Naftamatika WellSim rod pump
controller is used for sucker rod
control, anti-damage protection of
the downhole equipment, fluid
quantity and pump intake pressure
measuring.
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
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More than 450 controllers installed in Russia, USA, Lithuania, Belarus
 Strong partnership with National Instruments, Danfoss, Spirit Global
Energy Solutions
Naftamatika WellSim controller
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 pump pressure and liquid production.
• Real-time visualisation of well parameters
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)
Equipment placing scheme
Crank position hall
sensor
Combined
Load/Position sensor
Motherboard
RPM hall sensor
WellSim controller in a metallic –
antivandalism enclosure
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Motherboard
Adapter board
Sensors
Power supplies 24V,
12V
Battery
Circuit braker
Sound alarm
Motor control relay
Terminal block for all
wires
Additional 220V power
plug
WellSim as a part of control station
WellSim in a plastic enclosure
Controller:
• Enclosure
• Motherboard
• Adapter board
• Power supplies
• Intrinsicaly-safe barrier
• Motor starter control relay
• Customizable
Sensors
Load measuring:
• Naftamatika sensor
• Interface sensor
Position measuring :
• Analog Naftamatika
position sensor
(accelerometer based)
• Hall sensors or inductive
sensors
• Laser sensor
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 (variablefrequency drive)
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
Controller interface :
malfunction setpoints
Hardware specifications
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Controller motherboard has:
110 digital outputs/inputs (3,3 V)
30 analog inputs
4 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
Interfaces and communication protocols
Interfaces:
• RS-232
• Ethernet
• Possibilty to add other interfaces
Modbus RTU protocol
The controller is a complete network device that
supports TCP / IP protocol stack
Remote install-reinstall the controller firmware
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 the Ex zone 2
requirements
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
Metrological characteristics
Naftamatika WellSim
controller is a certified
measuring device of crude oil
production
In the future the controller can
be used as a pump intake
pressure measuring device
Controller features
• Data archivation without time
limitation
Controller features
Clear and user-friendly well-state detection
Controller features
• Password protection and different access rights
Controller features
• Web-interface for local or remote access
Controller features
• XSPOC integration or any other SCADA system integration
Diagnostics features
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Downhole and surface equipment load
detection
Valve checks
Automatic leakage calculation
Warnings about incorrect input data
Real-time signals from all sensors
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 Inductive and 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)
Advantages
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Full Rus/Eng GUI
Possibility to choose metallic or plastic enclosure
Possibility of using full graphic touch screen
Professional and user-friendly GUI, mathematical simulation, realtime 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
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
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
Exerience in implementation
More than 450 controllers established in:
• Tatneft (Russia)
• Oil companies from Canada and the USA
• AB Lotos Geonafta (Lithuaniа)
Belorusneft (Belorussia)
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 need flowmeter purchase
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 Lotos Geonafta:
15% energy saving because of WellSim controller use
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
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
Thanks for your
attention