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NAFTAMATIKA, s.r.o.

Naftamatika WellSim rod pump controller is used for sucker rod control , anti-damage protection of the down hole equipment, fluid quantity and pump intake pressure measuring. . NAFTAMATIKA, s.r.o. HQ located in Bojnice, Slovakia, European Union sales, R&D, manufacturing, assembling

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NAFTAMATIKA, s.r.o.

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  1. Naftamatika WellSimrod pump controller is used for suckerrod control, anti-damage protection of the downhole equipment, fluid quantity and pump intake pressuremeasuring.

  2. NAFTAMATIKA, s.r.o. • HQ located in Bojnice, Slovakia, European Union • sales, R&D, manufacturing, assembling • Moscow office, Russia– sales, R&D • Almetyevsk office, Russia – R&D, field services • More than 450 controllers installed in Russia, USA, Lithuania, Belarus • Strong partnership with National Instruments, Danfoss, Spirit Global Energy Solutions

  3. NaftamatikaWellSim controller

  4. Controller functions • Automation of processing, storing and real-time data analysis from sensors. • Controlling and automation of the oil well • Remote controlling and monitoring of well • Diagnostics and anti-damage protection of the downhole equipment. • Measuring of the pumppressure and liquid production. • Real-time visualisation of well parameters

  5. Hardware • Controller: • Motherboard • Adapter board • Power supply • Automatic switch • Intrinsicaly-safe barrier • Motor starter control relay • Sensors and cables: • Polished rod LoadCell with washers • Polished rod Position sensor • Cables and hardware set • Cables with inductive (or Hall) sensors for crankshaft position (optional for RPM)

  6. Equipment placing scheme Crank position hall sensor Motherboard Combined Load/Positionsensor RPM hall sensor

  7. WellSim controller in a metallic – antivandalismenclosure • Motherboard • Adapter board • Sensors • Power supplies24V, 12V • Battery • Circuit braker • Sound alarm • Motor control relay • Terminal block for all wires • Additional 220V power plug

  8. WellSimas a part of control station

  9. WellSim in a plastic enclosure • Controller: • Enclosure • Motherboard • Adapter board • Power supplies • Intrinsicaly-safe barrier • Motor starter control relay • Customizable

  10. Sensors Load measuring: • Naftamatika sensor • Interface sensor Position measuring : • Analog Naftamatikaposition sensor (accelerometer based) • Hall sensors or inductive sensors • Laser sensor

  11. Control functions based on control parameters • Control the well in auto mode by: • Pump fillage • Pump intake pressure • Timer • Schedule, Hand, Host • Control the well by controller or remotely by SCADA system • Well control in a manual mode (control manually by a toggle switch). • Well control by a VFD (variable-frequency drive)

  12. Control functions by malfunction setpoints Every operation mode has malfuction setpoints possibility: • Maximal and minimal Load setpoints • Minimal liquid pressure setpoints • Malfunction setpoint • Logical expressions With RPM and crank position sensors: • No Crank signal • No RPM signal • Low RPM • Warning of belt slippage

  13. Controller interface :malfunction setpoints

  14. Hardware specifications • Controller motherboard has:110 digital outputs/inputs (3,3 V)30 analog inputs4 analog outputs (0-10 v)31 digital outputs/inputs (24 V) • Up to 3 extension modules connection possibility • Any I/O configuration and data interfaces • Processor frequency 400 MHz • RAM memory 128 МB • Permanent memory 256 МB • FPGA– 40 МHz, 2 МB

  15. Interfaces and communication protocols • Interfaces: • RS-232 • Ethernet • Possibilty to add other interfaces • Modbus RTUprotocol • The controller is a complete network device that supports TCP / IP protocol stack • Remote install-reinstall the controller firmware

  16. Conformity with industrial safety requirements for explosure proof equipment • Technical Regulations of the Customs Union (Russia, Belorussia, Kazakhstan) • ATEX technical regulations • Load sensor meets the Ex zone 1 requirements and acceleration sensor meets theExzone 2 requirements

  17. Compliance with industrial safety requirements • LVD directive 2006/95/EC – GD SR 308/2004 Coll. of Laws • EMC directive 2004/108/EC – GD SR 194/2005 Coll. of Laws • EN 61010-1:2013 • EN 55011:2009 + A1: 2010 • EN 61000-3-2:2006 + A1:2009 + A2:2009 • EN 61000-3-3:2008 • EN 61326-1:2006

  18. Metrological characteristics NaftamatikaWellSimcontroller is a certified measuring device of crude oil production In the future the controller can be used as a pump intake pressure measuring device

  19. Controller features • Data archivation without time limitation

  20. Controller features Clear and user-friendly well-state detection

  21. Controller features • Password protection and different access rights

  22. Controller features • Web-interface for local or remote access

  23. Controller features • XSPOC integration or any other SCADA system integration

  24. Diagnostics features • Downhole and surface equipment load detection • Valve checks • Automatic leakage calculation • Warnings about incorrect input data • Real-time signals from all sensors

  25. Advantages • Possibility of using different sensor types. • Possibility of accelerometer sensor use:- Safe isntallation (installation directly to Load Cell, there’s no need in calculating any geometrical dimensions of well)- Reducing the cost of installation and maintenance • Possibility of using laser sensor: - The most accurate method for position measuring • - Safety • - Reducing the cost of installation and maintenance • Correct work with Inductiveand Hall sensors • - Correct RPM measuring in real time - Possibility of only one crank position sensor usage- Correct dynamometer card by real motor rotation change (working at slow oil wells)

  26. Advantages • Full Rus/Eng GUI • Possibility to choose metallic or plastic enclosure • Possibility of using full graphic touch screen • Professional and user-friendlyGUI, mathematical simulation, real-time graphic simulation of the production • A lot of outputs and inputs on the board • A lot of memory and high performance • A lot of possibilities of IO extensions • Ethernet port (Controller is a complete network device that supports the protocol stack TCP / IP) • Ability to generate reports and export of all historical data in Excel format

  27. Advantages • Surface and downhole equipment loading calculation (rods, gearbox, structure) • Possibility real-time monitoring of all sensors signals • Archiving information without time limitation • The use of evidence of additional sensors in the calculations • Password and access rights safety • Remote access to the controller via a Web-based interface (via Internet Explorer, Mozilla), including via the Internet • Remote install/reinstall controller software • View logs packets on receiving and transmitting of data

  28. Advantages • Possibility of leakage calculations:- manual input in %- dynamic calculation-valve check • Calculation of friction • Compliance with modern requirements for measurement instruments: the protection of code changes and unauthorized parameter changes • Possibility of using radio, integrated with a controller • Using of the multi – purpose National Instruments board, which allows to make solutions for different object types • SCADA-system integration possibility

  29. Exerience in implementation More than 450 controllers established in: • Tatneft (Russia) • Oil companies from Canada and the USA • AB LotosGeonafta (Lithuaniа) Belorusneft(Belorussia)

  30. The economic effect of implementation the Naftamatika WellSim controller • The increase time of maintenance intervals • Reducing the costs of repairs and maintenance of equipment • 15% energy saving using only pump-off control, (with VFD more then 25 %) • Reducing of thefts and vandalism • Increased production through artificial lift optimization • Costs reduction because of no needflowmeterpurchase

  31. The economic effect of implementation the Naftamatika WellSim controller Tatneft: More than 2000 $ per year at one oil well on average + flowmeter economy (3000-5000$ at one oil well) AB LotosGeonafta: 15% energy saving because of WellSim controller use

  32. Future software opportunities • Modbus TCP support • Surface dynamometer card control • Ambient temperature calculation while calculating oil production • Configuration flexibility of virtual and physical inputs • Settings of the maximum and minimum loads of rods • Interface and functionality of the controller with versatile configurations of channels with a universal logic control • Configuration flexibility of control modes • Complete surface and downhole 3D visualization

  33. Future software opportunities • Universal HTML5 GUI for use in OS Windows, Linux, Apple iOS, Android, etc. • Fully integration with variable frequency drives to use its parameters (f.e. Danfoss VLT SALT and other VFDs) • Digital Load and Position sensor • Possibility of using RPM control algorithm as a backup of the control algorithm • Own radio integrated directly in the controller

  34. Thanks for your attention

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