any integer value If the count of initial consecutive arrivals slower than the Slow

Arrival Time must be larger than this before going to the Afterflow state.

First Run Count A integer value Count of the number of initial consecutive arrivals that are slower than the Slow Arrival Time.

Plunger Swab Disabled, Enabled 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

Swab Runs Setpoint Any integer value The number of swab runs to complete.Swab Run Completed An integer value The number of swab runs completed in the current swab

cycle. This value is reset to zero upon completionSwab Now No, Yes Selecting Yes will cause the swabbing process to begin

immediately during Afterflow.Reset Plunger Counters No, Yes Clear the counters used to track the count of arrivals and

arrival types.Normal Consecutive Arrivals An integer value 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.

Normal Count An integer value The total number of normal arrivals since the last reset plunger counters was used.

Fast Count An integer value The total number of fast arrivals since the last reset plunger counters was used

Late Count An integer value The total number of late arrivals since the last reset plunger counters was used

Slow Count An integer value The total number of slow arrivals since the last reset plunger counters was used

Cycles before Maintenance Any integer value 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.

Total Cycles An integer value The total number of the time the logic has gone thru the Closing Valve state since the last reset plunger counters was used.


State 6 Afterflow

This is the 6 - Afterflow screen from PCCU.


The 6 –Afterflow tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.State Timer A time value in

hr:min:secThis is a copy of the current state timer

Max State Timer A time value in hr:min:sec


Option Plunger Catch Mode Disabled, Enabled 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.

Current Run Volume A floating point value

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.

Current Close Reason None = 0TIMER = 1DP = 2FR = 3TUBE-LINE = 4CASE-LINE = 5CASE = 6TURNER = 7,SWAB = 8SP = 9TUBE = 10AI1 = 11AI2 = 12,LOAD = 13NOW = 14CT_TL = 15LR_TIME = 16LINE = 17AFTER = 18,C_L = 19CL_TL = 20SLUG = 21

This was the reason that the valve was closed the last time.

Option Flow Time Close Disabled, Enabled Enables the option to use the flow timer to determine when to close the main valve

Option Afterflow Timer Close Disabled, Enabled Enables the option to use the afterflow timer to determine when to close the main valve

Option Turner FR Close Disabled, Enabled Enables the use of the Turner flow rate to determine when to close the valve.

Option Load Ratio Close Disabled, Enabled Enables the use of Load Ratio to close the valve.


The 6 –Afterflow tab continued:

Description Values CommentsOption DP Close Disabled, Enabled Enables the use of DP to close the valveOption Flow Rate Close Disabled, Enabled Enables the use of flow rate to close the valve.Option Tube-Line Close Disabled, Enabled Enables the use of the difference between tubing pressure

and line pressure to determine when to close the valve.Option Case-Tube Close Disabled, Enabled Enables the use of the difference between casing pressure

and tubing pressure to determine when to close the valve.Option Case Close Disabled, Enabled Enables the use of casing pressure to determine when to

close the valve.Option SP Close Disabled, Enabled Enables the use of static pressure to determine when to close

the valve.Option Tubing Close Disabled, Enabled Enables the use of tubing pressure to determine when to close

the valve.Option Line Close Disabled, Enabled Enables the use of line pressure to determine when to close

the valve.Option Slug Close Disabled, Enabled Enables the use of slug size to determine when to close the

valve.Option Input 1 Close Disabled, Enabled Enables the use of Input 1 to determine when to close the

valve.Option Input 2 Close Disabled, Enabled Enables the use of Input 2 to determine when to close the

valve.


Plunger – 6-Afterflow TimersThis is the 6 - Afterflow Timers screen from PCCU.

The Timers tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Flow Time Close Disabled, Enabled Enables the option to use the flow timer to determine when to

close the main valveFlow Cycle Time Limit A time value in

hr:min:secAmount of time to keep the main valve open before closing.

Flow Cycle Timer A time value in hr:min:sec

The amount of time that the well has been flowing. This value is equal to the plunger arrival timer plus the after flow timer.

Option AfterFlow Timer Close Disabled, Enabled Enables the option to use the afterflow timer to determine when to close the main valve

After Flow Time Limit A time value in hr:min:sec

Amount of time to keep the valve open after plunger arrival.

After Flow Timer A time value in hr:min:sec

The amount of time the well has been flowing after plunger arrival.


Plunger – 6-Afterflow TurnerThis is the 6 - Afterflow Turner screen from PCCU.


The Turner tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Turner Flow Rate A floating point

valueThe 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.

Turner FR Multiplied A floating point value

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.

Critical Velocity A floating point value in ft/sec

This is the velocity required to carry droplets of liquid out of the well.

Area of tubing A floating point value in sq ft.

This is the area of the tubing.

Case-Line In A floating point value

This is the difference between the casing pressure and the line pressure.

Line Pressure A floating point value

Current line pressure.


Current casing pressure.


The Turner tab continued:

Description Values CommentsTubing Pressure In A floating point

valueCurrent tubing pressure

SP In A floating point value

Current static pressure

Tf In A floating point value

Current temperature

Last Lift Velocity A floating point value

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).

Option Turner FR Close Disabled, Enabled Enables the use of the Turner flow rate to determine when to close the valve.

Packer Well No, Yes 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.

Turner Mode Tube, Case-SP Selects if Tubing pressure or the difference between Casing and Static pressure are used to calculate the Turner Flow Rate.

Line-Casing Test value A floating point value

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.

Tubing Length Any floating point value

The length of the tubing from the stop to the arrival sensor, used to calculate the lift velocity

Tubing ID Any floating point value

The INNER diameter of the well tubing used to calculate the Turner Flow Rate.

Evaluation Time Limit A time value in hr:min:sec

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.

Evaluation Timer A time value in hr:min:sec

The time that has elapsed after plunger arrival. When this value becomes equal to the Evaluation Time, the Evaluation flag is set to ON.

Evaluation Flag OffOn

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.

Turner Low Timer A time value in hr:min:sec

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.

Turner Low Time Limit A time value in hr:min:sec

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.


The Turner tab continued:

Description Values CommentsTurner Rate multiplier 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).

Turner Close Tune Any floating point value

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.



Turner Multiplier Min Any floating point value

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

Turner Multiplier Max Any floating point 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.

Plunger – 6-Afterflow LRThis is the 6 - Afterflow LR screen from PCCU.


The LR tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Load Ratio Close Disabled, Enabled Enables the use of Load Ratio to close the valve.Load Ratio A floating point

valueThe current value of the Load Ratio.

Load Ratio Close Limit A floating point value

If Load Ratio is below this value for Load Ratio close time, close the valve.

Load Ratio Close time A time value in hr:min:sec

Consecutive amount of time that Load Ratio must be below the Load Ratio setpoint before the valve is closed.

Load Ratio Close timer A time value in hr:min:sec

Elapsed time the Load Ratio has been below the Load Ratio close setpoint.



Load Ratio Close Tune Any floating point value

Tune Load Ratio Close by this amount

Load Ratio Close Min Any floating point value

Do not tune Load Ratio Close below this value.

Load Ratio Close Max Any floating point value

Do not tune Load Ratio Close above this value.

Plunger – 6-Afterflow DPThis is the 6 - Afterflow DP screen from PCCU.


The DP tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option DP Close Disabled, Enabled Enables the use of DP to close the valveDP In A floating point

valueCurrent DP

DP Limit Any floating point value

If DP is below this value for DP Low Time, close the valve

DP Low Time A time value in hr:min:sec

Consecutive amount of time that DP must be below the DP Setpoint before the valve is closed.

DP Low Timer A time value in hr:min:sec

Elapsed time that DP has been below the DP Setpoint.

DP Limit Tune Any floating point value

Amount to tune the DP Limit.

DP Limit Min Any floating point value

Do not tune DP Limit below this value.

Plunger – 6-Afterflow FRThis is the 6 - Afterflow FR screen from PCCU.


The FR tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Flow Rate Close Disabled, Enabled Enables the use of flow rate to close the valve.Flow Rate In A floating point

valueCurrent flow rate.

Flow Rate Limit Any floating point value

If flow rate is below this value for Flow Rate Low Time, close the valve.

Flow Rate Low Time Limit A time value in hr:min:sec

Consecutive amount of time that flow rate must be below the Flow Rate Limit before the valve is closed.

Flow Rate Low Timer A time value in hr:min:sec

Elapsed time that flow rate has been below the Flow Rate Limit.

FR Limit Tune Any floating point value

Amount to tune the Flow Rate Limit.

FR Limit Min Any floating point value

Do not tune FR Limit below this value.

Plunger – 6-Afterflow T-LThis is the 6 - Afterflow T-L screen from PCCU.


The T-L tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Tube-Line Close Disabled, Enabled Enables the use of the difference between tubing pressure

and line pressure to determine when to close the valve.Tube-Line A floating point

valueThe difference between tubing and line pressure.

Tube-Line Close Limit Any floating point value

If the difference between tubing and line pressure is less than this value, close the valve.

Tube Line Close Tune Any floating point value

Amount to tune the tubing pressure/line pressure difference.

Tube Line Close Min Any floating point value

Do not tune the tubing pressure/line pressure difference below this value..

Plunger – 6-Afterflow C-TThis is the 6 - Afterflow C-L screen from PCCU.


The C-T tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Case-Tube Close Disabled, Enabled Enables the use of the difference between casing pressure

and tubing pressure to determine when to close the valve.Case Tube A floating point

valueThe difference between casing and tubing pressure.

Case-Tube Close Limit Any floating point value

If the difference between casing and tubing pressure is less than this value, close the valve.

Case Tube Close Tune Any floating point value

Amount to tune the casing pressure/tubing pressure difference.

Case Tube Close Min Any floating point value

Do not tune the casing pressure/tubing pressure difference below this value.

Plunger – 6-Afterflow TubeThis is the 6 - Afterflow Tube screen from PCCU.


The Tube tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Tubing Close Disabled, Enabled Enables the use of tubing pressure to determine when to close

the valve.Tubing Pressure In A floating point

valueCurrent tubing pressure

Tubing Close Action Lo Close, Hi Close 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.

Tubing Close Limit Any floating point value

This is the test value used to begin the Tubing Close Timer.

Tubing Close Time Limit A time value in hr:min:sec

The amount of time that the static pressure must either go above or fall below the Tubing Close Limit before the valve closes.

Tubing Close Timer A time value in hr:min:sec

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.

Tube Close Tune A floating point value

Amount to tune the Tube Close Limit

Tube Close Min Tune A floating point value

Do not tune Tube Close Limit below this value

Plunger – 6-Afterflow CaseThis is the 6 - Afterflow Case screen from PCCU.


The Case tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Case Close Disabled, Enabled Enables the use of casing pressure to determine when to

close the valve.Casing Pressure In A floating point

valueCurrent casing pressure

Case Close Limit Any floating point value

If casing pressure falls below this value, close the valve.

Case Close LimitTune Any floating point value

Amount to tune the close casing pressure.

Case Close Min Any floating point value

Do not tune close casing limit below this value.

Plunger – 6-Afterflow SPThis is the 6 - Afterflow SP screen from PCCU.


The SP tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option SP Close Disabled, Enabled Enables the use of static pressure to determine when to close

the valve.SP In A floating point

valueCurrent static pressure

SP Action Lo Close, Hi Close 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.

SP Close Limit Any floating point value

This is the test value used to begin the SP Close Timer.

SP Close Time Limit A time value in hr:min:sec

The amount of time that the static pressure must either go above or fall below the SP Close Limit before the valve closes.

SP Close Timer A time value in hr:min:sec

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.

SP Close Tune Amount to tune SP close limitSP Close Min Tune Do tune SP close limit below this value.

Plunger – 6-Afterflow SlugThis is the 6 - Afterflow Slug screen from PCCU.


The Slug tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Slug Size Close Disabled, Enabled Enable the use of slug size to close valve.Slug Size Any floating point

valueCurrent slug size

Slug Size Close Limit Any floating point value

Slug size must be below this value before the valve is opened.

Fluid Gradient Any floating point value

Slug Size constant (default = 0.433)

Plunger – 6-Afterflow InputsThis is the 6 - Afterflow Inputs screen from PCCU.


The Inputs tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Plunger Status See previous.Cycle Status See previous.Option Input 1 Close Disabled, Enabled Enables the use of Input 1 to determine when to close the

valve.Input 1 In A floating point

valueCurrent Input 1 value

Input 1 Action Lo Close, Hi Close 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.

Input 1 Close Limit Any floating point value

This is the test value used to begin the Input 1 Close Timer.

Input 1 Close Time Limit A time value in hr:min:sec

The amount of time that Input 1 must either go above or fall below the Input 1 Close Limit before the valve closes.

Input 1 Close Timer A time value in hr:min:sec

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.

Option Input 2 Close Disabled, Enabled Enables the use of Input 2 to determine when to close the valve.


Current Input 2 value

Input 2 Action Lo Close, Hi Close 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.

Input 2 Close Limit Any floating point value

This is the test value used to begin the Input 2 Close Timer.

Input 2 Close TimeLimit A time value in hr:min:sec

The amount of time that Input 2 must either go above or fall below the Input 2 Close Limit before the valve closes.

Input 2 Close Timer A time value in hr:min:sec

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.


Plunger – 6-Afterflow BlowThis is the 6 - Afterflow Blow screen from PCCU.

The Blow tab contains the following values:

Description Values CommentsController State See previous.Main Valve State See previous.Blow Valve State Closed, Open Current state of the Blow ValvePlunger Status See previous.Cycle Status See previous.Current Run Volume A floating point

valueThe 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.

After Flow Timer A floating point value in minutes

The amount of time the well has been flowing after plunger arrival.

Option BV Cushion Disabled, Enabled 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.

Blow Valve Cushion Time Limit


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.

Blow Valve Cushion Timer A time value in hr:min:sec

Elapsed time since the plunger arrived and Blow Valve Cushion Option is enabled.


State 0 FAIL

The 0 – FAIL screen is as follows:

The 0 – FAIL tab contains the following values:

Description Values CommentsStateMachine See previous.Plunger Status See previous.Cycle Status See previous.Current Fail Reason None=0,

Plunger Non-Arrival=1,DI x = 3,AI x LOW = 4,AI x HIGH = 5,REMOTE = 6,DISABLE = 7,RESET = 8

This value indicates the current reason why the FAIL state is activated

Current Fail Date/ Time A date and time This is the time and date when the FAIL State was entered.Fail Main Valve State None, Close, Open 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.

Fail Blow Valve State None, Close, Open 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.


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.


The Misc tab contains the following values:

Description Values CommentsCurrent State State expressed

as a stringThis is the current state of the plunger logic

State Timer A time value in hr:min:sec


Max State Timer A time value in hr:min:sec



Plunger Arrival In A 32-bit integer value

This is the value of the PI that is connected to the plunger arrival sensor

Hold? NO, YES 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.

AP In A floating point value

Current AP


Current DP

Tf In A floating point value

Current temperature


Current flow rate

Volume A floating point value

Current accumulated volume

Z factor A floating point value

Current calculated compressibility factor

Baro Press A floating point value

Current barometric pressure

LinePressure A floating point value

Current line pressure

Tubing Pressure In A floating point value

Current tubing pressure


Current casing pressure

Hold Input A floating point value

Current value of Hold Input.





LastCntrctHrUpdt A date and time The date and time when the contract hour was last crossed.LogTime A time value in

hr:min:secThe amount of time that this application has been executing for today.

Version A string value This is the part number of the Plunger application.Current State A string value This the current state of the Plunger controller.


Closed

This is the Plunger Lift Statistics Closed Times screen from PCCU.

The Closed Times tab contains the following values:

Description Values CommentsClose Cycle Average A time value in

hr:min:secThis is the average of the last ten closed cycle times

ClosedTimeToday A floating point value in percent

The percent of time for today that the valve was closed.

ClosedTimeYest A floating point value in percent

The percent of time for yesterday that the valve was closed.

ClosedTodayTotal A time value in hr:min:sec

The total amount of time that the valve has been closed for today.

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]


The last ten close cycle times along with last ten close reasons..


Plunger – Statistics Closed – Closed-CasingThis is the Plunger Lift Statistics Closed-Casing screen from PCCU.

The Closed-Casing tab contains the following values:

Description Values CommentsCsngPress0CsngPress1CsngPress2CsngPress3CsngPress4CsngPress5CsngPress6CsngPress7CsngPress8CsngPress9

A floating point value

The last ten casing pressures taken at the end of the Closed Valve State (just before valve was opened).


Plunger – Statistics Closed – Closed-TubingThis is the Plunger Lift Statistics Closed-Tubing screen from PCCU.

The Closed-Tubing tab contains the following values:

Description Values CommentsTbngPress0TbngPress1TbngPress2TbngPress3TbngPress4TbngPress5TbngPress6TbngPress7TbngPress8TbngPress9


The last ten tubing pressures taken at the end of the Closed Valve State (just before valve was opened).


Plunger

This is the Plunger Lift Statistics Plunger Status screen from PCCU.


The Plunger Stats tab contains the following values:

Description Values CommentsNormal Count An integer value The total number of normal arrivals since the last reset plunger

counters was used.Consecutive Normal Arrivals An integer value 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.

Fast Count An integer value The total number of fast arrivals since the last reset plunger counters was used

Slow Count An integer value The total number of slow arrivals since the last reset plunger counters was used

Late Count An integer value The total number of late arrivals since the last reset plunger counters was used

Current Fail Date/ Time A date and time This is the time and date when the FAIL State was entered.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]

A list of values 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-ArrivalsThis is the Plunger Lift Statistics Plunger Arrivals screen from PCCU.


The Plunger Arrivals tab contains the following values:

Description Values CommentsPlungArrivalYest An integer value The number of plunger arrivals yesterday.PlngArrivalToday An integer value The number of plunger arrivals today.PlngAriveAvg A time value in

hr:min:secThe average of the last ten plunger arrival times.

PlngArive0PlngArive1PlngArive2PlngArive3PlngArive4PlngArive5PlngArive6PlngArive7PlngArive8PlngArive9


The last ten plunger arrival times and date/times

Plunger – Statistics Plunger – Plunger Non-ArrivalsThis is the Plunger Lift Statistics Plunger Non-Arrivals screen from PCCU.

The Plunger Non-Arrivals tab contains the following values:

Description Values CommentsNon-Arrival 0Non-Arrival 1Non-Arrival 2Non-Arrival 3Non-Arrival 4Non-Arrival 5Non-Arrival 6Non-Arrival 7Non-Arrival 8Non-Arrival 9

A date and time The last ten dates and times when the plunger did not arrive before the Max Arrival Time


Flow

This is the Plunger Lift Statistics Flow Cycle screen from PCCU.


The Flow Cycle tab contains the following values:

Description Values CommentsCycleStatus Running = 0

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

This shows the status that has been determined through the operation of the cycle.


FlowTimeToday A floating point value in percent

The percent of time for today that the valve was not closed.

FlowTimeYest A floating point value in percent

The percent of time for yesterday that the valve was not closed.

FlowCycleAvg A time value in hr:min:sec

The average of the last ten flow cycle times.

FlowCycle0FlowCycle1FlowCycle2FlowCycle3FlowCycle4FlowCycle5FlowCycle6FlowCycle7FlowCycle8FlowCycle9


The last ten flow cycles times and close reasons

Plunger – Statistics Flow – Run volumeThis is the Plunger Lift Statistics Flow Run Volume screen from PCCU.


The Run Volume tab contains the following values:

Description Values CommentsRun Volume average A floating point

valueThe average of the last ten run volumes.

Run VolumeRun VolumeRun VolumeRun VolumeRun VolumeRun VolumeRun VolumeRun VolumeRun VolumeRun Volume


The last ten run volumes.

Blow

This is the Plunger Lift Statistics Blow – Blow Valve screen from PCCU.

The Blow Valve tab contains the following values:

Description Values CommentsBlow Count An integer value Number of times the Blow Valve has been opened.Blow Time 0Blow Time 1Blow Time 2Blow Time 3Blow Time 4


The last five amount of times that the Blow Valve was opened.

Blow Date/Time 0Blow Date/Time 1Blow Date/Time 2Blow Date/Time 3Blow Date/Time 4

A date and time The last five dates and times the Blow Valve was opened.


Slug

This is the Plunger Lift Statistics Slug – Slug Open screen from PCCU.

The Slug Open tab contains the following values:

Description Values CommentsSlug 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]

A floating point value in gallons

Last 10 slug sizes at open.


Plunger – Statistics Slug – Slug CloseThis is the Plunger Lift Statistics Slug – Slug Close screen from PCCU.

The Slug Close tab contains the following values:

Description Values CommentsSlug 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]

A floating point value in gallons

Last 10 slug sizes at close.


Register ListThe register list for this application may be found in document PlungerRegistersRevAA.doc

Initial Set-UpFlow Computer

• Program the XFC or XRC and calibrate internal transducers using Totalflow’s installation and operations manual

•Plunger Lift Control

All plunger configuration and operations can be done locally using Totalflow’s PCCU (version 4.5 or newer) or remotely using Totalflow’s 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 Plunger Lift Control 95 of 972102890-001 January 15, 2007

Change Log:Version: 001

• Initial release


Recommended Module Wiring - Direct I/O Option


1 2 3 4

J2

J1

J3J4

1 2 3 4

1 2 3 41 2 3 4 O

PEN

CLOSE

Vbatt

Plunger Arrival Switch

BLOW

OPEN

CLOSE

MAIN

abb totalflow plunger user guide

Documents

ten run volumes

gathering

ext pressure

aga3 measurement

turner tab

plunger lift

slug size

normal window