Automatic Well Testing

Problems

• Previous integrator abandoned project before it was 100% complete.
• Reported values for water, gas, and oil volumes were incorrect.
• HMI was largely unreadable due to poor color choices and font sizes.
• Field devices were not installed according to the National Electric Code.
• Field devices were not calibrated correctly.
• Flow rate for the Phase Dynamics water cut monitor was not within specs, which yielded an incorrect water cut.

Solutions

• Modified calculations in PLC program to yield correct results.
• Modified HMI to use high-contrast colors and larger font sizes.
• Reinstalled field devices to comply with local and Federal codes.
• Tested and calibrated all field devices.
• Coordinated with Phase Dynamics to modify update interval from 5 seconds to 2 seconds.
• Modified flow control parameters to bring flow rate within Phase Dynamics specs.

Results

• Increased product quality.
• More productive employees.
• More reliable equipment.
• Better able to document environmental compliance.

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Details

Client: BreitBurn Energy
Location: Orcutt, CA

PLCs:

• (2) Automation Direct - Productivity 3000
• 38 discrete, 16 analog

HMIs:

• (2) Maple Systems - 4.3" color touchscreen - 5043T
• 65 tagnames

Remote Alarming:

• none

Data Historian:

• none

Other Components Integrated through SCADA:

• Phase Dynamics - water cut monitor

Networking, Protocols, and Drivers:

• Modbus RTU
• TCP/IP
• EIA-568A
• RS-485