Sercel GRC ESP-Series Manual de usuario

Field

Installation

Manual

ESP

MONITORING

SYSTEMS

Doc No. 006-0211-00 Rev AK Page 1 of 33

ESP MONITORING SYSTEMS

FIELD INSTALLATION MANUAL

Gauges:

ESP-1500, ESP-2500, ESP-3500, Spy Pro

Surface Equipment:

SPS-1500, Scout-3000, Data Pro

NOTICE

This manual is intended for private information only, with the understanding that any

other use of the subject matter, in whole or in part, by reference or otherwise, shall be

only with the prior knowledge and approval of Sercel-GRC Corp, and with the further

understanding that this manual is for informational purposes only and that suggestions

and recommendations contained herein shall not be understood or construed as a

guarantee or warranty of any method, product or device.

Federal copyright law protects the publication. No part of this publication may be copied

or distributed, transmitted, transcribed, stored in a retrieval system, or translated into

any human or computer language, in any form or by any means, electronic, magnetic,

manual or otherwise, or disclosed to third parties without the express written permission

of Sercel GRC Corp.

Any questions concerning the content of this manual, equipment operation, field

maintenance, maintenance assistance and operation or maintenance training courses

should be directed to Sercel-GRC.

Document Number: 006-0211-00

Sercel-GRC Corp.

13914 E. Admiral Place, Ste. B

Tulsa, OK 74116-2107 USA

E-Mail: [email protected] or [email protected]

Telephone: (1) 918-834-9600 / Fax: (1) 918-838-8846

Visit our web page at www.Sercel-GRC.com

Doc No. 006-0211-00 Rev AK Page 2 of 33

Table of Contents

INTRODUCTION.............................................................................................................3

ESP Downhole Gauge Pressure Measurement.................................................................. 3

Surge panel and surface choke.......................................................................................... 3

Surface interface................................................................................................................ 3

Customer Service/Support...........................................................................................4

BENCH TESTING AND VERIFICATION PROCEDURES..............................................5

Tools Required................................................................................................................... 5

Process Steps for Bench Test and Verification................................................................... 5

Process Steps for Insulation Test with Megger Tester (Fluke 1550C) on Surface............... 6

Process Steps for Resistance Test with Analog Type Meter (Simpson 260) on Surface..... 6

INSTALLATION PROCEDURES FOR DOWNHOLE GAUGE.......................................7

Installing the ESP Sensor with WYE Point Adapter to the Motor ........................................ 7

Installing the Resistance Temperature Detector “RTD” ...................................................... 9

Installing the ESP Sensor with Single Wire to the Motor....................................................12

Discharge Port Connection (ESP-3500 only).....................................................................14

Discharge Port Connection (Spy Pro only)........................................................................15

Testing the ESP Sensor While Installing Tubing......................................................16

Megger testing motor and cable........................................................................................16

INSTALLING THE SURFACE INTERFACE EQUIPMENT...........................................17

Wiring Detail......................................................................................................................17

ESP Gauge and Surface Control Interface Diagram Components.........................17

INSTALLING THE SURGE SUPPRESSOR AND SURFACE CHOKE........................18

Surface Choke ..................................................................................................................18

Surge Panel Protector/Suppressor....................................................................................19

Surface Choke and Surge Protector Panel Assembly........................................................21

APPENDIX 1.................................................................................................................22

TROUBLESHOOTING ......................................................................................................22

Sensor to Surface Communication Troubleshooting..............................................22

APPENDIX 2.................................................................................................................23

SCOUT and SPS Error Codes and Corrective Actions......................................................23

APPENDIX 3.................................................................................................................25

ESP Monitoring System Field Checklist.............................................................................25

APPENDIX 4.................................................................................................................26

Surface Read Out Device Specifications...........................................................................26

SPS-1500...............................................................................................................26

Scout-3000.............................................................................................................27

Data Pro.................................................................................................................28

APPENDIX 5.................................................................................................................29

ESP Sensors - Pass/Fail Criteria.......................................................................................29

ESP Sensors –Simpson Test Pass/Fail Criteria ...............................................................30

ESP Sensors –Megger Test Pass/Fail Criteria .................................................................31

APPENDIX 6 SPS-1500 Synchronization and Startup..............................................32

Doc No. 006-0211-00 Rev AK Page 3 of 33

INTRODUCTION

This field installation manual will explain in detail the operation and installation of all

Sercel-GRC ESP Monitoring Systems. ESP gauge instructions are for the following

gauge models: ESP-1500, ESP-2500, ESP-3500, and Spy Pro.

ESP Downhole Gauge Pressure Measurement

The intake pressure measures the pressure inside the motor housing. Motor oil protects

the intake pressure port from well fluid contamination.

The discharge pressure measures the pressure at the pump discharge port via a

hydraulic line connection to the discharge port on the pump. This connection is available

only on Dual Pressure gauges such as the ESP-3500, and Spy Pro 9 and 11.

Surge panel and surface choke

Surface interface

For detailed surface interface instructions, refer to:

Scout-3000 Field Operation Manual PN: 006-0191-00

SPS-1500 Operation Manual PN: 006-0202-00

Data Pro Operations Manual PN: 10029355

A system installation checklist is shown in APPENDIX 3of this manual. This checklist

will provide the installer with the ability to follow and record the installation of the

monitoring system. Please follow this guide and use the checklist provided when

installing all ESP Sensor Systems.

Doc No. 006-0211-00 Rev AK Page 4 of 33

Customer Service/Support

If assistance is needed, please contact one of our centers listed below. The engineers

and technicians will be more than happy to provide you with any assistance needed.

SITE

LOCATION

PHONE

Tulsa, USA

6540 E. Apache Street

Tulsa, OK 74115 USA

+1.918.834.9600

[email protected]

Dubai, UAE

Jebel Ali - Free Zone

Dubai, UAE

+971 4 8832142

[email protected]

Doc No. 006-0211-00 Rev AK Page 5 of 33

BENCH TESTING AND VERIFICATION PROCEDURES

Note: Bench test and verification procedures are applicable to all ESP sensors.

Tools Required

Power Supply 110 VAC/12-24VDC

Surface Readout (Scout-3000, SPS-1500, Data Pro, Field Test Box)

Signal and Ground wires

Alligator Clips

Simpson 260 analog type meter

Fluke 1550C insulation tester

Process Steps for Bench Test and Verification

1. To prevent injury, proper PPE should always be worn. Use caution when

working near or handling equipment. Utilize proper lifting techniques to

prevent injuries to personnel or equipment.

2. Remove the top shipping cap from the ESP Sensor.

3. Connect a signal wire from the Surface Readout to the signal wire on the

sensor Figure 1, or if using a WYE Point adapter connect to one of the three

pins inside the WYE adapter Figure 2. Connect the ground wire to the sensor

housing. Connect a motor RTD to the two white motor temperature wires.

4. Power on the Surface read out.

5. Data will display on the Surface Readout in approximant 2-5 minutes.

6. Record the parameter readings on the ESP Sensor Checklist; APPENDIX 3of

this manual, for test verification records.

7. ESP Sensor Pass/Fail Criteria is shown in APPENDIX 5.

8. See APPENDIX 6SPS-1500 Synchronization and Startup for the complete

SPS-1500 startup sequence.

Figure 1: I-Wire Connection Figure 2: WYE Connection

Signal Wire

Ground Wire

Motor RTD

Wires

Signal Wire

Motor RTD

Wires

Ground Wire

Doc No. 006-0211-00 Rev AK Page 6 of 33

Process Steps for Insulation Test with Megger Tester (Fluke 1550C)

on Surface

9. Connect the Megger Tester in reverse polarity by connecting the red wire to the

housing of the gauge and the black wire to the signal pin.

10.Apply voltage for 30 second duration.

11.ESP Sensor Megger Pass/Fail Criteria is shown in APPENDIX 5.

NOTE: MEGGER TEST THE SENSOR IN REVERSE POLARITY ONLY!!

LIMIT MEGGER VOLTAGE TO 5KV MAX

Process Steps for Resistance Test with Analog Type Meter (Simpson

260) on Surface

12.Connect the Analog Multimeter (on Rx10,000) in forward polarity by connecting

the black wire to the housing of the gauge and the red wire to the signal pin.

13.ESP Sensor Simpson Pass/Fail Criteria is shown in APPENDIX 5.

Doc No. 006-0211-00 Rev AK Page 7 of 33

INSTALLATION PROCEDURES FOR DOWNHOLE GAUGE

Installing the ESP Sensor with WYE Point Adapter to the Motor

It is recommended that the sensors be installed in a controlled environment or shop

prior to being sent to the field. If a sensor must be installed in the field follow the

procedures outlined below for sensors equipped with WYE point adapters.

1. Layout the sensor so that the three female connections on the Hockey puck

are aligned with the three pins coming out of the motor, and the holes on the

motor base are aligned with the holes on the motor head as shown in FIGURE 3.

2. Insure the O-ring has no sign of damage and install or replace with a new

O-ring if there are any signs of damage.

Figure 3: Aligning the motor pins to the Hockey Puck

3. Carefully stab the sensor into the motor, watching closely that the three pins

mate up with the three female connections on the hockey puck. IT IS VERY

IMPORTANT DURING THIS STEP YOU DO NOT TWIST THE SENSOR

WHILE STABBING INTO THE MOTOR BASE. DOING SO WILL RESULT IN

DAMAGING THE HOCKEY PUCK AND RUINING COMMUNICATION TO

THE SENSOR ONCE THE MOTOR IS STARTED.

Doc No. 006-0211-00 Rev AK Page 8 of 33

Figure 4: Gauge Stabbed into the Motor Base

4. Once the sensor has been stabbed as far as shown in FIGURE 4, finger-tighten

two of the motor base bolts at the top and bottom of the sensor to help support

the sensor weight. DO THIS BEFORE PROCEEDING TO STAB THE

SENSOR FULLY INTO THE MOTOR BASE.

5. Fully insert the sensor into the motor base making sure not to cut or pinch the

O-ring.

6. Install reaming bolts torque to minimum 25ft-lbs to insure proper seal.

7. To fill the sensor with oil, use either the drain and fill valve located at the

bottom of the sensor or through the drain and fill valve located on the motor.

Item

Part Number

Description

089-0252-00

PLUG, VENT & DRAIN

089-0254-00

GASKET, VENT & DRAIN

LEAD SEAL

089-0251-00

VALVE, DRAIN & FILL

089-0253-00

GASKET, LEAD SEAL

Table 1: Drain and Fill Valve Part Numbers

Note: Both gaskets (Items 2 and 4) listed above are single-use components.

Item 3 (valve) should be torqued to 210 in-lbs, and Item 1 (plug) should be torqued to

100 in-lbs.

8. After the sensor is installed verify sensor readings using a Surface Readout

and record the values on the ESP Sensor Checklist APPENDIX 3.

Doc No. 006-0211-00 Rev AK Page 9 of 33

Installing the Resistance Temperature Detector “RTD”

All ESP Gauges monitor Motor Temperature with a Platinum 1K RTD. There are

several RTD Motor Temperature Probe options including Probe, Threaded, and

customer supplied. Motor Temp probes are mounted inside the gauge assembly and

placed against the Motor Windings for maximum temperature transfer and fast

response. Motor Temperature Sensors can be ordered as an accessory or wired

permanently inside the gauge eliminating field connection concern. The factory installed

RTD is a Probe Style RTD with a stainless steel shielded sheath.

Also included in this document is the wye point solder procedure that Manufacturing

uses.

Motor RTD Connection Instructions (Spy Pro only - Factory Installed)

Since the RTD is factory installed. Determine where to place the RTD in the base

of the motor. The shielded RTD cable can be coiled inside the motor base.

Remember to keep the wire away from the motor shaft to prevent damage to the

RTD cable.

Motor RTD Connection Instructions (ESP-1500/2500/3500)

1. The first step is to determine where the RTD is going to be placed. It can be

either inside the ESP motor oil passage or inside the Sercel-GRC gauge. Inside

the gauge is the safest and is the least likely to come in contact with rotating

motor components. But it will be slower in responding to temperature variations

of the ESP motor. Placing the RTD inside the motor oil passages provides faster

response times to temperature changes, but runs the risk of making contact with

rotating parts.

2. Shorten the two wires coming from the gauge for the RTD to match where you

have determined to place the RTD. If it’s going inside the motor oil passage

secure the wiring and its excess to insure that the RTD is not drawn further into

the oil passage by the oil flowing through it. This prevents the RTD from coming

in contact with the rotating internal parts of the motor. Also insure that the wiring

will not come in contact with the end of the rotating motor shaft located where the

motor and ESP gauge are mated together. If the RTD is being placed inside the

gauge do not coil up the excess wire inside gauge but instead shorten the wires

and then insert the RTD and wiring back into the gauge. The reason for not

coiling the excess wire up and placing it inside the gauge is this can possibly

allow motor noise to show up on the motor temperature readings.

3. Strip 1/4” to 3/8” of insulation from the RTD and gauge wires.

4. Cut a piece of high temp heat shrink tubing, around 2.5”, and slide it over and

past both stripped gauge wires.

5. Using two more pieces of high temperature heat shrink tubing, around 1.5” long,

slide each piece over and past each individual gauge wire. The result should look

like the example in FIGURE 5.

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