Automatic Idle Time

Automatic Idle Time

Table of Contents

Introduction and Overview..........................................................................1

Rod Pump Control Approach ...........................................................................1
Idle Time Configuration..................................................................................1
Determining Idle Time ...................................................................................2
Provision for Over-Pumped Wells ................................................................2
Programming Parameters ...........................................................................3
Activate Automatic Idle Time ..........................................................................4
Disable Automatic Idle Time ...........................................................................4

Table of Tables
Table 1: Default Idle Time Settings..................................................................2
Table 2: Parameter 37 Settings and Definitions .................................................3
Table 3: Idle Time Abnormal Situation Settings .................................................4

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Introduction and Overview

Automatic idle time functionality is commonly available in various rod pump
controllers (RPC). The problem is that none have proven to be effective in a
majority of well configurations. Existing methods involve cycling the well while
varying the length of idle time, noting the length of time the well runs until pump-
off for each value of idle time. This process attempts to determine the value of idle
time when production starts to decrease by analyzing the non-linearity of the
relationship between idle time and run time (cf. Patent Number 5,064,348).

This technique is ineffective because the relationship between idle time and run
time does not indicate the same non-linear tendency as the relationship between
fluid production and idle time. Consequently, the idle time determined by this
method is not very accurate and is often too long, causing a corresponding loss of
production.

Rod Pump Control Approach

The method used in the ePIC RPC stabilizes the pump-off cycle time. This is done
on a continuous basis by adjusting the idle time according to the run times
preceding so that the desired cycle time is maintained. If there is an increase in run
times, there is a decrease in idle time and vice versa.

While this method cannot optimize the idle time applied to a rod pumped well with
the same results that would occur with a closely monitored and hand-tuned
pumping system, it will quickly and reliably stabilize the vast majority of pumping
systems to a very reasonable operating condition. As this method gives a
continuous stabilization of cycle time, it also automatically adjusts for the effects of:
• Power outages
• Production “kicks”
• Pump wear
• Tubing leaks

Idle Time Configuration

The automatic idle time function uses two preset values, desired cycle time and
minimum idle time (the preset cycle time also serves as the maximum idle time).

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Table 1 lists the RPC factory default values.

Table 1: Default Idle Time Settings

Default Description Value
Cycle Time 20 minutes
Minimum Idle Time 2 minutes

Determining Idle Time

The previous run time is calculated as follows:
1. If there is sufficient history for the average run time to be determined, as for the
software timed operation, the previous run time variable is set to this value, or
If there have been two or more undisturbed pump-off cycles immediately
preceding, the run times for those cycles are averaged and the previous run
time is set to this value, or
If there is one undisturbed pump-off cycle immediately before, the previous run
time variable is set to this value, or
If the immediate preceding cycle was disturbed or the controller has just been
powered up, the previous run time variable is set to the preset cycle time value.
2. The previous run time is subtracted from preset cycle time to determine the
next idle time.
3. If the resulting idle time is less than the minimum value allowed or is negative,
the RPC uses the minimum idle time value.

Provision for Over-Pumped Wells

The default cycle time may be excessive when the pumping system displacement is
larger in capacity than the production from the well. This results in a relatively
short run time and correspondingly long idle time. In such cases, it is desirable to
run shorter cycle times to avoid loss of production.

In order to accommodate these situations, there is a provision where, if it is

detected that the run time is less than 50% of the cycle time, the cycle time is
automatically reduced by one-half. This feature may be enabled or disabled and
may also be set to illuminate the fault lamp when this condition occurs, regardless
of whether an adjustment is made to the cycle time.

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Programming Parameters
P20 (Idle Time) is defined as the minimum idle time. Values from 00:00:01 to
99:59:59 are considered valid. A value of 00:00:00 causes a “PARAMETER 20
MISSING” error message.

P36 (Target Cycle Time) serves as a “long time” parameter. Values ranging from
00:00:00 to 99:59:59 are valid. When set to a non-zero value, the automatic idle
time is activated for operations. A value less than the value in P20 disables the
automatic idle time feature. The factory default value is 00:00:00.

P37 controls the provision for reducing cycle time if the run time percentage is less
than 50%. P37 is a byte parameter. Table 2 describes the values for this
parameter.

Table 2: Parameter 37 Settings and Definitions

P37 Cycle Time Adjustment Illuminate Fault Lamp
Value < 50 % Run Time < 50% Run Time
0 Disabled No
1 Disabled Yes
2 Enabled – Half Cycle No
3 Enabled – Half Cycle Yes

The factory default value is set to 0. This instructs the RPC to take no action and
not illuminating the fault lamp.

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Activate Automatic Idle Time

For most applications, the controller is set up as described in the existing manuals
with the exception of P20, P36, and P37 which should be left at the factory default
values. Table 3 describes set-up guidelines can be used for abnormal situations.

Table 3: Idle Time Abnormal Situation Settings

Condition
Low reservoir pressure and/or small
diameter casing
High reservoir pressure and/or
large diameter casing
Very low production wells known to
maintain production with longer idle
times
Recommended Settings
Reduce cycle time
Increase cycle time to reduce rod
stress
Set P37 to zero (0) to increase
cycle time if appropriate

Disable Automatic Idle Time

Set P36 to 00:00:00 and P20 to the desired idle time to disable automatic idle time.
This instructs the RPC to use a fixed idle time.

As there is no parameter which displays the actual idle time currently in use, it
must be calculated by subtracting the average run time in P205 (P207 if P205 is
zero) from the cycle time in P36. If the average run time is larger than the value of
P36, the value of P20 is the idle time.

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