Realift Rod Pump - Controller - Commissioning Manual.pdf

Realift Rod Pump Commissioning Manual

Version 3.0c 12/2014 Retain for future use.

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Technical Support Questions and requests related to any part of this documentation can be directed to one of the following support centers. Technical Support: Americas, Europe, Middle East, Asia Available Monday to Friday 8:00am – 6:30pm Eastern Time Toll free within North America DirectWorldwide Email

1-888-226-6876 +1-613-591-1943 [email protected]

Technical Support: Australia InsideAustralia Email

1300 369233 [email protected]

Safety Information Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it. The following special messages may appear throughout this bulletin or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of either symbol to a “Danger” or “Warning” safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER DANGERindicates an imminently hazardous situation which, if not avoided, will result indeath or serious injury.

WARNING WARNINGindicates a potentially hazardous situation which, if not avoided, can result indeath or serious injury.

CAUTION CAUTIONindicates a potentially hazardous situation which, if not avoided, can result inminor or moderate injury.

NOTICEis

used to address practices not related to physical injury. The safety alert symbol is not used with this signal word. NOTE: Provides additional information to clarify or simplify a procedure.

Please Note Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction, installation, and operation of electrical equipment and has received safety training to recognize and avoid the hazards involved. 2

Copyright © 2014 Schneider Electric Canada Inc.

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Before You Begin Do not use this product on machinery lacking effective point-of-operation guarding. Lack of effective point-ofoperation guarding on a machine can result in serious injury to the operator of that machine.

WARNING UNGUARDED MACHINERY HAZARD • Do not use this soft ware and related automation equipment on equipment which does not have point-of-operation protection. • Do not reach into machinery during operation. Failure injury. to follow these instructions can result in death or serious Only the user can be aware of all the conditions and factors present during setup, operation, and maintenance of the machine; therefore, only the user can determine the automation equipment and the related safeties and interlocks which can be properly used. When selecting automation and control equipment and related software for a particular application, the user should refer to the applicable local and national standards and regulations. The National Safety Council’s Accident Prevention Manual (nationally recognized in the United States of America) also provides much useful information. In some applications, additional operator protection such as point-of-operation guarding must be provided. This is necessary if the operator’s hands and other parts of the body are free to enter the pinch points or other hazardous areas and serious injury can occur. Software products alone cannot protect an operator from injury. For this reason the software cannot be substituted for or take the place of point-of-operation protection. Ensure that appropriate safeties and mechanical/electrical interlocks related to point-of-operation protection have been installed and are operational before placing the equipment into service. All interlocks and safeties related to point-of-operation protection must be coordinated with the related automation equipment and software programming. Coordination of safeties and mechanical/electrical interlocks for point-of-operation protection is o utside the scope of this documentation.

Start-up and Test Before using electrical control and automation equipment for regular operation after installation, the system should be given a start-up test by qualified personnel to verify co rrect operation of the equipment. It is important that arrangements for such a check be made and that enough time is allowed to perform complete and satisfactory testing.

CAUTION EQUIPMENT OPERATION HAZARD Before energizing equipment: • Verify that all installation and set up procedures have been completed. • Before operational tests are performed, remove all blocks or other temporary holding means used for shipment from all component devices. • Remove tools, meters, and debris from equipment. Failure to follow these instructions can result in minor or moderate injury. Follow all start-up tests recommended in the equipment documentation. Store all equipment documentation for future references. Software testing must be done in both simulated and real environments.


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Verify that the completed system is free from all short circuits and grounds, except those grounds installed according to local regulations (according to the National Electrical Code in the U.S.A., for instance). If highpotential voltage testing is necessary, follow recommendations in equipment documentation to prevent accidental equipment damage.

Operation and Adjustments The following precautions are from the NEMA Standards Publication ICS 7.1-195 (English version prevails):

•

Regardless of the care exercised in the design and manufacture of equipment or in the selection and ratings of components, there are hazards that can be encountered if such equipment is improperly operated.

•

It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe operation. Always use the manufacturer’s instructions as a guide for functional adjustments. Personnel who have access to these adjustments should be familiar with the equipment manufacturer’s instructions and the machinery used with the electrical equipment.

•

4

Only those operational adjustments actually required by the operator should be accessible to the operator. Access to other controls should be restricted to prevent unauthorized changes in operating characteristics.


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Table of Contents

1

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

1.1 1.2

2

Getting Started 2.1

2.2 2.3 2.4 2.5

3

3.8 3.9 3.10

3.11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Configuring the Computer for Communication with the Realift Rod Pump . . . . . . . . . . . . . . . . . . . . . . . . . 22 Establishing the Connection Between the Realift Rod Pump and the Computer . . . . . . . . . . . . . . . . . . . . 24 Changing the IP Address on the Realift Rod Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Resolving Conflicts in Location and Pump ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Establishing Communication Speed and Card Interval Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 RPC Version and RPC HMI Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Verifying Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3.7.1 Pinging the Realift Rod Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28 3.7.2 Verifying Detailed Communication Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Setting Time of New Day on the Realift Rod Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Viewing Counters and Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Administering Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.10.1 Saving a Parameter Set . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3.10.2 Opening a Parameter Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 34 3.10.3 Deleting a Parameter Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 35 3.10.4 Viewing Parameter Set Names . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 36 3.10.5 Resetting the Realift Rod Pump to Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Configuring Energy Saving Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Configuring the Drive 4.1

4.2

5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Starting the Commissioning Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.1.1 Using ViewX to Start the Commissioning Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.1.2 Starting the Commissioning Software Using WebX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Creating and Deleting Pump Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Creating and Deleting Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Accessing Pump Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Navigating the User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.5.1 Configuration Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 19 2.5.2 Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 20

Configuring Time and Network Parameters 3.1 3.2 3.3 3.4 3.5 3.6 3.7

4

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Commissioning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Defining the Drive Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.1.1 Configuring the Interface for an Altivar 71 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.1.2 Configuring the Interface for a Generic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.1.3 Configuring the Interface for a Starter or Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 External Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Configuring Pump Control 5.1 5.2 5.3 5.4

5.5 5.6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Setting the Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Setting On & Off Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Setting Pump Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Setting Fill Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 5.4.1 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 48 5.4.2 Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 5.4.3 Downhole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Setting Startup Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Setting Control Triggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51


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Configuring Well Data 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9

7

Configuring Well Fault Detection 7.1 7.2 7.3 7.4

8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Using API Dimensions in Surface or Downhole Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Setting a Measured Stroke Length (Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Setting the Proximity Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Setting the Proximity Angle (Mark II Pump Jack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Setting the Proximity Debounce Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Setting the Load Cell Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Entering Downhole Calculation Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Entering Wellhead Information Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Entering Rod Taper Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Setting Stroke Alarm Alarm Parameters Parameters .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 68 Setting Per Real-Time 70 Viewing Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Resetting Detection for Well and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Configuring the Pump Jack for Standard Operation 8.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Setting the Fill Control Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 8.1.1 Setting the Surface Fill Control Level . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 75 8.1.2 Setting the Downhole Fill Control Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

9

Testing Realift Rod Pump System Operation

10

Verifying Realift Rod Pump Control During Operation 10.1 10.2 10.3

11

12.5

Using the History Card Browser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Viewing Periodic Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Viewing Stored Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Transferring Stored Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Changing Card Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Changing Card Storage Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Commissioning Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 A.1 A.2 A.3

6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Viewing Trends and Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Modifying the Plot Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Transferring Stored Trends and Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Managing History Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 14.1 14.2 14.3 14.4 14.5 14.6

A

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Summary Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Well Activity Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Surface and Downhole Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Card Display and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 12.4.1 Defining Filtering Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 94 Configuring External Sensors and Water Cut Percentage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Viewing History Trends and Events 13.1 13.2 13.3

14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Reading Downhole Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Sample Downhole Card Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Viewing System Status 12.1 12.2 12.3 12.4

13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Checking Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Forcing a Pump Off State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Testing Well Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Optimizing Realift Rod Pump Operation 11.1 11.2

12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Well Data Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Pump Control Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114


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B

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1 B.2 B.3 B.4 B.5 B.6 B.7 B.8

C


115 Creating a New Rod Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Dynagraph Plots Are Not Displayed But a Grid Appears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Dynagraph Plots Are Blank But No Grid Appears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 ClearSCADA Database Corrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Drive Runs in Hand or Manual Mode Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Realift Rod Pump Speed Oscillates or Realift Rod Pump Does Speed Hunting . . . . . . . . . . . . . . . . . . . 118 Difference Between Fill Control Level and Fill Target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Operation in “Downhole Mode” and Pump Fill Indicates 0% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

The Data Stored in Periodic and Stored Cards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

C.1

Periodic Cards

C.2

Stored Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

D

User Privilege Levels

E

Resetting the SCADAPack 535 E E.1 E.2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Reinstalling the SCADAPack 535 E Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Reinstalling the Application Package File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139


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1


Introduction

Realift Rod Pump is an advanced rod pump controller for automating a rod pump. This manual describes the procedure for commissioning the Schneider Electric Realift Rod Pump system.

WARNING UNEXPECTED EQUIPMENT OPERATION • Read and understand this manual before operating the Realift Rod Pump system. • Any changes made to parame ter settings must be perf ormed by qualified personnel. Failure to follow these instructions can result in death or serious injury.

1. 1

Before You Begin Before you start to commission the Realift Rod Pump, confirm that:

•

The Realift Rod Pump HMI software installation procedure is complete (see Realift Rod Pump Software Installation Manual).

•

The Realift Rod Pump hardware installation procedure is complete (see Realift Rod Pump Hardware Installation Manual).

• •

The Hand Off Auto (HOA) switch on the enclosure is set to Off. The drive or motor starter contactor is configured and ready for power to be applied.

The commissioning procedure for Downhole Realift Rod Pumps is described in this section.

1. 2

Commissioning Overview The Realift Rod Pump is commissioned using the Realift Rod Pump HMI software. The software is built on the Schneider Electric ClearSCADA platform. ClearSCADA is installed automatically as part of the Realift Rod Pump HMI installation and places a ClearSCADA Server icon, a ClearSCADA Service Manager icon, and a ViewX icon on the desktop. This manual contains the following information:

•

Setting up WebX or ViewX to use the Realift Rod Pump HMI software is described in Getting Started on page 11.

•

Defining initial time and network parameters is described in Configuring Time and Network Parameters on page 21.

• •

Configuring the drive you are using with the Realift Rod Pump is described in Configuring the Drive on page 39.

• •

Configuring the pump is described in Configuring Pump Control on page 43.

• •

Configuring how faults are detected and reported is described in Configuring Well Fault Detection on page 67. Configuring the pump jack for standard operation is described in Configuring the Pump Jack for Standard Operation on page 73.

•

Verifying Realift Rod Pump control during operation is described in Verifying Realift Rod Pump Control During Operation on page 83.

Testing the Realift Rod Pump system operation is described Testing Realift Rod Pump System Operation on page 81. Configuring how the data from the well is reported is described in Configuring Well Data on page 53.


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• • • • •

Optimizing Realift Rod Pump operation is described in Optimizing Realift Rod Pump Operation on page 87.

•

In Appendix B - Troubleshooting on page 115, you can find troubleshooting information for common commissioning-related situations.

Viewing the system status is described in Viewing System Status on page 91. Viewing history trends and events is described in Viewing History Trends and Events on page 97. Managing history cards is described in Managing History Cards on page 105. In Appendix A - Commissioning Checklist on page 113, you can find a commissioning checklist of the items you should cover when configuring an Realift Rod Pump.


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2


Getting Started

The first steps in using the Realift Rod Pump HMI software to commission a Realift Rod Pump are explained in this chapter.

2. 1

Starting t he C ommissioning S oftware After first connecting to the Realift Rod Pump, you can start the commissioning software and log on. You can use either the ViewX interface or the WebX interface.

2.1.1

Using V iewX to Start t he Commissioning Software You can use the Realift Rod Pump HMI software with ViewX. If installed on the PC, using ViewX provides a faster, more convenient interface. Before you can use the Realift Rod Pump HMI commissioning software with ViewX, you have to configure ViewX to show the Realift Rod Pump as the home page. To set the Realift Rod Pump as the home page: 1. Start ViewX by double-clicking the ViewX icon on the Windows desktop. If there is no ViewX icon on the desktop, you can start ViewX using the Start button: — Select Start > All Programs > Schneider Electric ClearSCADA > ViewX. 2. In ViewX, select File > Log On. The Log On dialog box appears. 3. In the Log On dialog box, enter the super-user Username and Password and click OK. When you installed the Realift Rod Pump HMI software, you were directed to change the default super-user (see Changing the Default Super-User on page 29 of the Realift Rod Pump Software Installation Manual). Upon installation, the default Username and Password are: — Username: schneider_dof — Password: S4v33n3rgy! 4. When you are logged on, select Tools > Options. The Options dialog box appears. 5. Click the browse button (

) next to the Home Page text box. The Select Home Page dialog box appears.

6. In the Select Home Page dialog box, expand the Digital Oil Field. 7. Select Login and click OK to clo se the Select Home Page dialog box. 8. In the Options dialog box, click the Edit button next to Features. The Features dialog box appears. 9. In the Features dialog box, select the Display Home Page On Logon chec k box. 10. Click OK to close the Features dialog box. 11. Click OK to close the Options dialog box. 12. Close ViewX. To start the commissioning software using ViewX: 1. Start ViewX by double-clicking the ViewX icon on the Windows desktop. If there is no ViewX icon on the desktop, you can start ViewX using the Start button: — Select Start > All Programs > Schneider Electric ClearSCADA > ViewX. 2. The Realift Rod Pump HMI Main Menu, shown in Figure 2.3, appears. 3. Click the Login button near the top of the screen and enter the following user name and password: — Username: admin1 — Password: welcome The dialog box in Figure 2.1 appears.


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Figure 2.1 :

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Con fir m Act ion

4. Read the warning and click Yes to continue. A second confirmation dialog appears. 5. Click Yes to continue. 6. The Current User field changes from Guest to admin1.

2.1.2

Starting t he C ommissioning S oftware U sing W ebX WebX enables you to access the Realift Rod Pump HMI software on the server itself or remotely. If you are using a recent version of Internet Explorer, Realift Rod Pump may not display properly in Internet Explorer. If this is the case, you can use ViewX, as explained in Using ViewX to Start the Commissioning Software on page 11, if you are at the server or you can use Remote Desktop Connection to connect to the server using the server’s IP address, in which case you can use ViewX remotely. To start the commissioning software using WebX: 1. Double-click the Realift Rod Pump Login icon, sh own in Figure 2.2, on your Windows desktop. The Realift Rod Pump HMI Main Menu, shown in Figure 2.3, appears. Fig ure 2 .2:

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Rea lif t Rod Pu mp Lo gin I con


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2. Click the Login button near the top of the screen and enter the following username and password: — Username: admin1 — Password: welcome The Current User field changes from Guest to admin1. Fig ure 2 .3:

2. 2

Rea lif t Rod P ump Mai n Men u

Creating and Deleting Pump Profiles The pump profile contains the information particular to that pump, for example, the control mode, the speed settings, the fill control settings, the stroke length and stroke length method, the direction of rotation, the downhole calculation parameters, the rod taper information, and the drive type and settings, etc. Because each situation and each rod pump is different, a new pump profile must be created for each pump the Realift Rod Pump HMI software commissions. If this is a networked system, new Realift Rod Pumps can only be added locally at the server. Depending on your license you may be able to create only one pump profile. If this is the case, you will delete the pump profile each time you are finished commissioning a rod pump so that you can create a new profile for the next rod pump you commission. To create a pump profile: 1. In the Admin Actions pane in the upper right-hand corner of the Realift Rod Pump HMI Main Menu, click Create a New Pump. 2. The Enter Pump Information dialog box appears, as shown in Figure 2.4.


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Fig ure 2 .4:

Ent er Pu mp In for mat ion

3. In the Enter Pump Information dialog box, enter brief a description of the pump's Location (for example, TestLocation2) and a Pump ID (for example, TestPump2). The Location and Pump ID text boxes cannot be empty, are limited to a maximum of 14 characters, and can contain only letters, numbers, underscores, and hyphens. If the Location or Pump ID entries are invalid, the Realift Rod Pump HMI software displays a message. 4. Click OK. You are prompted to re-enter your password. 5. Enter your password and click OK. The Realift Rod Pump HMI software creates the new pump profile. While it is creating the new pump profile, a message is displayed requesting you to wait until it has finished creating the pump profile. 6. The Location and PumpID appear under Pump List in the Main Menu. Each pump entered into the Realift Rod Pump HMI database on the same computer is listed under Pump List and can be accessed here for later modification, as shown in Figure 2.5. Figu re 2.5:

Pump List: Locat ion and Pump ID

To delete a pump profile: 1. In the ClearSCADA main screen (see Figure 2.3), select the pump you want to delete in the Pump List. 2. Under Admin Actions, click Delete Selected Pump. A Confirm Action dialog box appears requesting that you confirm that you want to delete the selected pump. 3. Click Yes. The selected pump is deleted.

2. 3

Creating and Deleting Users To increase security on the Realift Rod Pump system, you should create a new user and password for yourself.

WARNING UNEXPECTED EQUIPMENT OPERATION Access to configuration settings should be restricted to reduce the possibility of unauthorized device reconfiguration. Failure to follow these instructions may result in death or serious injury.

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To create a new user: 1. In the Admin Actions pane in the upper right-hand corner of the Realift Rod Pump HMI screen, shown in Figure 2.6, click Manage Users. Fi gu re 2. 6:

Ad min Ac ti on s

The User Account Information page appears, including a list of current system users, if any, and their privilege level, as shown in Figure 2.7. Figu re 2.7:

User Accou nt Information Window

When the Realift Rod Pump HMI software is first installed, there are three default users. Their names indicate their user privilege level. For more information on which parameters are available for each privilege level, see User Privilege Levels on page 127. — admin1: The admin1 user has complete Realift Rod Pump control, including the ability to edit Realift Rod Pump values, add and delete pumps, and add and delete users. The default password is “welcome”. — config1: The config1 user can navigate the Realift Rod Pump system and edit the values, but cannot add or delete pumps or users. The default password is “welcome”. — view1: The view1 user can only navigate the system and view data, but cannot edit values or add pumps and users. The default password is “welcome”. For security reasons, it is recommended that you create new users with Admin, Config, and View rights and that you delete these default users.


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CAUTION RISK OF SYSTEM INTRUSION There is a risk of an unauthorized user gaining access to the system and changing parameters. Create new users with secure passwords and delete the default users. Failure to follow these instructions may result in death or serious injury. 2. On the User Account Information page, click Create User. The Create New User dialog box appears, as shown in Figure 2.8. Figure 2 .8:

Cre ate N ew Us er Di alo g Box

3. In the Create New Users dialog box, select the user privilege level from the Choose User Privilege Level list: — Admin: An Admin user has complete Realift Rod Pump control, including the ability to edit Realift Rod Pump values, add and delete pumps, and add and delete users. — Config: A Config user can navigate the Realift Rod Pump system and edit the values, but cannot add or delete pumps or users. — View: A View user can only navigate the system and view data, but cannot edit values or add pumps and users. 4. Enter a New User Name. The user name is limited to a maximum of 20 characters and can contain only letters, numbers, underscores, and hyphens. 5. Enter and confirm a password. The password is limited to a maximum of 20 characters and can contain only letters, numbers, underscores, and hyphens. 6. Click OK. The new User Name with that user’s privilege level is added to the list of user accounts. 7. Click Exit to return to the main screen. If this is a networked system, you can only add new users locally at the server. To increase security, once you have created a new Admin user, you should log in with that account and delete the default Admin user (admin1) in order to ensure that no one else can use it. You can delete users in the User Account Information page by clicking a User Name in the Name/Type list to select it and then clicking Delete User to remove that user from the system.

2. 4

Accessing P ump C onfiguration Parameters You can access the pump configuration parameters from the Realift Rod Pump HMI software main menu page. To access the pump configuration parameters: 1. Under the Pump List, click PumpID for the pump you want to configure. 2. Click the Navigate to Selected Pump button. The main Status page for the pump appears, as shown in Figure 2.9.

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Fi gu re 2 .9 :

St at us Pa ge

3. Confirm that the correct Location and PumpID appear in the upper left-hand corner of the page, as shown in Figure 2.10. Figure 2.10: Location and Pump ID

2. 5

Navigating the User Interface On the Status page, shown in Figure 2.11, you can find many of the navigational tools you can use to view Realift Rod Pump data and edit Realift Rod Pump operating parameters.


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Figure 2.11: Navigating a Realift Rod Pump HMI Page

The user interface is organized into pages and panes:

•

Pages Pages, similar in concept to an operating system’s windows, organize Realift Rod Pump HMI controls and data into nine major functional areas, shown in Figure 2.12 on page 19. The functions available on each Realift Rod Pump HMI page are discussed in detail in this section.

•

Panes Pages are subdivided into panes, which group together similar controls and data fields. Several functional panes are displayed in Figure 2.11: — Summary — Well Activity Summary — Surface & Downhole Data — Card Display & Settings

The pane found on each of the nine major functional area pages is the Navigation Pane, illustrated in Figure 2.12.

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Figu re 2.12: Navig ation Pane

To access a page and its controls and data fields:

• 2.5.1

Click the icon for that page.

Configuration Fields In the Realift Rod Pump HMI software, any value that appears in a gray field is a read-only value that cannot be changed by the user. Gray fields indicate current values, though some are configurable values that are not editable due to some other settings. A value in a white field can be changed by clicking the field. Both types of fields are illustrated in Figure 2.13. Figure 2.13: Gray and White Fields in a Typical Pane


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Other colors can also appear in shaded fields:

•

Green indicates that the Realift Rod Pump is operating as expected, as illustrated in Figure 2.14. In this example, Run Pump is Enabled in the Realift Rod Pump HMI software, RPC Status is Auto (the HOA switch on the enclosure is set to Auto), and Drive Status is forward — the Realift Rod Pump is running.

Figu re 2.14: Green

•

Yellow indicates that a system parameter needs to be defined or needs attention, as illustrated in Figure 2.15. In this example, although the Realift Rod Pump is Enabled in the Realift Rod Pump software, the RPC Status (the HOA switch on the enclosure) is set to Off; turning the switch to Auto makes it possible for the Realift Rod Pump to run and changes Drive Status to Forward.

Figu re 2.15: Yellow

•

Red indicates that a system parameter requires attention because the Realift Rod Pump has stopped the pump because of, for example, a well fault, or it indicates a communication problem between network and the Realift Rod Pump (see Figure2.16).

Fig ure 2. 16: Red

See Troubleshooting on page 115 for detailed information on diagnosing communications interruptions.

2. 5. 2

Buttons Other controls in this pane (for example, Set Curve Visibility and Set Filtering Options) are buttons. You click a button to initiate an action.

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3


Configuring Time and Network Parameters

When you commission a Realift Rod Pump, whether it be a newly installed Realift Rod Pump system or an existing system, you communicate with the Realift Rod Pump using one of two types of connections:

•

Direct connection to a Realift Rod Pump system at the well site, using a computer with either a wired or wireless connection to the system

•

Networked connection to a Realift Rod Pump system through a server.

The Realift Rod Pump uses a static IP address. When you connect to the Realift Rod Pump over a network, a router or a DHCP server assigns an IP address to your computer, allowing the computer and Realift Rod Pump to communicate. The Communication State field in the Connection and Name pane displays Connected. However, when you connect directly to the Realift Rod Pump at the well site, the IP addresses on the Realift Rod Pump system and on the computer are unlikely to belong to the same network. So, before you can commission the Realift Rod Pump system, you will have to configure both the computer and the Realift Rod Pump. You configure the connection with the Realift Rod Pump using the Time and Network Configuration page. If your SCADAPack 535 E does not have a valid license, a banner is displayed over the Communications pane of the Time and Network Configuration page informing you of this fact (s ee Figure 3.1). If this is the case, contact your local Schneider Electric representative. Figu re 3.1:

Missing SCADAPack 535 E Licens e

To configure the computer and the Realift Rod Pump for a direct connection: 1. Configure an IP address on the computer to work with the IP address on the Realift Rod Pump (see Configuring the Computer for Communication with the Realift Rod Pump on page 22). 2. Connect the computer to the Realift Rod Pump ( Establishing the Connection Between the Realift Rod Pump and the Computer on page 24). 3. Configure a new IP address on the Realift Rod Pump that works with your network (Changing the IP Address on the Realift Rod Pump on page 24). You may also need to resolve conflicts in Location and Pump ID between those displayed in the Communication pane and those of the Realift Rod Pump to which you are now connected.


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Figu re 3.2:

3.1

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Time and Networ k Con figu ratio n Page

Configuring the Computer for Communication with t he Realift R od Pump When you first connect a computer to a Realift Rod Pump, the Realift Rod Pump uses the SCADAPack 535 E’s factory address (192.168.0.101). The first step in connecting the computer and the Realift Rod Pump is configuring an IP address and subnet mask on the computer that work with the Realift Rod Pump’s default IP address. To configure an IP address and subnet mask on the computer with Windows 7: 1. Click the Start button and select Control Panel from the Start menu. 2. On the Control Panel, click Network and Internet. The Network and Internet window appears. 3. In the Network and Internet window, click Network and Sharing Center. The Network and Sharing Center window appears. 4. In the menu on the left, click Change adapter settings. The Network Connections are displayed. 5. Double-click the Local Area Connection icon in the Network Connections window. The Local Area Connection Status dialog box appears, as shown in Figure 3.3.

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Figu re 3.3:

Local Area C onnection Status Dialog Box

6. In the Local Area Connection Status dialog box, click Properties. The Local Area Connection Properties dialog box appears. 7. In the Local Area Connection Properties dialog box, scroll through the connection list and select the Internet Protocol Version 4 (TCP/IPv4) check box. 8. Click Properties. The Internet Protocol (TCP/IP) Properties dialog box appears, as shown in Figure 3.4. Figu re 3.4:

Inter net Protocol (TCP/IP) Proper ties


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9. Select Use the following IP address and enter a new IP a ddress for your computer: a. Set the first three numbers of the IP address to match the drive’s address, but set the fourth number to something different from the Realift Rod Pump IP address (for example, if the drive's IP address is 192.168.0.101, set the computer's IP address to 192.168.0.X, (where X is any number from 1 to 254 other than 101). b. Set the subnet mask. Typical values are 255.255.255.0 or 255.255.0.0. A Default Gateway is not needed. c. Click OK to save changes and exit from the Control Panel.

3.2

Establishing the C onnection Between th e R ealift Rod P ump a nd the C omputer This section describes the process for connecting to the Realift Rod Pump using the Realift Rod Pump’s factory IP address (192.168.0.101). After you establish communication with the Realift Rod Pump, you can change the Realift Rod Pump’s IP address to an address that conforms to an appropriate range for your network (see Changing the IP Address on the Realift Rod Pump on page 24). To connect the computer to the Realift Rod Pump (when the Realift Rod Pump is using its default IP address): 1. In the Navigation pane, click Time & Network Configuration. The Time & Network Configuration page appears, as shown in Figure 3.2. 2. In the Target IP Address field of the Communication pane, illustrated in Figure 3.5, enter the IP address of the Realift Rod Pump. To change the Realift Rod Pump IP address, see Resolving Conflicts in Location and Pump ID on page 25. Fig ure 3.5 :

Commun ica tio n Pa ne

3. If you still cannot connect to the Realift Rod Pump, contact your local Schneider Electric representative.

3. 3

Changing the IP Address on the Realift Rod Pump After you first connect to the Realift Rod Pump using its factory IP address, you can change the IP address to an address that works with your network.

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The following suggestions will help you determine the new IP address:

•

If the Realift Rod Pump is connected to an already existing network, it may helpful to choose an IP address within an appropriate range for that network.

•

If the Realift Rod Pump is to be connected behind a router to a stationary server, you should configure the router so that it does not dynamically assign any device to the same IP address as the address given to the Realift Rod Pump. This can be done by constraining the range of addresses the router uses for DHCP.

To create a new IP address for the Realift Rod Pump: 1. In the Communication pane, click the Change Realift Rod Pump IP Address button (see Figure 3.5 on page 24). The Realift Rod Pump IP Configuration dialog box appears, as shown in Figure 3.6. Figu re 3.6:

Realift Rod Pump IP Configuration

2. Under Value Applied at the Next Power Cycle, set the IP address. One possibility is 10.10.253.30. 3. Set subnet mask. One possibility is 255.255.255.0. 4. Connect to the Realift Rod Pump using the new IP address. In the Communication pane, the Communication State field, now shaded in yellow, reads Connection Lost. The Target IP Address field still shows the srcinal IP address. 5. In the Target IP Address field, enter the IP Address and Subnet Mask created for the Realift Rod Pump in steps 2 and 3. 6. In the Communication pane, confirm that the Communication State field, now shaded in gray, reads Connected. You are again connected to the Realift Rod Pump, now with a new IP address.

3. 4

Resolving Conflicts in Location and Pump ID When you use the Realift Rod Pump HMI software to commission a Realift Rod Pump system for the first time, the Location and Pump (or Well) ID fields in the Communication Pane, shown in Figure 3.5, should read Default and Factory. If you have already used the Realift Rod Pump HMI software to commission a Realift Rod Pump system, the ID fields might display names other than Default and Factory. When the values in the Location and Pump ID fiel ds do not match those of the Realift RodPump you are connecting to, a button called Resolve Conflict in Location & Pump ID appears to the right of the Location and Pump (or Well) ID fields in the communication pane.


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To resolve this conflict: 1. Click the Resolve Conflict in Location & Pump ID button. The Rod Pump Controller Logistics Information Conflict dialog box appears, as shown in Figure 3.7. The Rod Pump Controller Logistics Information Conflict dialog box presents two options for resolving the conflict, with the recommended command button highlighted: — Copy from Server to Rod Pump Controller: When you click Copy from Server to Rod Pump Controller, the location and pump ID on the Realift Rod Pump are replaced with the location and pump ID on the PC. — Copy from Rod Pump Controller to Server. When you click Copy from Rod Pump Controller to Server, the location and pump ID on the PC are replaced with the location and pump ID on the Realift Rod Pump. Figu re 3.7:

Reali ft Rod Pump Lo gistics Info rmation Confl ict Dial og Box

MODIFIED, INACCURATE OR INVALID READINGS The Resolve Conflict command replaces the location and pump ID information on either the server or the Realift Rod Pump. This can affect your process. Ensure the process is in a safe state before executing the command. Re-zero all inputs after executing this command. Failure to follow these instructions can result in equipment damage. 2. Click the highlighted button to transfer Location and Pump ID either from the server to the Realift Rod Pump or from the Realift Rod Pump to the server. Values in the Server and Rod Pump Controller panes should match when the conflict is resolved, as shown in Figure 3.8. This transfer may take up to 60 seconds. Figu re 3.8:

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3. Click Exit to close the Rod Pump Controller Logistics Information Conflict dialog box.

3.5

Establishing Communication Speed and Card Interval Settings In the Version and Connection Speed section of the Communication pane, as shown in Figure 3.9, you can set the communication settings and the card interval based on communication network capabilities. Figu re 3.9:

Version and Connection Speed Pane

To set the communication settings and card interval: 1. Click the Communication Settings field. The Communication Speed dialog box appears, as shown in Figure 3.10. Figure 3.10: Communication Speed Dialog Box

2. Select the speed you need from the list: — For high-speed networks, select the High Communication setting. — For slower networks, select Medium or Slow. Use the following table to determine your connection speed: Ta bl e 3. 1:

Co nn ec ti on Sp ee ds

S e t t i ng

C o n n e c t io n

High

Direct dedicated connection to Realift Rod Pump, usually copper or fiber

Medium Low

RadioconnectiontoRealift RodPump

Spe e d 1 Mbps 512kbps

Shared radio connection to multiple Realift Rod Pumps

256 kbps

or other field devices

3. Click OK to save yo ur selection. 4. When you are commissioning a Realift Rod Pump for the first time, click the Card Interval field and set the interval to between ten seconds to one minute to allow faster card collection for setting parameters. Once the


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Realift Rod Pump is completely commissioned, it is recommended that you set card intervals to a value greater than a few minutes, up to an entire day between cards, to limit network activity.

3.6

RPC Version and RPC HMI Version The Version and Connection Speed section of the Communication pane indicates the version of the Realift Rod Pump software installed. In the RPC Version box, the firmware version on the SCADAPack 535 E is listed as XYYYZ, where X is the major version number and YYY is the minor version number. Z indicates the types of control modes that this version can use. In the case of Realift Rod Pump, because it can use timed, torque, surface, and downhole (depending on the drive installed), the last digit is “3.” In the RPC HMI Version box, the Realift Rod Pump software version is listed as X.YY.ZZ, where X is the major version number, YY is the minor version number, and ZZ is the build number.

3. 7

Verifying Communications If the Realift Rod Pump cannot communicate properly with Realift Rod Pump HMI software due to a configuration mismatch, the Communication State field in the Communication pane (Time & Network Configuration page) displays Disconnected, as shown in Figure 3.11. You should verify communications before you proceed. If Communication State displays Connection Lost, there can be a number of possible causes, including: the drive might not be powered up or physically connected to the computer, the connection may be poor, or IP addresses or subnet masks may not match. Figure 3.11: Disconnected Communication State

To troubleshoot a Disconnected communication state: 1. Confirm that the Realift Rod Pump system’s Ethernet card is connected to the computer and powered up. 2. Check the IP address of the Realift Rod Pump displayed in Target IP Address field.

3. 7. 1

Pinging the Realift Rod Pump If the Communication State shows Disconnected, your next step is to test that the Realift Rod Pump is communicating properly by pinging the Realift Rod Pump from the computer. To ping the Realift Rod Pump on a computer: 1. Click the Start button. The Start menu appears. 2. Enter “cmd” in the search text box and press Enter. The Command Prompt window appears. 3. Enter “Ping yyy.yyy.yyy.yyy” (the target IP address) and press Ente r. 4. If the Realift Rod Pump system is communicating properly, the Realift Rod Pump system replies successfully, as shown in Figure 3.12.

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6

Figu re 3.12: Successful Pi ng

If you cannot successfully ping the target Realift Rod Pump system, as shown in Figure 3.13, your computer and the target Realift Rod Pump system may not be in the same domain. See Configuring the Computer for Communication with the Realift Rod Pump on page 22. If you still cannot communicate with your Realift Rod Pump, you can use the SCADAPack E Configurator to determine the device’s IP address information after connecting by USB. For more information, see the SCADAPack E Configurator User Manual. Figu re 3.13: Unsuc cessf ul Ping

3.7.2

Verifying Detailed Communication Settings Additional tools for addressing communication interruptions can be found in the Detailed Communication Settings dialog box, shown in Figure 3.14.


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The Detailed Settings dialog box can be opened from two locations:

•

By clicking the Detailed Settings button in the Communication pane (see Configuring the Computer for Communication with the Realift Rod Pump on page 22).

•

By selecting Custom in the Communication Speed dialog box and then clicking OK (see Establishing Communication Speed and Card Interval Settings on page 27).

Figure 3.14: Detailed Communication Settings Dialog Box

If the Communication Timeout Count is increasing or if you continue to lose the connection with the Realift Rod Pump, you can try these solutions:

•

If the Current Value (Realift Rod Pump system reading) for Data Collection Time is greater than the Set Value, you can increase the Set Value.

•

If the Current Value (Realift Rod Pump system reading) for Data Reply Time is greater than the Set Value, you can increase the Set Value.

Values in Set Value fields should be at least slightly higher than readings in Current Value fields. Table 3.2 contains a list of the preset values for High, Medium, and Low communication setting. Ta bl e 3. 2:

Co mmun ic at io n Se t Val ue s

D e f a u lt s

30

H ig h

Me d i u m 2 sec

L ow

Data Reply Time

0.5 sec

10 sec

DataCollectionTime

2sec

8sec

45sec

CardTransferTime

25sec

80sec

400sec


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Suggested values will be slightly higher than Current Value. You can also use the options in this dialog box to reset the Reestablishment Interval and change the communication speed between Realift Rod Pump and computer.

3. 8

Setting Time of New Day on the Realift Rod Pump The Time of New Day is the time of day the Realift Rod Pump system completes collection of a day’s statistics and begins collection of a new day’s statistics. The Time of Day value is the Time Stamp for 60-day stored trends. You can set this parameter in the Clocks pane, shown in Figure 3.15, when you are commissioning the Realift Rod Pump. Figu re 3.15 : Clocks Pane

The Clocks pane also offers two date and time readings:

• •

Server Date & Time: Current date and time on the computer being used to commission the Realift Rod Pump. Current date and time on the Realift Rod Pump. Realift Rod Pump Date & Time:

The server’s time and date is set through Windows. You can set the Realift Rod Pump’s time and date using the Realift Rod Pump HMI software. The rod pump cannot be enabled when you set the Realift Rod Pump’s time and date. To set the Realift Rod Pump’s time and date: 1. In the Summary pane on the Status page, ensure that the Status of the rod pump is Disabled. If the rod pump is running, click the box to the right of the Status and wait until the Status changes to Disabled. 2. In the Clocks pane on the Time & Network page, click the Set button to the right of the RPC Date & Time box. The Realift Rod Pump HMI software sets the Realift Rod Pump time to the server date and time.

RISK OF LOSS OF DATA Resetting the RPC Date & Time can cause inaccurate values for Run Time Since Reset and Run Time Total. Failure to follow these instructions may lead to a loss of data.

3. 9

Viewing Counters and Timers The Counters & Timers pane, shown in Figure3.16, displays pump data from several counters (including Rod and Pump Stroke Counts) and run times.


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Figure 3.16: Counters & Timers Pane

Because they are readings from the Realift Rod Pump, these parameters cannot be edited. However, the following can be reset:

• • •

3. 10

Rod Stroke Count Pump Stroke Count Run Time Since Reset.

Administering Parameter Settings When you have multiple wells, they may share many of the same parameters. The Realift Rod Pump HMI commissioning software enables you to save the settings used when you commission a well as parameter sets. You can then retrieve these parameter sets and transfer them to the new well. Then, instead of commissioning each well by setting each parameter individually, you only need to change the parameters that are particular to that well. You can also restore a previous set of parameters to an existing Realift Rod Pump unit.

3. 10. 1

Saving a Parameter Set After you enter a set of parameters into the commissioning software, you can save the settings that are stored in the Realift Rod Pump HMI software. You can then retrieve these parameter sets and transfer them to a new well. Because only the name of the parameter set is visible when you view a parameter set (see Viewing Parameter Set Names on page 36), you should ensure that your parameter set name is descriptive enough to identify the parameters it contains. The settings that are saved in the parameter set are those that are stored in the SCADAPack 535 E. The following settings, stored in the Realift Rod Pump HMI software, are not saved in the parameter set and are reset when you open a parameter set:

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• • • •

Pump Control Configuration: all parameters

•

Drive Configuration: all parameters unless the parameter set is from an embedded Realift Rod Pump in which case the drive configuration and control wiring parameters will need to be configured manually.

Well Data Configuration: all parameters Well Fault Detection: all parameters Time and Network: the following parameters are reset: Energy Save, Counters and Timers, Time of New Day, Location and Pump ID


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To save a parameter set: 1. Navigate to the Time & Network Configuration page and locate the Parameter Set Admin pane, as shown in Figure 3.17. Figure 3.17: Parameter Set Admin Pane

2. In the Parameter Set Admin pane, click Save. The Save Parameter Set page appears, as shown in Figure 3.18. Figure 3.18: Save Parameter Set Window

3. On the Save Parameter Set page, save your parameter set: — Overwrite:Select the name of an existing parameter set from the list and click Overwrite to replace the parameter settings with the current settings. — Save New:Click Save New to save the current parameter settings to a new parameter set. When you click Save New, the Save New Set dialog box appears, enabling you to enter a name for the new parameter set. Ensure that your parameter set name is descriptive enough to identify the parameters it contains. The parameter set name is limited to a maximum of 30 characters and can contain only letters, numbers, underscores, and hyphens.


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Opening a Parameter Set If you have already saved parameter sets, you can open a parameter set and overwrite the current settings with those in the parameter set. The settings in the parameter set are those that are stored in the SCADAPack 535 E. The following settings, stored in the Realift Rod Pump HMI software, are not stored in the parameter set and are reset when you open a parameter set:

• • • • •

Pump Control Configuration: all parameters Well Data Configuration: all parameters Well Fault Detection: all parameters Time and Network: the following parameters are reset: Energy Save, Counters and Timers, Time of New Day, Location and Pump ID Drive Configuration: The Min Speed and Max Speed are reset to “0”, the Drive Interface Type is reset to Altivar 71 Modbus, and the Drive Address is reset to “2”.

To open a parameter set: 1. Navigate to the Time & Network Configuration page. On the Time & Network Configuration page, the Parameter Set Admin pane is displayed, as shown in Figure 3.17. 2. In the Parameter Set Admin pane, click Open. The Open Parameter dialog appears, as shown in Figure 3.19. Figure 3.19: The Open Parameter dialog

3. Select the name of the parameter set from the list and click Open. A Confirm Action dialog box appears requesting that you confirm that you want to open the selected parameter set and informing you that the c urrent Realift Rod Pump values will be overwritten by the values from the selected parameter set. To guard against unintended Realift Rod Pump operation, opening a parameter set automatically sets Run Enable to Disabled.

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WARNING UNEXPECTED EQUIPMENT OPERATION The Open Parameter command replaces the parameters on the controller. This can affect your process. Ensure the process is in a safe state before executing the command. Verify your configuration after executing this command. Failure to follow these instructions can result in death or serious injury. 4. Click Yes to open the selected parameter set and overwrite the current Realift Rod Pump values. You can manually change individual settings that differ from the saved parameter set.

3.10.3

Deleting a Parameter Set If you have already saved parameter sets, you can delete parameter sets that you no longer need. To delete a parameter set: 1. Navigate to the Time & Network Configuration page. On the Time & Network Configuration page, the Parameter Set Admin pane is displayed, as shown in Figure 3.17. 2. In the Parameter Set Admin pane, click Delete. The Delete Parameter dialog appears, as shown in Figure 3.20. Figure 3.20: The Delete Parameter dialog

3. Select the name of the parameter set from the list and click Delete. A Confirm Action dialog box appears requesting that you confirm that you want to delete the selected parameter set and informing that this action cannot be undone. 4. Click Yes to delete the selected parameter set.


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Viewing P arameter S et N ames If you have already saved parameter sets, you can view existing parameter sets. If your user account only has View privileges, this is the only parameter set option available to you. To view a parameter set: 1. Navigate to the Time & Network Configuration page. On the Time & Network Configuration page, the Parameter Set Admin pane is displayed, as shown in Figure 3.17. 2. In the Parameter Set Admin pane, click View. The View Parameter dialog appears, as shown in Figure 3.21. Figure 3.21: The View Parameter dialog

3.10.5

Resetting t he Realift R od Pump to Factory S ettings You can us e the Realift Rod Pump HMI commissioning software to reset the Realift Rod Pump to factory settings. When you reset the Realift Rod Pump to factory defaults, the events stored on the SCADAPack 535 E are cleared. These events, however, are still stored in the database. If you transfer events as explained in Transferring Stored Trends and Events on page 102, after having reset the RPC, the events in the database will be cleared. To reset the Realift Rod Pump to factory settings using the commissioning software: 1. Navigate to the Time & Network Configuration page. On the Time & Network Configuration page, the Parameter Set Admin pane is displayed, as shown in Figure 3.17. 2. In the Parameter Set Admin pane, click Reset RPC to Factory Settings. A Confirm Action dialog box appears requesting that you confirm that you want to reset the Realift Rod Pump to factory settings and informing that this action cannot be undone.

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WARNING UNEXPECTED EQUIPMENT OPERATION The Reset RPC to Factory Settings command replaces the current parameters with the factory defaults. This can affect your process. Ensure the process is in a safe state before executing the command. Verify your configuration after executing this command. Failure to follow these instructions can result in death or serious injury. 3. Click Yes to reset Realift Rod Pump to factory settings. Resetting the Realift Rod Pump to factory settings does not change the card storage location. To change the card storage location, refer toChanging Card Storage Location on page 112. To restore your drive to factory settings, refer to the documentation provided by the manufacturer of your drive.

3. 11

Configuring Energy Saving Times If electricity costs vary during the day, you can use the Realift Rod Pump’s energy saving capabilities to schedule operation for periods when electricity is the least expensive. The Realift Rod Pump system can suspend operation for a period of time each day to conserve energy and save costs. You can define Begin Time and End Time values for each day of the week to define the period during which the Realift Rod Pump does not operate. If the defined Begin Time is equal to or greater than the End Time, Energy Save is inactive. The Energy Save times are relative to the Realift Rod Pump clock setting in the Clocks Pane (see Setting Time of New Day on the Realift Rod Pump on page 31). You should verify that the server time matches the Realift Rod Pump. To configure energy saving times: 1. Navigate to the Time & Network Configuration page. On the Time & Network Configuration page, the Energy Save pane is displayed, as shown in Figure 3.22. Figu re 3.22: Energy Save Pa ne

2. For each day in the Energy Save pane, enter a Begin Time in 24-hour format to mark the beginning of the period during which the pump jack does not operate. 3. For each day, enter an End Time in 24-hour format to mark the end of the period during which the pump jack does not operate. The Realift Rod Pump stops the pump jack at Begin Time, and restarts at End Time, resuming normal pump jack operation. The total time between Begin Time and End Time for a single day cannot exceed 24 hours.


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4


Configuring the Drive

After you have configured the connection settings between the computer and the Realift Rod Pump system, you will configure the drive’s parameters.

WARNING UNEXPECTED EQUIPMENT OPERATION • Read and understand this manual and th e drive’s manual before operating the Realift Rod Pump system. • Any changes made to parame ter settings must be perf ormed by qualified personnel. Failure to follow these instructions can result in death or serious injury. To configure the parameters of the drive: 1. On the Status page, stop the pump by clicking the Run Pump button and waiting until Run Pump is Disabled and RPC Status is Disabled. 2. Click Drive Configuration in the Navigation pane. The Drive Configuration page appears (see Figure 4.1). The actual appearance of the Drive Configuration page depends on the type of drive s elected. The Drive Configuration page is also used to configure external control wiring, if any, to the Realift Rod Pump. Figure 4. 1:

Dri ve Co nfi gu rat ion P age


39

R e aRP liofutdmp C h a p t— Ce 4o r n f igu rintg hDerive

4. 1

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Defining the Drive Interface The Drive Configuration page enables you to define the configuration of the drive. The steps involved in configuring the drive depend on the type of drive installed.

RISK OF EQUIPMENT DAMAGE If you physically change the drive without either: • Switching the HOA switch to off or • Clicking the Run Pump button in the Realift Rod Pump HMI software to turn it to Disabled You must either: • Cycle the HOA switch from auto to off and back to au to, or • Cycle the Run Pump button in the Realift Rod Pump HMI software to turn it from Disabled to Enabled. Otherwise, the Realift Rod Pump will not restart in auto mode following the drive change. Failure to follow these instructions can result in equipment damage. For information specific to the type of drive, see the following sections:

• • • 4.1.1

Configuring the Interface for an Altivar 71 Drive on page 40 Configuring the Interface for a Generic Drive on page 40 Configuring the Interface for a Starter or Contactor on page 41.

Configuring t he I nterface f or a n A ltivar 7 1 D rive To configure the drive interface for an Altivar 71 drive: 1. In the Drive Interface pane, click the Drive Interface Type field. The Drive Type dialog box appears. 2. Select Altivar 71 Modbus from the list and click OK. 3. The drive address is set to 2 on the Altivar 71 in the factory and it is recommended that this not be changed. To change the drive address on an Altivar 71, consult the documentation that came with the drive. 4. Click the Set Drive Defaults needed for SCADAPack Control of Drive button to set the drive defaults. 5. If you are replacing the Altivar 71 or configuring a drive from factory settings, ensure the Altivar 71’s communication parameters are set as follows: Drive Menu > 1.9 Communications > Modbus Network Modbus Address: 2 Modbus Baud Rate: 38.4 kbps Modbus format: 8-N-1 Modbus time out: 2 seconds

4.1.2

Configuring the Interface for a Generic Drive To configure the drive interface for a generic drive: 1. In the Drive Interface pane, click the Drive Interface Type field. The Drive Type dialog box appears. 2. Select the drive type from the list and click OK: — Generic Analog 0-20mA — Generic Analog 4-20mA.

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3. In the Drive Interface pane, click the Min Speed field and enter a value for the minimum drive speed at 0 or 4 mA in the Drive Speed dialog box that appears (see Figure 4.2). Fig ure 4.2 : Dri ve S pee d Di alo g Box

4. Click OK. 5. Click the Max Speed field and enter a value for the maximum drive speed at 20 mA in the Drive Speed dialog box that appears. 6. Click OK.

4.1.3

Configuring the Interface for a Starter or Contactor To configure the drive interface for a starter or contactor: 1. In the Drive Interface pane, click the Drive Interface Type field. The Drive Type dialog box appears. 2. Select Starter or Contactor from the list and click OK.

4. 2

External Control Wiring On the Drive Configuration page, you can also set the following SCADAPack 535 E digital inputs:

•

•

Bypass Contactor (DI-12): You can click the Bypass Contactor (DI-12) field and select No Bypass Connector, Active Low, or Active High. When the Bypass Contactor (DI-12) is active (either Active High or Active Low), it will stop the Realift Rod Pump while it is running, or prevent the Realift Rod Pump from running if it is not running, and be reported as a status in the HMI software. The Bypass Contactor is intended to indicate to the Realift Rod Pump that the drive is disconnected from the pump motor. External Fault Trigger (DI-15): You can click the External Fault Trigger (DI-15) field and select either Active Low or Active High. The external fault trigger can be any external device, sensor, or series of devices connected to DI-15. When the external fault trigger (DI-15) is active (either Active High or Active Low), it will stop the Realift Rod Pump while it is running, or prevent the Realift Rod Pump from running if it is not running, and be reported as a status in the HMI software.


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5


Configuring Pump Control

After you test Realift Rod Pump operation, you can begin to configure the pump settings. You configure the pump settings using the Pump Control Configuration page (Figure 5.1) in the Realift Rod Pump HMI commissioning software. Pump Control settings determine, at a high level, how the Realift Rod Pump controls the pump jack, including:

• • • • Figu re 5.1:

Control Mode type used When different controls take effect When speed is adjusted How long the Realift Rod Pump system runs with a low pump fill before stopping and entering a Pump Off state.

Pump Control Configurati on Page


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5.1

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Setting the Control Mode The General Control pane, shown in Figure 5.2, displays the Selected Control Mode, the Current Control Mode, and the Produced Resource. Fig ure 5.2 :

Gen era l Con tro l Pa ne

To define the parameters in the General Control pane:

•

Click Pump Control Configuration in the Navigation pane. The General Control pane is displayed in the Pump Control Configuration page, as shown in Figure 5.1. The parameters are explained in the following sections.

Selected Control Mode To set the control mode:

•

Click Selected Control Mode and select one of the following modes: — Timed:The Realift Rod Pump operates as a timer, running for Pump On Time and stopping for Pump Off Time, both of which are fixed, user-entered values. — Torque:The Realift Rod Pump system repeats cycles of running until the Torque Fill falls below the Torque Fill Minimum for the Pump Off Count Limit, remaining off for Pump Off Time. While running, speed is increased if the Torque Fill is above the Torque Fill Target and decreased if below the target. This control mode is only supported by systems using the Altivar 71 drive. — Surface:The Realift Rod Pump system repeats cycles of running until the Surface Fill falls below the Surface Fill Minimum for the Off Count Limit, Fill remaining Pump OffifTime. While running, speed is increased if the Surface FillPump is above the Surface Target off andfor decreased below. — Downhole:The Realift Rod Pump system repeats cycles of running until the Downhole Fill falls below the Downhole Fill Minimum for the Pump Off Count Limit, remaining off for Pump Off Time. While running, speed is increased if the Downhole Fill is above the Downhole Fill Target and decreased if below.

Current Control Mode The Current Control Mode field displays the currently selected control mode. If the value in Selected Control Mode displayed does not match the value in Current Control Mode, refer to Configuring Well Fault Detection on page 67. Produced Resource The Produced Resource displays the type of resource produced by the pump. This is set to “Oil.”

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5. 2


Setting On & Off Times In the On & Off Time Settings pane, shown in Figure 5.3, you can set on and off time settings. Fig ure 5 .3:

On & Of f Tim e Set tin gs Pa ne

To define on and off time settings:

•

Click Pump Control Configuration in the Navigation pane. The On & Off Time Settings pane is displayed in the Pump Control Configuration page, as shown in Figure 5.1. The parameters are explained in the following sections.

Auto Off Time Adjust Auto Off Time Adjust determines whether the system adjusts Pump Off Time based on operating conditions. The On setting tells the Realift Rod Pump to add additional Pump Off time if the Fill Status is less than the Fill Target when it restarts after Pump Off (and completes Pre-Control Strokes). Off Time is added if the well’s reservoir is not given sufficient time to replenish to a point where Fill Status achieves Fill Target after restarting. Similarly, the Realift Rod Pump subtracts time if the pump fill is greater than the Fill Target after a Pump Off period and after Minimum Strokes complete. It is recommended that Auto Off Time Adjust be turned On for routine operation. If this setting is On, you will also need to configure Auto Adjust Min Off Time and Max Off Time. Off Time (non-Timed) Off Time determines the amount of time the system waits in Pump Off mode before restarting in any non-timed setting (Torque, Surface, or Downhole). Set Off Time to a value that allows the well reservoir to replenish sufficiently so that the pump jack restarts and resumes at the desired production level. If Auto Off Time Adjust is on, this value may increase or decrease incrementally as Realift Rod Pump evaluates Fill Status. If Auto Off Time Adjust is on, the value of Off Time (Non-Timed) cannot be lower than the value of Auto Adjust Min Time. Realift Rod Pump will automatically change it to match the value of Auto Adjust Min Time. Off Time (Non-Timed) is defined in minutes (min). The suggested value at start up is 30 minutes, but can vary depending on the time necessary for the well’s reservoir to replenish. Auto Adjust Max Off Time Auto Adjust Max Off Time is the upper limit of Pump Off Time when in Auto Off Time Adjust Mode. Off Time automatically increases incrementally to adapt to reservoir state until desired Fill Status is achieved or it reaches the upper limit. The Auto Adjust Max Off Time is defined in minutes (min). The suggested value is 90 minutes.


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Auto Adjust Min Off Time Auto Adjust Min Off Time is the lower limit of Pump Off Time when in Auto Off Time Adjust Mode. Off Time automatically decreases incrementally to adapt to reservoir state until desired Fill Status is achieved or it reaches the lower limit. The Auto Adjust Min Off Time is defined in minutes (min). The suggested value is five minutes.

UNINTENDED EQUIPMENT OPERATION Enter values for Off Time (Timed Mode) and On Time (Timed Mode) even if a Control Mode other than Timed is used. If the load cell, proximity sensor, or both sensors stops transmitting a signal, the Realift Rod Pump reverts to the next available Control Mode, which may be Timed mode. Failure to follow these instructions can result in equipment damage. Off Time (Timed Mode) Because a loss of communication with the load cell or proximity sensor will cause the system to revert to Timed mode, it is important to define Off Time (Timed Mode) and On Time (Timed Mode). Set this parameter large enough for the pump to refill to the desired pump fill before restart. The Off Time (Timed Mode) is defined in minutes (min). The suggested value is the time (including Pump On Time) that results in a run percentage equal to or slightly less than the run time required to keep up with reservoir production. If it is desired that the system pump off periodically when in Timed mode, you can set Off Time (Timed Mode) to a non-zero value. Set it large enough for pump fill to increase slightly during the idle period. This will reduce fluid pound and hammer. On sandy wells where the pump might bind when stopped, it may be preferable to set the pumping unit to never stop. you desirespeed a fall-back state whereas the systemtoruns continuously, case,Ifthe Startup can be reduced needed reduce hammer. set Off Time (Timed Mode) to zero. In this Off Time (Timed Mode) and On Time (Timed Mode) are not affected by the Auto Off-time adjust. On Time (Timed Mode) Because a loss of communication with the load cell or proximity sensor will cause the system to revert to timed mode, it is important to define Off Time (Timed Mode) and On Time (Timed Mode). On Time is the amount of time the pump runs in Timed Mode. Select an appropriate On Time, even if Timed is not the preferred mode. The On Time (Timed Mode) is defined in minutes (min). The suggested value is 30 minutes. Off Time (Timed Mode) and On Time (Timed Mode) are not affected by the Auto Off-time adjust.

5. 3

Setting Pump Speeds In the Speed Settings pane, illustrated in Figure 5.4, you can set speed values for pump jack operation. You do not need to set speed setting values when you first configure the pump and run it in hand mode. However, the speed settings need to be set before the Realift Rod Pump will operate in auto mode. You should enter them after observing pump jack operation. See Configuring the Pump Jack for Standard Operation on page 73.

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The speed settings are not used if you have selected starter or contactor on the Drive Configuration page. Fig ure 5.4 :

Spe ed Sett ing s Pa ne

Startup Speed The Startup Speed is the system speed when starting in Auto Mode. The system maintains this speed until the pump completes a selected number of strokes (Pre-Control Strokes), at which point the Realift Rod Pump adjusts speed to the range defined by Minimum Speed and Maximum Speed. In Timed mode, the system runs at Startup Speed until it reaches On Time, after which, it stops. The Startup Speed is defined by default in Hertz (Hz), but it can be changed by clicking the Units for Speed Settings box. The suggested value is at or above the mid-point of the range between Minimum Speed and Maximum Speed. If Startup Speed is set to 0, RPC Status displays No-Run. Maximum Speed The Maximum Speed is the fastest drive speed when the pump is in Auto Mode and is adjusting the speed based on the pump fill. It limits the upper end of pump jack speed so that it does not operate faster than the pump jack’s capabilities. The Startup Speed is defined by default in Hertz (Hz), but it can be changed by clicking the Units for Speed Settings box. If you are using a generic drive, do not confuse the Maximum Speed setting with Max Speed (Defining the Drive Interface on page 40), the maximum speed at which the Realift Rod Pump operates under any conditions. Max Speed takes precedence (defined on the Configuration Page), even if Maximum Speed is set higher. If you are using an Altivar 71, the Altivar 71 uses the Maximum Speed (defined directly on the Altivar 71 by selecting 1. Drive Menu > 1.1 Simply Start > High Speed) as the Max Speed when operating in hand mode. The value varies depending on well conditions, but should not exceed the Max Speed defined on the Drive Configuration Page (Defining the Drive Interface on page 40). Minimum Speed Minimum Speed is the slowest drive speed when the Realift Rod Pump is operating in Auto Mode and adjusting speed based on the pump fill. The Startup Speed is defined by default in Hertz (Hz), but it can be changed by clicking the Units for Speed Settings box. The Minimum Speed varies, but should be set to a point equal to or below Startup Speed. Units for Speed Settings Units for Speed Settings determines whether speed is displayed as Hz or SPM (Strokes per Minute). SPM:Hz Ratio The SPM:Hz Ratio is a calculated ratio of drive output frequency in Hz compared to theratio pump jack speedauto in Strokes per Minute (SPM). It is strongly recommended that you calculate the SPM:Hz prior to using mode so that the values calculated by Realift Rod Pump correspond to actual measurements. The ratio is calculated in step 2 of the procedure described in Setting the Fill Control Levels on page 75.


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Setting Fill Controls You need to set two parameters for each control mode used in the Fill Control Settings pane (Figure 5.5). These parameters are used to determine whether pumping should stop or change speed: Fill Target and Fill Minimum. The control modes and parameters are explained in the following sections. Fig ure 5. 5:

5.4.1

Fil l Con tro l Set tin gs Pan e

Torque If operating in Torque mode, you only need to set the Fill Minimum and Fill Target parameters for Torque. Torque mode is only supported by systems using the Altivar 71 drive. Fill Minimum Fill Minimum provides a point where the Realift Rod Pump system detects a Pump Off state. If the pump fill is less than the Fill Minimum for the Pump Off Count Limit number of strokes, then the Realift Rod Pump stops the pump jack and remains idle for Pump Off Time. The lower the Fill Minimum, the less likely it is that the Realift Rod Pump enters a Pump Off state. It is recommended that you enter a Fill Minimum from 15% to 30% below the value set at commissioning. Fill Target The Fill Target represents the ideal fill level for the rod pump. If the calculated fill status of the rod pump exceeds the fill target, the frequency of rod pump will increase (up to the defined maximum speed, see Maximum Speed on page 47). If the calculated fill status is lower than the fill target, the frequency of rod pump will decrease (down to the defined minimum speed, see Minimum Speed on page 47) until it the pump fill again matches the fill target. The Fill Target value is determined through observation after configuration is complete and the Realift Rod Pump is started for initial monitoring. See Configuring the Pump Jack for Standard Operation on page 73. Fill Status The Fill Status fields provide ongoing readings of the current Fill Status reported by the Realift Rod Pump.

5. 4. 2

Surface If operating in Surface mode, you need to set both Surface and Timed modes. The drive reverts to Timed mode if the load cell signal is lost.

RISK OF EQUIPMENT DAMAGE In the event that the load cell signal is lost and Timed mode is not set, equipment damage can occur. Set Timed mode as well, when you are using Surface mode. Failure to follow these instructions can result in equipment damage.

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Fill Minimum Fill Minimum provides a point where the Realift Rod Pump system detects a Pump Off state. If the pump fill is less than the Fill Minimum for the Pump Off Count Limit number of strokes, then the Realift Rod Pump stops the pump jack and remains idle for Pump Off Time. The lower the Fill Minimum, the less likely it is that the Realift Rod Pump enters a Pump Off state. It is recommended that you enter a Fill Minimum from 15% to 30% below the value set at commissioning. Fill Target The Fill Target represents the ideal fill level for the rod pump. If the calculated fill status of the ro d pump exceeds the fill target, the frequency of rod pump will increase (up to the defined maximum speed, see Maximum Speed on page 47). If minimum the calculated fillsee status is lowerSpeed than the target, of fill rodagain pumpmatches will decrease the defined speed, Minimum on fill page 47) the untilfrequency it the pump the fill (down target. to Fill Target values are determined through observation after commissioning is complete and the Realift Rod Pump is started for initial monitoring. See Configuring the Pump Jack for Standard Operation on page 73. Fill Status The Fill Status fields provide ongoing readings of the current Fill Status reported by the Realift Rod Pump.

5.4.3

Downhole If operating in Downhole mode, you need to set both Downhole and Timed modes. The drive reverts to Timed mode if the load cell signal is lost.

RISK OF EQUIPMENT DAMAGE In the event that the load cell signal is lost and Timed mode is not set, equipment damage can occur. Set Timed mode as well, when you are using Downhole mode. Failure to follow these instructions can result in equipment damage. Fill Minimum Fill Minimum provides a point where the Realift Rod Pump system detects a Pump Off state. If the pump fill is less than the Fill Minimum for the Pump Off Count Limit number of strokes, then the Realift Rod Pump stops the pump jack and remains idle for Pump Off Time. The lower the Fill Minimum, the less likely it is that the Realift Rod Pump enters a Pump Off state. It is recommended that you enter a Fill Minimum from 15% to 30% below the value set at commissioning. Fill Target The Fill Target represents the ideal fill level for the rod pump. If the calculated fill status of the ro d pump exceeds the fill target, the frequency of rod pump will increase (up to the defined maximum speed, see Maximum Speed on page 47). If the calculated fill status is lower than the fill target, the frequency of rod pump will decrease (down to the defined minimum speed, see Minimum Speed on page 47) until it the pump fill again matches the fill target. Fill Target values are determined through observation after commissioning is complete and the Realift Rod Pump is started for initial monitoring. See Configuring the Pump Jack for Standard Operation on page 73. Fill Status The Fill Status fields provide ongoing readings of the current Fill Status reported by the Realift Rod Pump.


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Setting Startup Timers In the Startup Timers pane, illustrated in Figure 5.6, you can define the start times of the timers described in this section. If a specific timer is not needed, you can disable it by setting its value to 0. Fig ure 5.6 :

Sta rtu p Ti mers Pa ne

Power Cycle Start Delay This setting helps prevent multiple pump jacks from restarting simultaneously when power is restored after a power outage. This guards against high startup current consumption and harmonics. The Power Cycle Start Delay is defined in seconds (sec). You should stagger start times of multiple units so that they start one at a time with a suggested interval of 30 seconds between starts. Start Warning Time If a start warning indicator (SWI), such as a horn or flashing light is used, you can set the amount of time the unit delays starting up while the SWI operates. The Start Warning Time is defined in seconds (sec). Connecting the SWI to the SWI relay is explained in the Realift Rod Pump Hardware Installation Manual. The suggested time is in the range of five to ten seconds. Start Reverse Time In some situations, the pump should run backwards for a partial stroke when it restarts after a Pump Off period to free any trapped gas. The pump then resumes normal forward operation. The Start Reverse Time is defined in seconds (sec).

RISK OF EQUIPMENT DAMAGE Certain sucker rod pumps are not designed for reverse operation. Attempting to run these rod pumps in reverse operation can result in equipment damage. Failure to follow these instructions can result in equipment damage. You can set Start Reverse time to run the pump backwards for the desired time. If the SPM value is known, you can use it to calculate the proper time setting to achieve the desired rotation. The suggested time is zero to five seconds.

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5. 6


Setting Control Triggers In the Control Triggers pane, Figure 5.7, set the control triggers as follows. Figure 5 .7:

Con tro l Tri gge rs Pa ne

Pre-Control Strokes It is usually desirable to allow the pump jack to run for a number of strokes immediately following restart. This allows the system to reach normal operating state and ignore any initial system instability before the Realift Rod Pump makes speed adjustments to the pump. The Pre-Control Strokes is defined in strokes. Suggested strokes vary with time required for any start-up transients to disappear, but a typical value is 20 strokes. Speed Change Strokes The number of strokes run between speed changes. The Realift Rod Pump can adjust speed with every stroke; however, you may prefer that speed be adjusted once every 5 or 10 strokes. The Speed Change Strokes is defined in strokes. Speed is adjusted by the amount of the speed range (the difference between Maximum Speed and Minimum Speed) proportional to how much Fill Status differs from Fill Target. If Fill Status suddenly drops to a value much lower than Fill Target (for example, from 83% to 55% while Fill Target is 85%) and if speed is set to adjust with every stroke, the Realift Rod Pump immediately reduces speed by a large amount to minimize fluid pound and equipment wear. The suggested setting is one stroke. Pump Off Count Limit When pump detects a persistent pump fill at less than the Fill Minimum (as in a Pump Off situation), you should set the number of strokes the pump continues to run before it finally switches to Pump Off. This allows the pump to run through temporary gas pockets or other anomalies affecting pump fill but not serious enough to warrant pumping off. The Pump Off Count Limit is defined in strokes. The suggested setting is three strokes.

RISK OF EQUIPMENT DAMAGE Operating at less than the fill minimum increases the possibility of damage to the rod pump. Set the Pump Off Count Limit to a limit low enough to protect the equipment. Failure to follow these instructions can result in equipment damage.


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6


Configuring Well Data

After you configure the pump settings, you return to the Well Data Configuration page (see Figure 6.1) to configure well data. You can return to the Well Data Configuration page by clicking the Well Data Configuration icon on the navigation pane. The Well Data Configuration page appears, as shown in Figure 6.1. Figure 6. 1:

Well Data Co nfi gurati on Pa ge

6. 1

Using API Dimensions in S urface or D ownhole Mode Using API (American Petroleum Institute) dimensions is the preferred method for determining Stroke Length in Surface or Downhole mode. These dimensions are entered in the Pumping Unit Information Pane, shown in Figure 6.2.


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R e aRP liofutdmp C h a p t— C e 6o r n f ig u r inW g eDlla ta

Figu re 6.2:

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Pumping Unit Informati on Pane

API dimensions are a series of six measurements on a typical pump jack, used to calculate Stroke Length based on the geometry of the pump jack unit: • Rn —Distance from the center of the crankshaft to the center of the Pitman Arm wrist pin in inches, where n = the corresponding pin position

• • • • •

K —Distance from the center of the crankshaft to the center of the saddle bearing, in inches C —Distance from the center of the saddle bearing to the center of the equalizer bearing, in inches P —Effective length of the Pitman, in inches A —Distance from the center of the saddle bearing to the center line of the polished rod, in inches I —Horizontal distance between the center line of the saddle bearing and the center line of the crankshaft, in inches.

RISK OF EQUIPMENT DAMAGE Ensure that the pumping unit information is accurate. Inaccurate pumping unit information can negatively affect the operation of the rod pump and, in some cases cause equipment damage. Failure to follow these instructions can result in equipment damage. Some pump jack manufacturers provide the API dimensions for the units they manufacture. If this data is available, enter it into the appropriate fields in the Realift Rod Pump HMI Software. In some instances, the K value may not be given, but it can be calculated if I, G (distance from crank axis to bottom of frame, in inches), and H (distance from saddle bearing axis to bottom of frame, in inches) are known, using the following equation. Fig ure 6.3 :

K=

Equ ati on t o Cal cul ate K 2

[(H-G) +I ]

2

During the installation of the Realift Rod Pump HMI software, a spreadsheet was installed with the API dimensions of the most common rod pumps. You can find it in the Schneider Electric Realift Rod Pump installation directory.

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Fig ure 6 .4:

Con ven tio nal P ump Jac k C A

P K

H

If H, I, and G are known, K can be calculated

G R1 , R2 , or R n

I Fig ure 6 .5:

Air -Ba lan ced P ump Jac k

C

A

K

P

H

G

R1, R2 , or Rn

I



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Figure 6.6 :

Mar k II Pump Jac k

C A

K

P

H

G R1, R2 , or Rn

I


To enter the API dimensions: 1. Click the Enter API Dimensions button. 2. Enter the appropriate measurements for the part icular pump jack. 3. Change Stroke Length Method to Using API. If any of the API dimensions are left blank (i.e., “0”), the Stroke Length Method will be set to Not Using API and cannot be changed until correct API dimensions are entered.

6. 2

Setting a Measured Stroke Length (Torque) When operating in Torque mode (or if API dimensions are unavailable), you will use a measured stroke length. You use API dimensions whenever operating in Surface or Downhole mode. Using a measured stroke length assumes that the up and down motion of the rod string follows a sinusoidal pattern. Differences in pump jack geometry mean this is often not the case, and surface and downhole card shapes can be distorted. When you set a measured stroke length, you will set the parameters in the Pumping Unit Information section. Figure 6. 7:

Pumpin g Unit In for mat ion

Stroke Length Determine the stroke length using the Stroke Length diagram, Figure 6.8.

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Fi gu re 6. 8:

St ro ke Le ng th

Polished Rod

BottomofStroke

Stroke Length

TopofStroke

Stroke Length Method The Stroke Length Method box indicates the method used to calculate the stroke length. In this case, it displays “Not Using API.” If you want to use API dimensions, click Enter API Dimensions and follow the instructions in section 6.1: Using API Dimensions in Surface or Downhole Mode on page 53. Direction of Rotation Click the Direction of Rotation button and select the direction. The crank arm direction of rotation is either clockwise or counterclockwise when the pump jack is viewed from the side, as in Figure 6.8, with the polished rod on the right. SPM:Hz Ratio Parameter Click the Calibrate button to have the Realift Rod Pump calculate the SPM:Hz ratio. The SPM:Hz Ratio is a calculated ratio of motor speed in Hz compared to pump jack speed in Strokes per Minute (SPM). You can also calculate the SPM:Hz Ratio by counting the actual number of strokes per minute and comparing these to motor speed. Calibration using this method is discussed in Step 2 on page 78.

6. 3

Setting the Proximity Angle In the Sensor and Enclosure Configuration Data Pane, Figure 6.9, first determine the proximity angle, using the procedure in this section, and then enter the resultant value into the Proximity Angle field. Figu re 6.9:

Sensor and En closu re Conf iguration D ata Pan e

The Realift Rod Pump uses the Proximity Angle to determine the location of the center axis of the Pitman Arm wrist pin relative to the position at which the crank arm first triggers the proximity sensor. The Proximity Angle is measured from bottom dead center (BDC) in a counter-clockwise direction when viewing the pump jack from its side with the polished rod on the right, as shown in Figure 6.4. Figure 6.10, Proximity Angle, Conventional Pump Jack, shows this in more detail.


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Figure 6.10: Proximity Angle, Conventional Pump Jack

Pitman Arm Gear Box

Crank Axis

Proximity Sensor

Wrist Pin Pump Jack Base Crank Arm

Proxmity Angle BDC (0 )

Rotation (CCW)

The Proximity Angle should be between 0° and 90° (absolute value) when the proximity sensor is mounted below the level of the crank axis, as in Figure 6.10. In certain instances it may be necessary to mount the proximity sensor above the crank axis; if this is the case, the absolute value will be between 90° and 180°. The direction of rotation dictates whether the Proximity Angle is positive or negative. In Figure 6.10, the crank arm is rotating counter-clockwise and triggers the proximity sensor after it passes BDC. The Proximity Angle in this instance is positive (+). Alternately, if the crank arm is rotating clockwise, triggering the proximity sensor before passing BDC, the Proximity Angle is negative (-). Set the Proximity Angle by determining the point at which the crank arm first triggers the proximity sensor during a stroke. It is recommended that someone else operate the pump jack hand brake when performing the following procedure: 1. Using the potentiometer on the Realift Rod Pump enclosure, set pump jack speed at or just above its minimum value. 2. Using the HOA switch (see Testing Realift Rod Pump System Operation on page 81) place the Realift Rod Pump in Hand mode and slowly rotate the crank arm.

WARNING UNEXPECTED EQUIPMENT OPERATION • Read and understand this manual before operating the Realift Rod Pump system. • Ensure that the pump jack is stopped with handbrake engaged before approaching it to make observations, take measurements, or adjust the equipment. Failure to follow these instructions can result in minor or moderate injury. 3. Switch HOA to Off as the helper quickly applies the pump jack brake, stopping the crank arm just as it triggers the proximity sensor.

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4. After the pump jack is stopped with the hand brake engaged, confirm that the LED indicator on the base of the proximity sensor is lighted, as shown in Figure 6.11. Figure 6.11: Location of LED Indicators on Base of Proximity Sensor

With the crank arm held in place by the hand brake, the Proximity Angle can now be determined (see Figure 6.12).

•

If you have access to a hand-held protractor with plumb-bob or similar tool (there are also a number of smart phone applications that do this), use this tool to measure the angle from vertical (BDC, or 0°) to the center axis of the wrist pin to obtain the Proximity Angle in degrees (°).

RISK OF INACCURATE DATA The proximity angle is used in calculations to determine the load and the productivity of the well. Ensure that any tools you use to determine the proximity angle have been properly calibrated. Failure to follow these instructions can result in inaccurate data.

•

If no such tool is available, calculate the Proximity Angle by measuring the distance Y from the crank axis to a point yourpin choosing axis, thenismeasuring at a right to the center axis of theof wrist to obtainalong X (if the the vertical proximity sensor mounted above theangle Crankfrom Axis,that thepoint procedure is still the same).


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Figure 6.12: Measuring the Proximity Angle (Proximity Sensor Activated after Straight-down Position

Crank Axis Proxmity Angle Proximity Sensor

Y

Wrist Pin

X

BDC (0 )

Rotation (CCW)

Calculate X÷Y and look up the corresponding angle value in Table 6.3. Use the left hand column of the table if the Proximity Sensor is mounted below the Crank Axis, and the right hand column if it is above the Crank Axis. Check whether the crank arm triggers the proximity sensor before or after it passes BDC and enter the correct sign (+ or -) as per the table. Tab le 6.3 : Angle in Degrees

X/Y Below Crank Axis

0

0.00

90

5

0.09

92.5

22.90

10

0.18

95

11.43

15

0.27

100

5.67

20

0.36

105

3.73

25

0.47

110

2.75

30

0.58

115

2.14

35

0.70

120

1.73

40

0.84

125

1.43

45

1.00

130

1.19

50

1.19

135

1.00

55

1.43

140

0.84

60

1.73

145

0.70

65

2.14

150

0.58

70

2.75

155

0.47

75

3.73

160

0.38

80

5.67

165

0.27

85

11.43

170

0.18

87.5

22.90

175

0.09

(Y=0)

180

0.00

90

60

Pro ximity Ang le Cal cul ati on

∞

Angle in Degrees

X/Y Above Crank Axis (Y=0)

∞


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If the proximity sensor is triggered before the wrist pin reaches bottom dead center, the proximity angle is negative (-). the proximity sensor is triggered after the wrist pin reaches bottom dead center, the proximity angle is positive (+).

6. 4

Setting the Proximity Angle (Mark II Pump Jack) The location of the Pitman Arm wrist pin can vary by design. The Mark II pump jack places the wrist pin on the opposite side of the crank axis from the portion of the arm that is likely to trigger the proximity sensor. The angle that should be entered is the angle of the wrist pin side of the crank arm relative to BDG when the proximity sensor is triggered. (see Figure 6.13). Figu re 6.13: Mark II P ump Jac k

Proxmity Angle (- 165 )

Wrist Pin Crank Axis

Proximity Sensor

Rotation (CCW)

BDC (0 )

6. 5

Setting the Proximity Debounce Time The Realift Rod Pump requires only one signal from the proximity sensor per rotation of the crank arm. The design of some crank arms may be such that the proximity sensor is triggered more than once as the arm passes by (see Figure 6.14).


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Figure 6.14: Multiple Triggering of Proximity Sensor

Crank Arm Cross Section

Proximity Sensor Rotation In such instances, set the Proximity Debounce Time to an interval long enough so that any subsequent triggering of the proximity sensor is ignored until the rotation is complete. The default Debounce Time is 3000 ms (3 sec.), but this value can be adjusted.

WARNING UNEXPECTED EQUIPMENT OPERATION • Read and understand this manual before operating the Realift Rod Pump system. • Ensure that the pump jack is stopped with handbrake engaged before approaching it to make observations, take measurements, or adjust the equipment. Failure to follow these instructions can result in death or serious injury. To adjust the debounce time: 1. Release the hand brake and using the HOA switch, set the pump jack back into motion.

UNEXPECTED EQUIPMENT OPERATION Do not operate the pump jack at speeds too slow to allow for proper lubrication of the gear box. Failure to follow these instructions can result in equipment damage. 2. Slow the pump jack down to the slowest speed at which you intend to operate the unit. This should be roughly the same as the Minimum Speed as set on page 98, Set Pump Speeds. 3. While operating at slow speed, time the interval necessary for the crank arm to pass completely clear of the proximity sensor. 4. Set the Proximity Debounce Time to an interval that is longer than the time required for the crank arm to clear the proximity sensor, but not so long that the sensor cannot reset before the next rotation should speed be increased during normal operation of the Realift Rod Pump. A debounce time of less than 3 seconds is not recommended.

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6. 6


Setting the Load Cell Size You enter the size of the load cell on the Realift Rod Pump in the Sensor and Enclosure Configuration Data pane of the Well Data Configuration page (see Figure 6.9). Load Cell Size The Downhole Realift Rod Pump system uses force measurements from a load sensor (load cell) mounted on the pump jack’s polished rod as its basis for control. To enter the Load Cell Size, click the Load Cell Size field and enter the load cell size (either 30 klb or 50 klb, depending on your load cell) in the Load Cell Size dialog box that appears and press Enter. [Units: thousands of pounds (klb), minimum: 0, maximum: 200, default: 0]

6.7

Entering D ownhole C alculation P arameters Enter the Downhole Calculation Parameters, Figure 6.15. Figure 6.15: Downhole Calculation Parameters Pane

Damping Factor The Damping Factor is the downhole calculation parameter that affects the shape of the Downhole Card. A typical value is 0.080, although the Damping Factor can be adjusted to correct the shape of the Downhole Card. The suggested value is 0.080. Rod String Speed of Sound The Rod String Speed of Sound is the velocity of sound traveling in the rod material. For steel, this value is approximately 16300 ft/sec; for fiberglass, approximately 14900 ft/sec. The Rod String Speed of Sound is defined in feet per second (ft/sec). Tubing Fluid Gradient The Tubing Fluid Gradient exerts pressure by a vertical foot of fluid in the well tubing. A typical value, which depends on rod and tubing diameters and fluid characteristics, falls within 0.400 to 0.420 psi/ft. The Tubing Fluid Gradients is defined in pounds per square inch per foot (psi/ft). The recommended value is 0.4, unless more is known about system geometry and fluid characteristics. Casing Fluid Gradient The Casing Fluid Gradient exerts pressure by a vertical foot of fluid in the well casing, excluding tubing. A typical value is from 0.400 to 0.430 psi/ft, although this depends on casing and tubing diameters and fluid characteristics. The Casing Fluid Gradient is defined in pounds per square inch per foot (psi/ft). The recommended value is 0.4 psi/ft, unless more is known about system geometry and fluid characteristics. Copyright © 2014 Schneider Electric Canada Inc.

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Pump Diameter The Pump Diameter is the inside diameter of the pumping chamber in the pump at the bottom of the well. The Realift Rod Pump calculates the Pump Area from the Pump Diameter to estimate production. The Pump Diameter is defined in inches (in). Enter the diameter of the pump currently installed in the well. Pump Efficiency Factor The Pump Efficiency Factor is multiplied by the theoretical production to result in the Realift Rod Pump production values. The Pump Efficiency Factor is defined as a percentage (%). When you modify the Pump Efficiency Factor, the Realift Rod Pump production values do not update immediately but take time to update. It suggestedtotoactual set the value to 80%, until enough time elapses Realiftaccordingly. Rod Pump estimated production can beiscompared production and the Pump Efficiency Factorthat adjusted Include Buoyancy in Calculation Include Buoyancy in Calculation determ ines whether the RealiftRod Pump includes the effects of buoyancy in computing the Downhole Card. Select Yes or No. Set to No, unless you include buoyancy in the load results on the Downhole Card.

6. 8

Entering W ellhead I nformation P arameters Enter the Wellhead Information Parameters, as shown in Figure 6.16. Figure 6.16: Wellhead Information Pane

Stuffing Box Friction Stuffing Box Friction is the term for load cell data based on friction where the polished rod enters the stuffing box. When the rod moves downward, the amount of force is added to the load cell reading. When the rod moves upward, the amount of force is subtracted from the load cell reading. The Stuffing Box Friction is defined in pounds (lbs). The suggested value is from 50 to 100 pounds. Casing Pressure at Surface The Casing Pressure at Surface is the gas pressure found at the surface in the well casing (a pressure gauge can be plumbed into the system at the wellhead). The Casing Pressure at Surface is defined in pounds per square inch (psi). Enter the value measured by the pressure gauge, or enter a value in the 50 to 150 psi range. Tubing Pressure at Surface The Tubing Pressure at Surface is the gas pressure found at the surface in the well tubing (a pressure gauge can be plumbed into the system at the wellhead). The Tubing Pressure at Surface is defined in pounds per square inch (psi). Enter the value measured by the pressure gauge, or enter a value in the 50 to 150 psi range.

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6. 9


Entering Rod Taper Parameters In the Rod Taper Information pane, enter the Rod Taper parameters, as shown in Figure 6.17. Figure 6.17: Rod Taper Information Pane

Number of Tapers The Number of Tapers is the number of rod string sections currently installed in the well, with a value ranging from one to six. (Taper) Length The Taper Length is the length of the rod string sections in the well. The (Taper) Length is defined in feet (ft). (Taper) Diameter The Taper Diameter is the diameter of the rod string sections in the well, excluding joints. The (Taper) Diameter is defined in inches (in). (Taper) Weight The Taper Weight is the weight per foot of the rod tapers in the well. The (Taper) Weight is defined in pounds per foot (lbs/ft). See Table 6.4 for fiberglass and steel weights for typical rod sizes. Ta ble 6. 4:

We ig ht Ta bl e

Rod S ize (in)

We igh ts , F ib er glas s ( lbs/ f t)

3/4

0.47

1.634

7/8

0.64

2.224

1

0.79

2.904

1.2

1.22

4.07

1.25

1.34

4.55

1.5

1.91

6

1.625

2.09

7


Weigh t, S te el ( lbs /ft )

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(Taper) Modulus The Modulus is the elasticity of the material of the rod string sections in the well. The Modulus for steel is 30.5 Mpsi. For fiberglass, it is 7.2 Mpsi. The (Taper) Modulus is defined in millions of psi (Mpsi).

RISK OF EQUIPMENT DAMAGE Ensure that the rod taper information is accurate. Inaccurate rod taper information can negatively affect the operation of the rod pump and, in some cases cause equipment damage. Failure to follow these instructions can result in equipment damage.

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7


Configuring Well Fault Detection

On the Well Fault Detection page (see Figure 7.1), you can set operational limits that define when the Realift Rod Pump stops the pump to avoid hardware damage if well operating conditions fall outside these limits.

WARNING UNEXPECTED EQUIPMENT OPERATION • Read and understand this manual before operating the Realift Rod Pump system. • Any changes made to parame ter settings must be perf ormed by qualified personnel. Failure to follow these instructions can result in death or serious injury. Fig ure 7 .1:

Wel l Fau lt Det ect ion P age

The system reports a Well Alarm or Well Fault when a data value consistently falls outside of a defined range for a specified period of time or number of strokes. Well faults and alarms apply in both hand and auto mode. Changing the Realift Rod Pump from Auto to Hand mode while it is running resets the current values of the well alarm detection count to zero, but not the current values of the well fault detection count. Changing the Realift Rod Pump from Auto to Hand mode while it is in a pump-off state, for example, due to an alarm or a fault state, clears any existing alarms or faults and causes the pump to restart.


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Well Alarm and Well Fault detection parameters are described in Table 7.5: Tab le 7. 5: Para meter

Per S tro ke an d Rea l-Time Ala rm P ara met ers Per Stroke Alarm Descriptio n

Real-Time Alar m Descriptio n

Enable

Detection is enabled when the check box is selected.

Detection is enabled when the check box is selected.

Startup Ignore

Upon startup, the number of strokes to ignore before detection begins.

Upon startup, the number of seconds to wait before detection begins.

Threshold Value

The value that must be exceeded to cause the Detection Count to increment.

The value that must be exceeded to cause the Detection Count to increment.

Once Detection Count begins, the Well Alarm number of strokes to be counted Detection Count, before a Well Alarm condition is Limit Value reported. The number of consecutive Well Well Fault Alarms the Realift Rod Pump allows Detection Count, before it reports a Well Fault and Limit Value ceases to attempt to restart, requiring manual intervention.

Once Detection Count begins, the number of seconds to wait before a Well Alarm condition is reported. The number of consecutive Well Alarms the Realift Rod Pump allows before it reports a Well Fault and ceases to attempt to restart, requiring manual intervention.

If Pump Off Time is zero it will not shut down due to pump off, unless a per stroke or real-time alarm occurs and, in that case, then a pump off time of 1 minute will occur following the alarm. If a fault occurs, the pump stops. When a Well Alarm is triggered, the parameter name is highlighted in yellow. When a Well Fault is triggered, the parameter name is highlighted in red. In addition, the Well Fault Configuration icon in the Navigation pane is highlighted and a message appears in the Alarm List on the Main menu page, shown in Figure 2.3 on page 13. If the undesired condition persists such that Well Alarm Detection Count Current Value reaches Well Alarm Detection Count Limit Value, a Well Alarm is recorded under the Well Fault Detection Count Current Value and the Realift Rod Pump enters a Pump Off state. A corresponding alarm message appears on the Realift Rod Pump HMI Main Menu in the Alarm List window. If a bypass or external fault is detected during a Pump Off, the pump off time is set to zero and, once the bypass or external fault condition is removed, the Realift Rod Pump will restart.

7. 1

Setting Per Stroke Alarm Parameters Use the settings in the Per Stroke pane, shown in Figure 7.2, to configure Per Stroke alarm parameters. During initial setup, do not enable any Well Fault parameters. These are addressed in detail in Configuring the Pump Jack for Standard Operation on page 73.

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Figu re 7.2:


Per Stroke and Real-Time Alarm Panes

Every Per Stroke alarm operates in the same way: conditions are evaluated by the Realift Rod Pump with each complete stroke; detection for each parameter does not begin until Startup Ignore is complete.

•

If the Current Value exceeds the Threshold Value, the Well Alarm Detection Count begins to count strokes. If the Current Value remains above the Threshold Value for the number of strokes indicated by the Well Alarm Detection Count Limit Value, a Well Alarm is reported and the Realift Rod Pump stops the pump jack for one Pump Off period.

•

If, upon restarting, the Well Alarm condition has not cleared, another Well Alarm is reported and the Realift Rod Pump stops the pump jack again for one Pump Off period.

•

If the number of reported Well Alarms equals the number indicated in the Well Fault Detection Count Limit Value, the Realift Rod Pump stops the pump jack again and reports a Well Fault. The pump jack does not

•

restart until the Well Fault is manually cleared. For example, if the Threshold Value for High Belt Slip is set at 8% and the Well Fault Detection Count has a Limit Value of four strokes: — If, on the first stroke, the Current Value is 5%, zero is entered for the Current Value under the Well Alarm Detection Count. — If, on the second stroke, the Current Value is 10%, one stroke is entered for the Current Value under the Well Alarm Detection Count. — If, on the third stroke, the Current Value is 10%, a second stroke is entered for the Current Value under the Well Alarm Detection Count. — If, on the fourth stroke, the Current Value is 9%, a third stroke is entered for the Current Value under the Well Alarm Detection Count. — If, on the fifth stroke, the Current Value is 4%, one stroke is removed from the Current Value under the Well Alarm Detection Count and the stroke count returns to two. — If, on the sixth stroke, the Current Value is 10%, a third stroke is entered for the Current Value under the Well Alarm Detection Count. — If, on the seventh stroke the Current Value is 9%, a fourth stroke is entered for the Current Value under the Well Alarm Detection Count. The limit value of four triggers a Well Alarm and a Pump Off period.

There are four parameters for Per Stroke alar ms, each of which can be enabled or disabled. When commissioning the Realift Rod Pump, clear the Well Alarm and Well Fault detector check boxes. See Table 7.6 for suggested initial values.


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Table 7.6:

Suggested Initial Values for Per Stroke Alarm Settin gs

Parameter

Startup Ignore Well Alarm Detection Well Fault Detection (Strokes) Count Limit (Strokes) Count Limit

High Slip Belt

5

High Imbalance Low Max Card Load Low Fluid Load

7.2

5 5

5

5 5

3 5

3 3

5

3

Setting Real-Time Alarm Parameters You can use the settings in the Real-Time Alarms pane, Figure 7.2, to configure Real-Time alarm parameters. Not all alarms apply to all drives; High Torque, Low Torque, Low Output Frequency, and High Motor Power only apply to the Altivar 71 drive. Real-Time alarms operate in the same way; detection for each parameter does not begin until Startup Ignore time has elapsed:

•

If the Current Value exceeds the Threshold Value, the Well Alarm Detection Count begins to record the duration. If the Current Value persists above the Threshold Value for the time indicated by the Well Alarm Detection Count Limit Value, a Well Alarm is reported and the Realift Rod Pump stops the pump jack for one Pump Off period.

•

If, on restart, the Well Alarm condition has not cleared, another Well Alarm is reported and the Realift Rod Pump stops the pump jack again for one Pump Off period.

•

If the number of reported well alarms exceeds the number indicated in the Well Fault Detection Count Limit Value, the Realift Rod Pump stops the pump jack again and reports a Well Fault. The pump jack does not restart until the Well Fault is manually cleared.

•

For example, if the Threshold Value for High Torque is set at 300% and the Well Alarm Detection Count has a Limit Value of five seconds: — If, on the first second, the Current Value is 250%, zero is entered for Current Value under Well Alarm Detection Count. — If, on the second second, the Current Value is 310%, 1 second is entered for the Current Value under Well Alarm Detection Count. — If, on the third second, the Current Value is 330%, an additional 1 second is entered for Well Alarm Detection Count. — If, on the fourth second, the Current Value is 309%, another 1 second is entered. — If, on the fifth second, the Current Value is 250%, 1 second is removed from the count; the count returns to 2 seconds. — The count continues until the Limit Value of five seconds is reached, triggering a Well Alarm and a Pump Off period.

The Well Alarm Detection Count for each real-time parameter is reset to “0” if one of the following conditions is met:

•

The Well Alarm Detection Count for a parameter is reset to “0” after the Well Fault Detection Count increments and the pump has restarted (for example, after the pump off time has elapsed).

•

The Well Alarm Detection Count for a parameter is reset to “0” if the external Fault Reset has been triggered or if the Reset Detection for Well and Drive button has been clicked.

•

The Well Alarm Detection Count for a parameter is reset to “0” if the parameter, which was disabled, is enabled.

The Well Fault Detection Count for each real-time parameter is reset to “0” if one of the following conditions is met:

•

The Well Fault Detection Count for a parameter is reset to “0” if the external Fault Reset has been triggered or

•

if the Reset Detection for Well and Drive button has been clicked. The Well Fault Detection Count for a parameter is reset to “0” if the parameter is disabled.

There are a total of six possible parameters for the Real-Time alarm (High Torque, Low Torque, and High Motor Power only apply to the Altivar 71), each of which can be enabled or disabled. You can set each of the Well Alarm

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Detection Count Limits to a value from 0 to 819 seconds. If the alarm detection count exceeds the maximum allowable limit (819 seconds), the Well Alarm Detection Count Limit stops incrementing. When commissioning the Realift Rod Pump, disable Well Alarm and Well Fault detectors. See Table 7.7 for suggested initial values. Table 7.7:

Suggested Initial Valu es for Real-Time Alarm Setti ngs

Parameter High Torque1

30

5

3

Low Torque1

30

5

3

Low Output Frequency1

30

5

3

High Motor Power1

30

5

High Load Cell Load Low Cell 1

7. 3

Well Fault Startup Ignore Well Alarm Detection Detection (Seconds) Count Limit (Seconds) Count Limit

30 30

5 5

3 3 3

Only applies to the Altivar 71.

Viewing Sensor Status If a proximity sensor or load cell signal is lost, the Realift Rod Pump generates a sensor alarm, shown in Figure 7.3, and automatically reverts to the next available control mode:

•

If the load cell signal is lost, the Realift Rod Pump reverts to Torque Mode, if the drive type is an Altivar 71, otherwise the Realift Rod Pump reverts to Timed mode.

•

If the proximity sensor signal is lost, the Realift Rod Pump reverts to Timed Mode, beginning with a Pump Off period and the Missed Prox Count increments. When the Missed Prox Count has incremented to 5, an alarm is generated. Clicking the Reset button resets the Missed Prox Count to 0. Clicking Load Cell or Proximity Sensor in the Sensor pane displays a graphic with load cell and proximity sensor data (see Figure 7.4). You can select the values to be displayed by selecting or clearing the check boxes at the bottom of the dialog box.

See also Off Time (Timed Mode) and On Time (Timed Mode), page 46. Fi gu re 7 .3 :

Se ns or P an e


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When a lost sensor begins to function again, the Realift Rod Pump automatically resumes operation in its previously selected control mode. Figu re 7.4:

7.4

Load Cell and Proximity Sensor Data

Resetting Detection f or W ell and Drive In the lower right-hand corner of the Well Fault Detection page, the Run Time Current Run and the Stroke Count Current Run are displayed (see Figure 7.5). The Run Time Current Run is the length of time the Realift Rod Pump has been running since its last Pump Off. The Stroke Count Current Run is the number of strokes since the last Pump Off. You can clear selected parameters by clicking the Reset Well Fault Detection Counters button on the Well Fault Detection page. Figu re 7.5:

Reset Well Fault Detection Coun ters

Additionally, when you click the Reset Detection for Well and Drive button on the Well Fault Detection page, a digital input on the SCADAPack 535 E (DI-14) is set to True for one second. This digital input can be used to reset faults on a drive. Consult your drive manufacturer’s documentation for more information. If an Altivar 71 is used, when you click the Reset Detection for Well and Drive button on the Well Fault Detection page, a reset faults command is issued to the drive. This command will clear so me faults on the Altivar 71, provided that the fault condition has been removed. Consult your drive manufacturer's documentation for details. Messages in the Alarm List on the main menu (see Figure 2.3) can be cleared after Well Fault Detection counters have been reset by highlighting that message and clicking the Acknowledge Selected Alarm button.

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8


Configuring the Pump Jack for Standard Operation

After you enter Pump Control, Well Data, and Well Fault Detection parameters, you configure the Realift Rod Pump for standard operation. Before starting this procedure, you should confirm that:

•

The HOA switch is Off and the speed potentiometer is set to a speed at or just above the equipment’s minimum speed.

•

In the Time & Network Configuration page’s Communication pane, the Communication State field reads Connected (Configuring the Computer for Communication with the Realift Rod Pump on page 22).

•

In the Status page’s Card Display & Settings pane, the Card Interval is set to a maximum of 10 seconds (Card Display and Settings on page 94).

After confirming baseline settings for the pump jack and Realift Rod Pump HMI software, use the following procedure to configure the Realift Rod Pump: 1. Set the speed potentiometer to a point at or just ab ove minimum speed. 2. In the Main Status page, confirm that the Run Pump command is set as shown in Figure 8.1: — Run Pump: Enabled — RPC Status: Hand — Drive Status: Forward Figu re 8.1:

Summary Pane: Enabled, Hand, Forward

3. On the enclosure, place the HOA switch in Hand position. 4. Observe that the pump jack moves smoothly and in the proper direction. If abnormal behavior is observed, stop the pump jack immediately and investigate why operation is not as expected. 5. Wait for the first dynamometer card to appear on the display. Depending on the operating mode of the Realift Rod Pump (Torque, Surface, or Downhole), use the Set Curve Visibility control to emphasize the correct curve to view. The first Dynacard after startup may display unusual results. It can be ignored. 6. Observe the dynamometer plot. When viewing a Torque card, the plot may resemble the Torque plot shown in Figure 8.2.


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Fig ure 8.2 :

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Exa mple Torq ue P lot

If viewing a Surface card, the plot may be similar to the Surface plot shown in Figure 8.3. Fig ure 8.3 :

Exa mple S urf ace P lot

If viewing a Downhole card, the plot may resemble the Downhole plot shown in Figure 8.4. Ideal Downhole cards have a roughly rectangular shape.

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Fig ure 8 .4:

Exa mple Do wnh ole P lot

7. After several dynamometer plots have been generated with consistent results, set the Control Load parameters: — For Surface Fill Control Level, see Setting the Surface Fill Control Level on page 75. — For Downhole Fill Control Level, see Setting the Downhole Fill Control Level on page 76. No Control Load parameter is required to operate in Torque mode.

8. 1

Setting the Fill Control Levels When operating in either surface or downhole mode, the Realift Rod Pump calculates Fill Status from the shape of the respective dynamometer card. Fill Status is the ratio of Effective Stroke to Total Stroke:

• •

Effective Stroke is the portion of the downstroke where fluid is flowing through the open traveling valve. Total Stroke is the total length of the downstroke.

Ideally, the Fill Status ratio is 1:1. However, as the fluid level changes, so too does Effective Stroke. For both surface and downhole cards, Effective Stroke is determined by finding the position, on the downstroke, where load first decreases below a determined level. The determined level is called Control Load.

8.1.1

Setting the Surface Fill Control Level For a surface card, Control Load is set directly through the Surface Fill Control Level (SFCL) parameter. You should set SFCL such that the downstroke portion of the card intersects SFCL for the first time (from right to left) where load is descending toward its lowest value. You can use the following equation to determine Control Load: CL=SFCL where: — CL is Control Load — SFCL is the chosen Surface Fill Control Level The lowest value of load for the card is called Card Minimum Load, abbreviated Lmin, in Figure 8.5.


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Deter mining Surface Fill Contr ol Level

d a o L

Lmax

Upstroke

Control Load

Downstroke

L min Total Stroke Position

Effective Stroke A

B

C

D

In Figure 8.5:

•

The Surface Total Stroke is the distance on the plot from A (lowest position of the stroke) to D (highest position of the stroke).

•

The Surface Effective Stroke is calculated where the curve first falls below SFCL when the curve travels from A to C.

In the Surface & Downhole Data pane on the Status page, Figure 8.6, enter the SFCL. Figu re 8.6:

8. 1. 2

Surface & Downhole Data Pane

Setting the D ownhole Fill C ontrol L evel For a downhole card, Control Load is set indirectly through the parameter called Downhole Fill Control Level (DFCL). Control Load is DFCL percent of the way from Card Min Load to Card Max Load, i.e., Control Load is given by the following equation:

CL = DFCL



 L ma x – L mi n 

-----------------------------------100 + L mi n

Where: — CL is Control Load — DFCL is the chosen Downhole Fill Control Level — Lmax is the Downhole Card Maximum Load — Lmin is the Downhole Card Minimum Load 76


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Set DFCL such that, for most cards, Control Level intersects the downstroke where the slope of load versus position is close to vertical. In general, DFCL is at or below 35% to achieve a representative Downhole Effective Stroke and, therefore, Downhole Fill Status. Displacement :

Figu re 8.7 :

Deter mining Dow nhole Cont rol Percen tage

d a o L

Lmax Upstroke

Control Load

Downstroke

L min Total Stroke A

B

C

Effective Stroke

Position

In Figure 8.7:

•

The Downhole Total Stroke is the distance on the plot between A (lowest position of the stroke) and C (highest position of the stroke).

•

The Downhole Effective Stroke is the distance between A and B (position where the slope of load versus position is nearly vertical).

In the Surface & Downhole Data pane on the Status page, shown in Figure 8.6, enter the DFCL. In general, a good Downhole Fill Control Level is about 35%. After observing operation, it may be advantageous to adjust this value (likely to a value less than 35%) to achieve a more accurate measurement of Downhole Effective Stroke. 1. On the in Pump Control shown Figure 8.8. Configuration page, confirm Fill Minimum and Fill Target in the Fill Control Settings pane, Figure 8. 8:

Fil l Con tro l Set tin gs Pa ne

The Realift Rod Pump system adjusts speed once every Speed Change Strokes to maintain Fill Status equal to Fill Target: — If Fill Status is greater than Fill Target, speed is increased. — If Fill Status is less than Fill Target, speed is decreased. — at If speed decreases Minimum Speed. to Minimum Speed and Fill Status continues to decrease from Fill Target, speed is held — If Fill Status is less than Fill Minimum for a count of Pump Off Count Limit, the Realift Rod Pump system enters a Pump Off state.


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— If Fill Minimum is set to 0%, the Realift Rod Pump does not enter a Pump Off state. Adjust settings as necessary to obtain optimal production rate. — If Fill Minimum is greater than 100%, the Realift Rod Pump will enter a Pump Off state (see Forcing a Pump Off State on page 83). For a more detailed explanation of the Fill Control Settings, refer to Forcing a Pump Off State on page 83. 2. Calibrate the SPM:Hz Ratio to convert motor speed (Hz) into pump rate (strokes per minute or SPM).

RISK OF EQUIPMENT DAMAGE During calibration, the Realift Rod Pump will not detect a pump off condition. The Realift Rod Pump continues with calibration and checks for pump off after the end of calibration. Before you begin calibration, verify that the well will not enter a pump off state by examining the Dynacards. Failure to follow these instructions can result in equipment damage. SPM:Hz Ratio a. With the pump jack operating smoothly at a moderate speed, confirm that there is minimal belt slippage and look for any other conditions that might affect motion. Check for excessive belt or pulley wear. b. Navigate to the Well Data Configuration page in the Realift Rod Pump HMI software and, in the Pumping Unit Information pane, shown in Figure 8.9, click the Calibrate button to calibrate SPM:Hz Ratio: Figu re 8.9:

Pumping Unit Informati on Pane

The Realift Rod Pump monitors the next six strokes, comparing the speed of the motor (Hz) with each stroke identified by the proximity sensor. The software indicates when calibration is complete. After calibration, Pump Rate in either Hz or SPM is displayed in the Summary pane of the Status page, shown in Figure 8.1 on page 73. Clicking in that field changes the units from Hz to SPM and back again. 3. Navigate to the Well Fault Detection page (see Configuring Well Fault Detection on page 67) and confirm that the Current Value fields are populated and within expected ranges. Adjust any Threshold or Limit Values as necessary to trigger the Well Alarm or Well Fault detectors at the desired levels, shown in Figure 8.10.

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Figure 8.10: Well Fault Detection Values and Settings

4. Confirm that the Realift Rod Pump is reading the well data properly. If the feedback is satisfactory, return the HOA switch to Off. 5. Navigate back to the Status page. With the HOA switch on the drive enclosure set to Off, confirm the following settings in the Summary pane, shown in Figure 8.11: — Run Pump: Enabled — RPC Status: Off — Drive Status: Not Ready Figu re 8.11: Summary Pan e

— The Realift Rod Pump does not operate unless the Run Pump command is Enabled and the HOA switch is in either the Hand or Auto position. — If Run Pump reads Enabled, but the RPC Status reads Off, this indicates that the HOA switch is in the Off position. — Similarly, if RPC Status reads No-Run, this may indicate that some other input wired in series with the run command, such as a vibration or tank level sensor, is telling the Realift Rod Pump that it cannot start at this time. The No-Run message also appears if a required parameter such as the Start Up Speed is set to zero. — The Realift Rod Pump starts normally after the situation triggering the No-Run message is resolved. Disable the Run Pump command by clicking the Run Pump field in the Summary pane. RPC Status should change to Disabled. 6. On the Pump Control Configuration page, set Control Mode to the desired setting: Timed, Torque (for Altivar 71 only), Surface, or Downhole (see Setting the Control Mode on page 44). In Timed Mode, the Realift Rod Pump does not actively control pump speed and fill rate; it only runs the unit at constant speed for specified on and off times. Timed mode requires that the Off Time and On Time values for Timed Mode be set (see Setting On & Off Times on page 45). 7. On the Pump Control Configuration page, verify and configure Bypass Contactor and External Fault Trigger. 8. If using Torque (for Altivar 71 only), Surface, or Downhole Mode, set Auto Off Time Adjust to On. In addition, confirm that the Off Time (non-Timed), Auto Adjust Max Off Time, and Auto Adjust Min Off Time parameters are set at the required values (see Setting On & Off Timeson page 45). 9. Navigate to the Well Fault Detection page and enable any of the Per Stroke or Real-Time Well Fault detectors desired by clicking on the Enable box in each control pane.


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10. Set the HOA switch on the drive enclosure to Auto. The pump jack should not operate yet as the Run Pump field was set to Disabled in Step 5. 11. Return to the Status page and enable the Realift Rod Pump by clicking the Run Pump field and setting it to Enabled. The pump jack should now begin to operate and RPC Status values, which may vary depending on your Realift Rod Pump HMI software settings, begin to appear.

WARNING UNEXPECTED EQUIPMENT OPERATION • Read and understand this manual and the drive’ s manual before operating the Realift Rod Pump system. • qualified Any changes made to parameter settings must be perf ormed by personnel. • Verify that it is saf e to enable the rod pump bef ore doing so. Failure to follow these instructions can result in death or serious injury. — If a Start Warning Indicator (SWI) is installed, the SWI activates for the amount of time set in the Startup Timers pane in the Pump Control Configuration page (Refer to Set Startup Times on page 99). RPC Status displays Start Warning. Pump jack motion begins when SWI time completes. — If Start Reverse Time is set, the pump jack turns in reverse at the speed set in the Startup Speed field in the Speed Settings pane for the amount of time specified, then stops and begins to move forward, again at Startup Speed (see Setting Pump Speeds on page 46). RPC Status displays Start Reverse and Drive Status displays Reverse. — The pump jack runs for the number of strokes set in the Pre-Control Strokes field before it adjusts speed or initiates Pump Off. Allow the pump jack to complete the Pre-Control Strokes before attempting to collect well data (see Setting Control Triggers on page 51). — If any Well Fault Detectors are enabled, detection does not begin until the Startup Ignore period has elapsed (see Configuring Well Fault Detection on page 67). 12. Navigate to the Well Fault Detection page and enable any of the Per Stroke or Real-Time Well Fault detectors desired by clicking on the Enable box in each control pane (see Setting Per Stroke Alarm Parameters on page 68 and Setting Real-Time Alarm Parameters on page 70). 13. Set the HOA switch on the drive enclosure to Auto. The pump jack should not operate yet because the Run Pump field is set to Disabled (Step 5 on page 79). 14. Return to the Status page and enable the Realift Rod Pump by clicking the Run Pump field and setting it to Enabled. The pump jack should now begin to operate, with RPC Status readings varying, depending on your Realift Rod Pump HMI software settings.

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9


Testing Realift Rod Pump System Operation

After you update the Realift Rod Pump HMI software settings with the drive settings, you should test Realift Rod Pump system operation. To test Realift Rod Pump system operation:

• Figure 9. 1:

Click Well Data Configuration in the Navigation pane. The Well Data Configuration page appears, as shown in Figure 9.1.

Well Data Co nfi gurati on Pa ge

The next steps are performed on the Realift Rod Pump enclosure: 1. With the HOA control set to Off, set the speed at or just above the minimum speed the equipment allows. 2. Switch the HOA control to Hand mode to start the Realift Rod Pump.


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3. Gradually increase speed, using the potentiometer, until the pump jack begins to move. After the pump jack is in motion, monitor operation and make sure that you: — Do not run the pump jack at excessive speed; verify the information on the nameplate. — Stop immediately if any deviation from expected pump jack operation occurs and investigate why operation is not as expected.

RISK OF EQUIPMENT DAMAGE When you are testing the Realift Rod Pump, excessive speed can damage the rod pump equipment. When you are increasing the speed of the rod pump avoid running the rod pump at excessive speed. Failure to follow these instructions can result in equipment damage. 4. Set the HOA switch to Off to stop the pump jack.

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10


Verifying Realift Rod Pump Control During Operation

Allow the pump jack to run until the Pre-Control Strokes, Startup Timers, and Startup Ignore counters elapse. Continue to run the pump to allow the well to stabilize (time can vary, depending on the well). Verify Realift Rod Pump operation by conducting a few simple tests:

• • •

10. 1

Check Speed Control Force a Pump Off State Test Well Fault Detection.

Checking Speed Control The Realift Rod Pump constantly adjusts pump jack speed based on Fill Status to maintain a fill level as close as possible to the Fill Target. The Realift Rod Pump checks Fill Status at intervals defined by the Speed Change Strokes (see Setting Control Triggers on page 51).

•

If the Fill Status exceeds the Fill Target, the Realift Rod Pump speeds up incrementally to return the Fill Status to the target level. The speed change increment is proportional to the difference between the Fill Status and the Fill Target. The Realift Rod Pump continues to increase speed until either the Fill Target is attained or until the motor reaches the Maximum Speed value (see Setting Pump Speeds on page 46).

•

If the Fill Status drops below the Fill Target, the Realift Rod Pump slows the pump jack to return the Fill Status to the target level or until the Minimum Speed value is reached.

Test the Speed Control by adjusting the Fill Target up or down slightly, observing the Realift Rod Pump as it changes speed to accommodate the new settings. After confirming satisfactory Realift Rod Pump behavior, return the Fill Target value to the desired operating level.

10. 2

Forcing a Pump Off State If the Fill Status drops below the Fill Minimum, the Realift Rod Pump determines if it needs to enter a Pump Off state, using the following procedure: 1. If the Fill Status remains below the Fill Minimum for the number of strokes defined by the Pump Off Count Limit, the Realift Rod Pump enters a Pump Off state and stops the pump jack. 2. The Realift Rod Pump remains in the Pump Off state until the length of time in the Off Time (non-Timed) field elapses. The Realift Rod Pump then restarts. 3. After Startup Timers and Pre-Control Strokes elapse, the Realift Rod Pump re-evaluates the Fill Status in relation to the Fill Target and Fill Minimum: — If the Fill Status is above the Fill Target, the Auto Off Time Adjust feature subtracts one minute from the Off Time (non-Timed) value. — If the Fill Status is below the Fill Minimum, one minute is added to the Off Time (non-Timed) value. This procedure repeats for each Pump Off occurrence, continually adjusting Pump Off time as well conditions change. After verifying that Auto Off Time Adjust is on, test that Off Time (non-Timed) does adjust after a Pump Off period/cycle. To test that Off Time (non-Timed) does adjust after a Pump Off period/cycle: 1. Set the Off Time (non-Timed) value to one minute, Auto Adjust Max Off Time to three minutes and Auto Adjust Min Off Time to one minute. 2. Set both Fill Minimum and Fill Target values to 101%. Observe that the Realift Rod Pump stops the pump after the correct number of Pump Off Count Limit strokes and restarts after the correct Off Time. 3. Check to see that the Off Time (non-Timed) value increases by one minute at each pump restart until it reaches its maximum value of three minutes.


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4. Set the Fill Target and the Fill Minimum to 25% and allow the Realift Rod Pump speed to increase until it reaches Maximum Speed. 5. Set the Fill Minimum back to 101% to force a Pump Off. 6. Upon restart, check to see that the Off Time (non-Timed) value is reduced by one minute. 7. Return the Fill Minimum and Fill Target back to their desired operating levels after satisfactory behavior is confirmed.

10.3

Testing Well Fault Detection If the Realift Rod Pump detects that the pump jack operates outside of certain user-specified parameters, it reports a Well Alarm. If the unwanted operating state persists, the Realift Rod Pump reports a Well Fault and stops operation until the Well Fault is manually cleared (see Configuring Well Fault Detection on page 67). Well Fault Detection works as follows:

•

After the Startup Ignore counts on the Well Fault Detection page are met, the Realift Rod Pump begins to monitor selected Well Alarm conditions.

•

For any monitored parameter, if the Current Value moves above or below the Threshold Value in an undesirable direction, the Well Alarm Detection Count begins. For example, if the Threshold Value for High Torque is set at 200%, and the Current Value exceeds 200%, the corresponding Well Alarm Detection Count increases.

•

After the system restarts, the Well Alarm monitoring sequence begins again. If the undesired state persists, another Well Alarm is recorded and another Pump Off state begins. In the High Torque example above, the Well Fault Detection Count Limit Value is set for three, which means the Realift Rod Pump repeats this process three times.

•

If the number of recorded Well Alarms reaches the Well Fault Detection Limit Value, a Well Fault is reported. The Realift Rod Pump stops the pump jack until the user manually clears the Well Fault condition.

To test the Well Fault Detection sequence: 1. In the Pump Configuration page, set the Auto Off Time Adjust parameter to Off and the Off Time (non-Timed) field to one minute (see Setting On & Off Times on page 45). a. Set the Well Alarm Detection Count Limit Values to five strokes or five seconds, depending on the parameter chosen. b. Set the Well Fault Detection Count Limit Values to three. c. With the pump jack in motion, after the Startup Ignore counts have elapsed, observe the Threshold and Current Values. d. Choose a Well Fault parameter to test and set its Threshold Value to a value that causes the Current Value to fall outside of the chosen condition. e. Enable detection by checking the Enable box for the chosen parameter. f.

Observe Realift Rod Pump operation as the Well Alarm Detection Counter reaches its Limit Value and the Realift Rod Pump enters a Pump Off state. Wait for the Realift Rod Pump to restart and allow the sequence to repeat.

g. When the number of Well Alarms reaches the Well Fault Detection Count Limit Value, observe that the Realift Rod Pump enters a Well Fault state and that the pump jack shuts down. h. Clear the Well Fault Message. This allows the Realift Rod Pump to restart when you click Reset Detection for Well and Drive on the Well Fault Detection page.

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Figure 10.1: Reset Well Fault Detection Counters

i.

Disable detection by un-checking the Enable box for the chosen parameter. Test other parameters as desired. When the desired parameters have been tested, disable every detector except those that are to be monitored in routine operation.

2. To clear a message saved in the Alarm List on the Main Menu page after Well Fault Detection counters have been reset, highlight the message and click the Acknowledge Selected Alarm button. 3. Return the Auto Off Time Adjust parameter to the desired value for routine operation.


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11


Optimizing Realift Rod Pump Operation

You can optimize Realift Rod Pump operation by careful configuration and by paying attention to alarms, but the downhole cards also give invaluable information about the efficiency of the Realift Rod Pump. The downhole card is a graphical representation of the forces acting on the pump plunger as it moves upward and downward in the well, capturing and releasing fluid with each stroke.

11. 1

R ead i n g D o w n h o l e C ar d s One keyobtained to optimizing Realift Rod Pump operation interpreting downhole cards. While acceptable operation can be by observing the Surface card, theisDownhole card is the preferred method to obtainwell optimal performance. Rather than being a plot of Load vs. Time, shown in Figure 11.1, the Downhole card is a plot of Load vs. Position, shown in Figure11.2. The resulting shape is sometimes referred to asfolded onto itselfor a circular plot. Figu re 11.1: Plot: Load vs. Time

L max

L min


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Figu re 11.2: Plot: Loa d vs. Positio n

L max

L min

Ideally, the Realift Rod Pump should have good fluid flow with valves working properly. This would generate a card such as the one shown in Figure 11.2. The ideal card shown in Figure 11.2 demonstrates the instantaneous increase in load from Lmin to Lmax as the pump plunger begins its upward stroke, the load remaining constant as it completes its travel to the top. As soon as the pump plunger starts back down, the load instantly falls back to Lmin where it remains constant as the pump travels to its bottom position again. The load falling instantly to Lmin and remaining constant for the entire downstroke (Ptop to Pbottom) indicates that the traveling valve on the pump has opened properly, transferring the fluid from pump to tubing. When the pump plunger reaches bottom, the barrel is empty and the reciprocating motion of the pump jack begins to lift the entire column of fluid up to the top again, causing more fluid to be pulled in from the reservoir through the standing valve. However, when a condition such as low fluid level or trapped gas stops the traveling valve from opening properly as the plunger starts downward, transfer of the contents of the pump to the tubing does not begin at the top of the stroke. The fluid in the tubing merely descends with the traveling valve, maintaining load at L max, until fluid is encountered or the gas compresses enough to open the traveling valve. Only when the plunger re-immerses in the fluid can the traveling valve open and transfer of fluid through the traveling valve occur.

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Figu re 11.3: Low Flu id Leve l

L max

L min

The Realift Rod Pump detects the condition where the traveling valve does not open at the top of the stroke and reduces pump speed to reduce mechanical stress on the system and to allow more time for the pump to fill. If speed reduction does not work and fill remains low, the Realift Rod Pump enters a Pump Off State and waits for a predetermined interval, called Pump Off Time, before restarting (see Setting Fill Controls on page 48). The shapes of individual downhole cards not only provide valuable clues to diagnose changes in fill level over time, but also aid in the evaluation of hardware conditions. Knowing if the reservoir is low, valves are leaking, tubing is unanchored, or if other factors are at play allows the operator to better manage production levels and anticipate whether maintenance is required. Figure 11.4 illustrates the most common downhole card shapes and the well conditions associated with them. Shapes vary among different pump jacks; these examples are for information only and do not represent absolute well conditions or recommended courses of action.


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Sample Downhole Card Shapes

Figu re 11.4: Sample Downho le Cards

Full Pump

Worn Plunger or Traveling Valve

Flowing Well, Rod Part, Inoperative Pump

Tubing Movement

90

Fluid Pound

Gas Interference

Worn Standing Valve

Worn or Split Barrel

Fluid Friction

Pump Hitting Up or Down

Drag Friction

Bent Barrel or Sticking Pump


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Viewing System Status

The Status page, shown in Figure 12.1, gives the user an overview of Realift Rod Pump system operation, including:

• •

The run status of the pump, Realift Rod Pump Status, and Drive Status

• •

Well run time (percentage) and gross production (barrels)

A summary of various Realift Rod Pump parameters, including the active control mode, the fill status, frequency command, pump rate, and fluid load Surface and downhole data, including total and effective strokes.

The Status page also enables you to configure sensor weight, filtering, and external sensors. Figu re 12.1 : Statu s Page


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Summary Data The Summary pane which can be seen in Figure 12.1 displays an overview of the following parameters of the Realift Rod Pump:

•

Run Pump: The Run Pump displays whether the Realift Rod Pump is Enabled or Disabled. Clicking Run Pump enables or disables the Realift Rod Pump.

•

RPC Status: The RPC Status is the current state of Realift Rod Pump system operation. RPC Status values are listed and defined in Table 12.8: Ta bl e 12 .8 : RP C St at us S ta t u s

A c t io n

Off

Realift Rod Pump HOA switch is in the Off position.

Hand

Realift Rod Pump is running continuously, its speed determined by the speed pot.

Start Delay

Realift Rod Pump is in the Power Cycle Start Delay phase of the Auto startup sequence

Start Warning

Realift Rod Pump is in the Start Warning Time phase of the Auto startup sequence.

Start Reverse

Realift Rod Pump is in the Start Reverse Time phase of the Auto startup sequence.

Auto

Realift Rod Pump is running in Auto mode.

Pump Off

Realift Rod Pump is not running and is in Pump Off state.

Well Flt

Realift Rod Pump is not running due to detection of a Well Fault.

Alarm

Realift Rod Pump is not running and is in Pump Off state due to detection of a Well Alarm.

No-Run

Realift Rod Pump is in Auto mode but not running (waiting for Run Command input (DI-11), to go high), or Startup Speed is zero.

Energy

Realift Rod Pump is not running because the time of day is during the Energy Save period.

Calibration

Realift Rod Pump is running and is in a self-calibration phase of operation.

Disabled

Run Enable is toggled off.

Stop Key

The stop key has been pressed, stopping the drive.

External Fault

Realift Rod Pump has an external fault active.

Drive Bypassed

Realiftand, Rod ifPump is inperforms Drive Bypassed state. TheWhile drive is disconnected the motor running, a freewheel stop. the RPC Status from is in the Drive Bypassed state, the drive will not restart.

Drive Fault

If the drive is an Altivar 71, clicking the drive status field displays further information. more detailed information is available. For other drive types, DI-3 has been set to true.

1

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1

Although the HOA switch in the Off position is by far the most common cause of the Off status, there are other possibilities, including: —External sensor has opened Run Command input (DI-11) while HOA is in Hand position —Remote Disable (DI-2) (see the Realift Rod Pump Hardware Installation Manual for information on DI-11.)

•

Drive Status: The Drive Status is the current state of drive. The Drive Status can be Forward, Reverse, or Not Ready.

•

Active Control Mode: The Active Control Mode is the control mode in use. The Active Control Mode can be different from the Control Mode set on the Pump Control Configuration page. If a sensor detects a Well Fault, the Realift Rod Pump will change the control mode and the Active Control Mode will display the actual control mode.

•

Run Time Current Run: The Run Time Current Run is the length of time the Realift Rod Pump has been running since its last Pump Off.

• • •

Stroke Count Current Run: The Stroke Count Current Run is the number of strokes since the last Pump Off.

•

Fluid Height in Casing: The height of the fluid within the well casing.

Fill Status: The Fill Status is the pump fill in percentage for the active control mode. Pump Rate: The Pump Rate is the Realift Rod Pump speed calculated over the time duration between the last two times the crank arm passed the proximity sensor. [Units: Strokes per Minute (SPM), minimum: 0.0, maximum: 100.0]


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12. 2


•

Pump Intake Pressure: The Pump Intake Pressure is the pressure in the casing at the depth specified as the pump intake.

• •

Fluid Load: The weight of the fluid in the pump, in lbs.

•

Imbalance: The Imbalance is a calculated value indicating the balance between the counter weight and the rod string weight, based on the difference between maximum upstroke torque and maximum downstroke torque. A negative value indicates that the counterbalance weight is greater than the rod string weight. [Units: percent (%), minimum: -1000.0, maximum: +1000.0]

•

Frequency Command: The Frequency Command indicates the set frequency of the drive. If the Drive Status is Reverse, the Frequency Command is displayed as a negative.

•

Actual Frequency: The Actual Frequency is the frequency of the drive as reported by the Altivar 71 drive. If the Drive Status is Reverse, the Actual Frequency is displayed as a negative. For generic drives, the Frequency Command and Actual Frequency values are the same because the system does not use a frequency feedback with generic drive types.

Belt Slip: The Belt Slip is the difference between the rod pump system speed measured by the drive (motor speed) and the pump speed as determined by the proximity sensor (crank arm speed). [Units: percent (%), minimum: -1000.0, maximum: +1000.0]

Well Activity Summary The Well Activity Summary pane, as shown in Figure 12.2, displays the run time and gross production for the current day and the previous day. Figure 12.2: Well Activity Summary Pane

12.3

Surface and Downhole Data The parameters used to configure Fill Status are found in the Surface and Downhole Data pane, as shown in Figure 12.3. Figure 12.3: Surface & Downhole Data Pane

For detailed information on the Fill Control Level settings, see Configuring the Pump Jack for Standard Operation on page 73.


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Card Display and Settings The Card Display and Settings pane enables you to configure how cards are displayed. A key function configured in the Status page’s Card Display & Settings pane is the Card Interval, as s hown in Figure 12.4. Figure 12.4: Card Display & Settings Pane

Card Interval sets the frequency at which card data is collected by Realift Rod Pump HMI software. When configuring the Realift Rod Pump for the first time, this value is set in Establishing Communication Speed and Card Interval Settings on page 27. Changing the Card Interval is explained in Changing Card Interval on page 110. The Card Display and Settings pane also enables you to set the curves that will be displayed in the card. For more information, see Setting Curve Visibility on page 106.

12.4.1

Defining F iltering O ptions You can define the filtering options by clicking the Set Filtering Options button in the Card Display and Settings pane. The filters (Load Cell Filter Weight and Pump Fill Filter Weight) present the measured and calculated values in a more realistic manner by minimizing ofvalue noiseisand other spurious values. The system employs infinite impulse response exponential filters.the Theeffects current compared to the previous value by taking the entered percentage of the previous value and adding it to the corresponding percentage of the current value. For example, if you set the Load Cell Filter Weight to 60%, Realift Rod Pump takes 60% of the previous value and adds it to 40% of the current value. Setting the Load Cell Filter Weight to a very low percentage means that there will be little smoothing of data. Setting the Load Cell Filter Weight to a very high percentage means that there will be less progression of data.

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To define the filtering options: 1. Click the Set Filtering Options button. The Filtering Weights and Options dialog box appears. Figure 12.5: The Filtering Weights and Options Dialog Box

2. Define the Load Cell Filter Weight as a percentage. The Load Cell Filter Weight filters data directly from the load cell. If the load cell data is noisy, increase the value of the filter until the noise is sufficiently rejected. 3. Define the Pump Fill Filter Weight as a percentage. If this filter is used, each new pump fill calculation is averaged with the previous pump fill calculations to reduce the speed oscillations or “hunting” that result from an oscillating pump fill. 4. Click OK.


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Configuring External Sensors and Water Cut Percentage On the Status Page, clicking the View Other Sensors button brings up the External Sensors dialog box, as shown in Figure 12.6, where you can configure the displayed values of any external 4-20 mA analog sensors connected to the SCADAPack 535 E. Figure 12.6: External Sensors Dialog Box

Under External Sensors, you can configure the external sensors:

•

Input: The Input corresponds to the analog input on the SCADAPack 535 E that the external sensor is connected to.

• • •

Name and Units: You can enter a descriptive name and the units of the value the sensor is measuring.

•

Manual Calibration: You can enter values under Manual Calibration to convert the measured value into the value you want displayed. For example, if the measured temperature is in Fahrenheit, you can convert it to Celsius by entering “-32” in Offset and “0.5556” in Mult.

Value: The calibrated value reported by the external sensor. Assisted Calibration: Clicking on Range opens a dialog box where you can enter the values that will correspond to a measurement of 4 mA and 20 mA.

You can also define filters for external sensors and the proximity sensor in the External Sensors dialog box. When you select the Enable External Sensors Filtering check box, Realift Rod Pump enables an infinite impulse response exponential filter on the external sensor inputs. The current value is compared to the previous value by taking 70% of the previous value and adding it to 30% of the current value. The measured sensor results are smoothed out and the values displayed show a more natural progression. When you select the Enable Prox Sensors Filtering check box, Realift Rod Pump enables a filter designed to reduce spurious strokes. When selected, the Proximity Sensor must be true for at least two Realift Rod Pump program scans for it to count a stroke. In the Production pane, the gross and net production rates are displayed. The Net Oil rates are calculated using the Water Cut that you can enter by clicking the Water Cut field. When you modify the value in the Water Cut field, the Net Oil values update immediately.

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Viewing History Trends and Events

The History Trends and Events page, shown in Figure 13.1, provides the ability to track Realift Rod Pump and pump parameters over a period of time. Click the History Trends and Events icon in the Navigation pane to access History Trends and Events. Figure 13.1: History Trends and Events Page

By default, the History Trends and Events page displays the Pump Fill and Pump Off trends. You can also view the plots of any of the parameter sets in the Data Selection pane. There are three sources of data to choose from:

• • •

13. 1

Real-Time Trends Stored Trends Stored Events.

Viewing Trends and Events You can view the data displayed for each of the data sets listed in the Data Selection pane of the History Trends and Events page. Realift Rod Pump only records significant changes in trends in the database. Therefore, if the current reading is not significantly different from the last recorded reading, the date and time listed under Latest Data are the date and time of the last significant change in the trend.


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To view the plots on the History Trends and Events page: 1. Under Data Selection, click the name of the plot you want to view. A window appears with the data displayed in a plot (see Figure 13.2 for an example). Figu re 13.2: Example Plot Windo w

2. Under the Trace column, select the check box corresponding to each parameter you want displayed on the plot or clear the check box if you do not want the parameter displayed. 3. When you have finished, close the window by clicking the Close button in the upper right-hand corner of the window. Real-Time Parameters Available for Trending The parameters available in each Real-time plot page are shown in Table 13.9: Table 13.9: Real-Time Trending Parameters (History Trends and Events Window: Data Selection) Re al- T im ePlo t

P a r am e te r s Fluid Load (lbs) Fluid Height in Casing (ft) Downhole Card Force Max (lbs)

Downhole Diagnostics

Downhole Card Force Min (lbs) Pump Rate (SPM) Downhole Effective Stroke (in) Downhole Total Stroke (in) Pump Intake pressure (psi)

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Table 13.9: Real-Time Trending Parameters (History Trends and Events Window: Data Selection)(continued) R e a l- T imePlo t

P ar a me t er s Surface Card Max Load (lbs)

Surface Diagnostics

Surface Card Min Load (lbs) Polished Rod Power (HHP) Pump Rate (SPM) Pump Rate (SPM) Control Enabled1 Stroke Count

Counters and Timers

Rod Stroke Count Pump Stroke Count Run Time Today (%) Run Time Since Reset (hrs) Run Time Total (hrs) Fill Status Torque (%) (only f or ATV71 drives) Fill Status Downhole (%) Fill Status Surface (%)

Pump Fill and Pump Off

Fill Status Active (%) Pump Off Time (min) Pump Off Time Remaining (min) Pump Off Time Elapsed (min) Time Since On (hrs) Fill Status Downhole (%) Downhole Effective Stroke (in) Downhole Total Stroke (in)

Downhole Production and Power

Polished Rod Power (HHP) Production Today (bbl)2 Fluid Load (lbs) Fluid Height in Casing (ft) Pump Power (HHP) Torque (%) (only for ATV71 drives) Motor Voltage (V)

Speed Drive Parameters

Reference Frequency (Hz) Motor Current (A) Motor Power (HHP) Motor Power (kW)

1

The Control Enabled parameter indicates when the Realift Rod Pump is controlling the pump (i.e., when the pre-control strokes have ended).

2

The production today is calculated using the gross production and not the net production. In other words, water cut is not taken into consideration when calculating the production today.

Viewing Real-Time Trends Real-Time trends are recorded while the Realift Rod Pump HMI is connected to the Realift Rod Pump — data is collected as it is updated live in the Realift Rod Pump processor. Clicking on one of the parameter sets in the RealTime Trends list opens a window displaying the plot for those parameters, as shown in Figure 13.3.


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Figu re 13.3: Example Plot Win dow

Determine which parameters to view by clicking the check box next to the desired item at the bottom of the page, shown in Figure 13.4. Figure 13.4: Pump Fill and Pump Off Plot Window (Showing Only Fill Status)

Multiple parameters can be displayed simultaneously, providing a better picture of operational cause and effect over time, as shown in Figure 13.5. Figure 13.5: Gross Downhole Production and Power (Combination of Fill Status and Production)

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Viewing Stored Trends Stored Trends from the Realift Rod Pump must be refreshed before you can view the latest set o f data. Stored Trends from Realift Rod Pump parameters available for plotting are shown in Table 13.10: Table 13.10: Realift Rod Pump Parameter Stored Trends S to r e dT r e n d sPlo t

Pa r a me t e r s

On and Off Status

On and Off Status (on/off)

Pump Rate

Drive Frequency (Hz)

Run Time

Run Time (%)

Max and Min Load Max Drive Power Polished Rod and Pump Power Production Estimate 1

Maximum Load (lbs) Minimum Load (lbs) Maximum Drive Power (HHP or kW) Polished Rod Power (HHP) Pump Power (HHP) Production Estimate (bbl)1

The production estimate is calculated using the gross production and not the net production. In other words, water cut is not taken into consideration when calculating the production estimate.

Viewing Stored Events from Realift Rod Pump The Start/Stop History and Timestamped Events Log summarizes time-stamped events recorded by the Realift Rod Pump. The log displays Start and Stop (including Pump Off) times, Signal Status, Mode, Well Alarm and Well Fault occurrences, as shown in Figure 13.6. Figure 13.6: Recent Start/Stop History and Timestamped Events

If you transfer events as explained in Transferring Stored Trends and Events on page 102, after having reset the RPC, after having clicked the Reset RPC Values button in the Events and Start/Stop Log window, the events in the database will be cleared.


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Modifying the Plot Display You can customize how the trend and event plots are displayed. To customize the display of a plot:

•

Right-click the plot. A context menu appears (see Figure 13.7).

Figu re 13. 7: Plot Menu

Using the context menu, you can zoom in and out, display titles and other content, pan left or right, and more. By clicking just below the plot and using the mouse's scroll wheel, you can zoom in and out without using the plot menu. If you select Pan from the context menu, you can quickly zoom in and isolate any part of the plot for closer inspection by placing the cursor over the plot and using the mouse’s scroll wheel.

13.3

Transferring Stored Trends and Events To transfer the latest set of trend data from the Realift Rod Pump drive: 1. Click Transfer Stored Trends and Events in the Transfer Control and Status pane in the main History Trends and Events page. Figure 13.8: Transfer Control and Status Pane

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2. Click the Transfer Stored Trends and Events button to start the transfer of information from the Realift Rod Pump. A transfer indicator lights and the progress bar fills until transfer is complete: Figure 13.9: Transfer Control and Status Pane Indicators

3. Allow time for the transfer to complete. Stored trends can then be viewed in the same manner as real-time trends (see Viewing Trends and Events on page 97). The stored data plot pages are identified by the words Historic Data at the top of each plot, shown in Figure 13.10. Figure 13.10:Typical Historic Data Plot


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Managing History Cards

The History Cards page, shown in Figure 14.1, enables you to view past cards. You can store the history cards, transfer them, and change the interval at which the card is saved. Click the History Cards icon in the Navigation pane to access History Cards. Figu re 14.1: Histo ry Cards Pag e

14. 1

Using the History Card Browser The History Card Browser enables you to navigate through the stored history cards using the buttons at the top of the History Card Browser pane, as shown in Figure 14.2. Figu re 14.2: Histo ry Card Brows er

Clicking the Set Curve Visibility enables you to chose the curve that is emphasized in the displayed card. For more information, see Setting Curve Visibility on page 106. Clicking the Refresh button refreshes the display. Clicking the Up button takes you to the directory level up from the current view.


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Clicking the Home button takes you to the main directory holding the Stored Cards and Periodic Cards. Clicking the Active button opens the folder containing the most recent Periodic Cards. Setting Curve Visibility You can select the curve that is emphasized in a displayed card. You can select the curve that is emphasized before you display a card, or you can change the emphasized curve on a card that you’ve already opened. To select the curve emphasized: 1. Click the Set Curve Visibility button at the top of the History Card Browser pane. The Curve Visibility Options dialog box appears, as shown in Figure 14.3. Figure 14.3: The Curve Visibility Options

2. From the Emphasized Curve list, select the curve that you want emphasized in the display. The scaling of the card will adjust to best display the emphasized curve. 3. Under Additional visible curves, select the check box corresponding to the curve you want displayed and clear the check box corresponding to the curve yo u do not want displayed. 4. Click OK to close the dialogue box and save your changes. The changes are applied to the displayed history card (if any) and on future displayed cards until you change the curve visibility options again.

14.2

Viewing Periodic Cards Periodic Cards are collected in real time, while the Realift Rod Pump HMI is connected to the Realift Rod Pump drive. The cards are stored in folders identified by the time the folder was created and the first card was placed in it. Each folder stores up to 100 cards. Once 100 cards have been stored in a folder, the next card collected is stored in a new, automatically-created folder.

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Figure 14.4: Periodic Card Folders

Scroll down the folder list to see the folders currently in memory. Clicking on a folder displays its individual cards, each identified by its time stamp, as shown in Figure 14.5. Figure 14.5: Periodic Folder Contents

Clicking on the file name of the desired card displays the card data, as shown in Figure 14.6. If the data in the selected card has been corrupted, the History Card Browser will not display the card. It will display instead the last card with valid data.


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Figu re 14.6 : History Card

14.3

Viewing Stored Cards You can use the Stored Cards option to view:

• •

Cards stored locally on the Realift Rod Pump while the Realift Rod Pump HMI was disconnected Last Pump Off state or Well Fault, including well conditions immediately prior to an event.

If the data in the selected card has been corrupted, the History Card Browser will not display the card. It will display instead the last card with valid data. The card data is stored in a CSV file which could be viewed or modified by an outside program.

RISK OF LOSS OF DATA Editing the content of the CSV files using an external tool will change the values displayed in the card. Do not edit the CSV file using an external tool. Failure to follow these instructions may lead to a loss of data. The Realift Rod Pump system maintains a set of 18 cards, shown in chronological order in Table 14.11. Table 14.11: Card Set Descriptors C a r d D e s cri p t i o n

Stored 01 - 5th Last Card - Location Pump ID-year- month- date-hour minute_seconds.csv

4th Most Recent Card

Stored 02 - 4th Last Card - Location Pump ID-year- month-date-hour minute_seconds.csv

3rd Most Recent Card

Stored 03 - 3rd Last Card - Location Pump ID-year- month-date-hour minute_seconds.csv

2nd Most Recent Card

Stored 04 - 2nd Last Card - Location Pump ID-year- month-date-hour minute_seconds.csv

Most Recent Card

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5th Most Recent Card

Stored 05 - Last Card - Location Pump ID-year- month-date-hour minute_seconds.csv

5th to Last Card Before Last Stop

Stored 06 - 5th Card Before Last Stop - Location Pump ID-year-month-datehour minute_seconds.csv

4th to Last Card Before Last Stop

Stored 07 - 4th Card Before Last Stop -Location Pump ID-year-month-datehour minute_seconds.csv


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Table 14.11: Card Set Descriptors (continued) C a r d D e s c r ip t i o n

F i le n a m e in S t o r e d C a r d F o l d e r

3rd to Last Card Before Last Stop

Stored 08 - 3rd Card Before Last Stop -Location Pump ID-year-month-datehour minute_seconds.csv

2nd to Last Card Before Last Stop

Stored 09 - 2nd Card Before Last Stop -Location Pump ID-year-month-datehour minute_seconds.csv

Last Card Before Last Stop

Stored 10 - Last Card Before Last Stop -Location Pump ID-year-month-datehour minute_seconds.csv

5th to Last Card Before 2nd to Last Stop

Stored 11 - 5th Card Before 2nd Last Stop -Location Pump ID-year-monthdate-hour minute_seconds.csv

4th to Last Card Before 2nd to Last Stop

Stored 12 - 4th Card Before 2nd Last Stop - Location Pump ID-year-monthdate-hour minute_seconds.csv

3rd to Last Card Before 2nd to Last Stop

Stored 13 - 3rd Card Before 2nd Last Stop - Location Pump ID-year-monthdate-hour minute_seconds.csv

2nd to Last Card Before 2nd to Last Stop

Stored 14 - 2nd Card Before 2nd Last Stop - Location Pump ID-year-monthdate-hour minute_seconds.csv

Last Card Before 2nd to Last Stop

Stored 15 - Last Card Before 2nd Last Stop - Location Pump ID-year-monthdate-hour minute_seconds.csv

First Stroke of Last Start

Stored 16 - First Stroke of Last Start - Location Pump ID-year-month-datehour minute_seconds.csv

Pre-Control Stroke of Last Start

Stored 17 - Pre-Control Stroke Last Start - Location Pump ID-year-monthdate-hour minute_seconds.csv

Card Saved by Operator

Stored 18 - Card Saved by Operator - Location Pump ID-year-month- datehour minute_seconds.csv1

1

Stored by the operator using the Save Current Card button on the Status page.

As with Stored Trends and Events, you should refresh Stored Cards before viewing the most recent set. The 18 cards stored cards are created immediately by Realift Rod Pump but no data is stored in them until the event occurs. For example, the “Card Saved by Operator” is created but remains blank until you click Save Current Card on the Status page, then the card currently displayed on the Status page is stored in the “Card Saved by Operator.” When you transfer cards from the Realift Rod Pump using the Transfer Control and Status pane (see Transferring Stored Cards on page 110), Realift Rod Pump transfers all 18 cards, even if some of them are blank. When you transfer the stored cards, the most rec ent complete sets of 18 cards in folders identified by the timestamp (date and time) of the transfer, as shown in Figure 14.7 are displayed. Figu re 14.7: Stored Card Folder s

Clicking on a folder displays a set of downloaded cards, s hown in Figure14.8.


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Figure 14.8: Stored Card Contents, Folder 2012-03-12 1504_35

14.4

Transferring S tored C ards You can transfer the latest set of trend data from the Realift Rod Pump to the computer using the Transfer Control and Status pane (see Figure 14.9). When you transfer them, the Realift Rod Pump software creates a new folder for the latest cards. Figure 14.9: The Transfer Control and Status Pane

To transfer stored cards:

•

Click Transfer Stored Trends and Events in the Transfer Control and Status pane. The Transfer Control and Status pane is found on both the History Cards page and the History Trends and Events page. A transfer indicator lights and the progress bar fills until transfer is complete (see Figure 14.10).

Figure 14.10: Transfer Control and Status Pane Indicators

Stored trends can then be viewed in the same manner as real-time trends (see Viewing Stored Cards on page 108).

14.5

Changing Card Interval Using the Information and Settings pane of the History Cards page, you can change the interval between card collection. When you commission the Realift Rod Pump, you should set the interval to between 10 seconds to one minute to allow for faster card collection for setting parameters. Once the Realift Rod Pump is completely configured, you can set card intervals anywhere from a few minutes up to an entire day between cards.

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Figure 14.11: Information and Settings Pane

To change the card interval: 1. In the Information and Settings pane, click the Card Interval page. The Card Interval dialog box appears (see Figure 14.12). Figure 14.12: Card Interval Dialog Box

2. Enter the Card Interval Hours, Card Interval Minutes, and Card Interval Seconds to define the time the Realift Rod Pump collects each card. 3. Click OK to close the Card Interval dialog box and save you r changes. You can also define the card interval in the Communication pane on the Time & Network Configuration page (see Establishing Communication Speed and Card Interval Settings on page 27).


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Changing Card Storage Location You can view and change the directory in which the cards are stored on the computer. To view and change the directory in which the cards are stored: 1. Click the CSV File Storage Info button in the Information and Settings pane, shown in Figure 14.11. The Dynagraph CSV File Storage Information window appears (see Figure 14.13). Figure 14.13: The Dynagraph CSV File Storage Information Window

The following CSV file storage information is displayed: — Root Directory: The root storage directory. The cards are stored in folders underneath this directory, first by location, then by pump ID. — Current Storage Directory: The directory that cards are currently being stored in. You can force the Realift Rod Pump to create a new directory and start storing new cards in it by clicking the Manually Create New Directory button. The Realift Rod Pump will then create a new directory and the Number of Cards in Current Directory will be reset. — Card Transfer Status: The Card Transfer Status displays the current status of card transfer. — Max Number of Cards per Directory: The maximum number of cards per directory. This is set to 100 cards. — Number of Cards in Current Directory: The number of cards in the current directory. Once there are 100 cards in the current directory, a new directory is automatically created for the following cards and this number is reset. 2. Click the Root Directory field to change the root directory. The Enter Root Directory dialog box appears. 3. Enter the name of the new root directory.

RISK OF LOSS OF DATA Realift Rod Pump will not store cards directly in the root directory. Choose a local drive on the server and specify a directory name. Failure to follow these instructions may lead to a loss of data. 4. You must choose a local drive and you must specify a directory name; you cannot store cards directly in the root directory of the PC. 5. Click OK to apply your changes. When you change the card storage location, Realift Rod Pump starts transferring periodic cards to the new location. This cannot be stopped. You must use Windows Explorer to delete old or unwanted card files; deleting cards is not possible using the Realift Rod Pump HMI software.

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A

Commissioning Checklist

A.1

Drive Configuration Ta bl e A .1 :

A.2

Pr ep ar at io n

Did you connect the laptop and establish a connection? (see the Realift Rod Pump Software Installation Manual)

Y

N

Did you resolve any Location and Pump ID conflicts? (page 25)

Y

N

Did you Auto-Set HMI Settings Required for the Realift Rod Pump? (page 53)

Y

N

Did you enter the direction of rotation? (page 53)

Y

N

Did you select the Stroke Length Method? (page 53)

Y

N

Did you enter the Stroke Length or appropriate API data? (page 53)

Y

N

Well Data Configuration Table A.2 :

Table A. 3:

Pumping Unit Info rma tio n

Dow nhole Ca lcu lat ion Par ame ter s

What Damping Factor did you enter? (page 63) What Rod String Speed of Sound did you enter? (page 63)

ft/sec

What Tubing Fluid Gradient did you enter? (page 63)

psi/ft

What Casing Fluid Gradient did you enter? (page 63)

psi/ft

What Pump Efficiency Factor did you enter? (page 63) What Pump Diameter did you enter? (page 63) Have you entered the complete rod taper information? (page 65)

Table A.4:

% in Y

N

Sensor and Enclosure Configuration Data

What load cell size did you enter? (page 63)

klbs

Which Proximity Angle did you enter? 1 (page 57 or 61) Did you verify that no sensor alarms are present? (page 71)

o

Y

N

Did you start the Realift Rod Pump in hand mode and verify cards appear? (page 63)

Y

N

Did you calibrate SPM:Hz Ratio? (page 63)

Y

N

1

The proximity angle can be calculated with a smart phone tilt sensor.

Table A.5:

Configuring the Pump Jack for Stand ard Opera tion


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A.3

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Pump Control Configuration The parameters in Tables 18 and 19 may need to be adjusted throughout the commissioning process and during subsequent operation to improve well performance. Ta bl e A. 6:

Ge ne ra l Co nt ro l

Did you set Selected Control Mode? (page 44)

Y

N

Is Off Time (Timed Mode) set? (page 46)

Y

N

Is On Time (Timed Mode) set?1 (page 46)

Y

N

Is Auto Off Time Adjust on? (page 45)

Y

N

If Auto Off Time Adjust is on, is Auto Adjust Max Off Time set? (page 45)

Y

N

If Auto Off Time Adjust is on, is Auto Adjust Min Off Time set? (page 46)

Y

N

Is Off Time (non-Timed) set? (page 45)

Y

N

Ta bl e A. 7:

1

On & Of f Ti me Se tt in gs

Configure Timed Mode settings—a sensor alarm can cause the system to revert to timed mode, regardless of selected control mode.

Ta ble A. 8:

Sp ee d Se tt in gs

Did you enter Maximum, Minimum, and Startup speeds? (page 46)

Y

N

Are the applicable Fill Targets set? (page 48)

Y

N

Are the applicable Fill Minimums set? (page 48)

Y

N

Y

N

Did you set Pre-Control Strokes? (page 51)

Y

N

Did you set Speed Change Strokes? (page 51)

Y

N

Did you set Pump Off Count Limit? (page 51)

Y

N

Did you place the HOA switch in the Auto position? (see the Realift Rod Pump Hardware Installation Manual)

Y

N

Did you set Downhole Fill Control Level (DFCL)?1 (page 76)

Y

N

Ta bl e A. 9:

Fill C on tr ol S et ti ng s

Table A.10: Startup Ti mers (Opti onal) Did you set Start Warning Time? (page 50) Table A.11: Contr ol Triggers

Table A. 12: Initiation of Autom atic Co ntrol

1

DFCL can usually only be properly set after the well is pumped off. Excessive fluid pound can occur if the Realift Rod Pump does not observe the pump off as a result of this parameter not being properly set after a pumped-off card is observed.

Tab le A .13: Fin al Step s Did you save the Parameter Set? (page 32)

Y

N

Did you verify Realift Rod Pump Control during operation? (page 83)

Y

N

If configuring a stand-alone server, did you reduce Card Interval? (page 110)

Y

N

Didyouobserveanormalpump-offcycle?(Optional)

114

Y

N


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B


Troubleshooting

The information in this appendix is designed to help you with common situations.

B.1

Creating a New Rod Pump Background: When you click Create New Rod Pump, a ClearSCADA script creates a new Realift Rod Pump instance and then renames it appropriately. If no license is installed, the new instance remains empty and ultimately gets deleted by the script. If this process is interrupted before the new instance has been deleted (possibly by closing ViewX), the new instance will not have the correct name and will not show up in the Realift Rod Pump list. You will see the message: “Error at line XXX, column XX of Digital Oil Field. Login Type mismatch: ‘CINT’” The existence of this condition means that the create new Rod Pump Controller script will be unsuccessful in the future. Solution 1. In ViewX, check that the dat abase tree is visible, and that it say s “Database”. 2. If the database tree is not visible, click the Database button (

).

Or select View > Explorer Bar > Database. 3. Once the database is displayed, log on to ClearSCADA with the following credentials: Username:

admin1

Password:

welcome

4. Expand the database tree by clicking the symbol to the right of MAIN. 5. Expand the folder "RPC -" 6. Inside this folder, delete any instances that do not have names of the format “RPCXXXX”. Fig ure B .1: Dat aba se Tr ee in Vi ewX


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B.2

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Dynagraph Plots Are Not Displayed But a Grid Appears Figu re B.2: Dynagraph Plots Not Displayed

If the system shows a grid pattern but is blank, verify that the proximity sensor is installed. On the Well Fault Detection page, verify no sensor faults have occurred.

B.3

Dynagraph Plots Are Blank But No Grid Appears Figu re B.3: Dynagraph Plots Are Blank

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Background: The Dynagraph plot is generated by the following program: “C:\Program Files\Schneider Electric\DynagraphTool\Graphtool.exe” This program runs as a service and converts data to PNG images that are displayed as “remote images” in ClearSCADA. They are served on port 8080 by the following program: “C:\Program Files\Schneider Electric\DynagraphTool\mongoose-3-0.exe” The following program starts the graph tool and mongoose-3-0 and restarts them if necessary: “C:\Program Files\Schneider Electric\DynagraphTool\GraphRunningCheck.exe” These three programs run as services. Solution: 1. Verify that these services are running: a. Click Start. b. Type “Services” and press Enter. The Services dialog box appears. c. Click the top of the "Name" column so that the services are listed in alphabetical order. d. Look for each of these services and verify that they are running. e. If they exist and have been stopped, start them and set them to start automatically 2. If they are not on the list of services. a. Use "My Computer" and navigate to the following directory: “C:\Program Files\Schneider Electric\DynagraphTool\” b. Verify that each of the 3 service executable files described above actually exists and has not been deleted by anti-virus software. If they have been, restore them from another Realift Rod Pump-HMI installation. 3. If the executable files for these services do exist but the services are not on the services list in the Services dialog box: a. Navigate to: “C:\Program Files\Schneider Electric\DynagraphTool\” b. Right-click the "The Services -- Setup GraphRunningCheck and Mongoose service.exe" file and select "Run as Administrator" from the context menu. c. Right-click the "The Services - Start.exe" file and select "Run as Administrator" from the context menu. 4. Verify that the services are now running. If they are, when you go back to the software, the cards may still be blank. To restore the cards when the services have been restarted: a. From the Realift Rod Pump HMI Software Main Menu, navigate to a pump by clicking on the pump and then clicking Navigate to Pump button. b. In the Card Display & Settings dialog box, at the lower right corner of the Status page, click Set Curve Visibility.


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Figu re B.4: The Car d Disp lay & Set tings Dialo g Box

c. Select or clear the check box corresponding to one of the curves. This will change the curve visibility and cause the graph to refresh. 5. If the services are running but the card is still blank, port 8080 may be blocked or another service could already be installed that listens on port 8080. a. Try disabling any anti-virus software, especially McAfee. b. Try disabling any other web-servers that exists on port 8080 (ClearSCADA WebX listens on port 80 not port 8080). 6. If you still cannot get the cards to appear, try either installing the software onto a different computer or installing onto a virtual machine.

B.4

ClearSCADA Database Corrupt The icon in the System tray is pink and the message says the Database is corrupt. To correct this situation: 1. Click the Start button. 2. Enter “cmd” in the Search programs and files text box and press Enter. The Command Prompt window appears. 3. Enter “checkdks /F” in the Com mand Prompt window and press Enter. 4. Restart the computer.

B.5

Drive Runs in Hand or Manual Mode Only Background: The drive runs in hand or manual mode but will not work in automatic or timed mode, or, if it runs it starts but quickly shuts off. The Drive Status Code in the upper left corner o f the Status page indicates "Run" but the output frequency is 0.0Hz. Solution:

B.6

•

Verify that Startup Speed (Keypad Start Speed) is set to an appropriate value. See Setting Pump Speeds on page 46.

•

Verify that Maximum Speed (Keypad Max Speed) is set to an appropriate value. See Setting Pump Speeds on page 46.

Realift Rod Pump Speed Oscillates or Realift Rod Pump Does Speed Hunting Background: The Realift Rod Pump speed is oscillating or the Realift Rod Pump is doing speed hunting.

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Solution: You can increase the pump fill filter weight. The Pump Fill Filter Weight filters “Pump fill” so that it can not update as quickly. Each new pump fill calculation is averaged with the previous pump fill calculations to reduce the speed oscillations or “hunting” that result from an oscillating pump fill. To increase the pump fill filter weight: 1. Go to the Status page. 2. In the lower right corner of the Status page, click the Set Filtering Options button in the Card Display & Settings pane. 3. Define the Pump Fill Filter Weight as a percentage. For more information, see Card Display and Settings on page 94.

B.7

Difference Between Fill Control Level and Fill Target The difference between the Fill Control Level in the Surface & Downhole Data pane on the Status page and the Fill Target in the Fill Control Settings pane on the Pump Control Configuration page:

B.8

•

The Fill Control Level determines how the Realift Rod Pump calculates pump fill. When the well is less than 100% full, the rods begin to hammer. This is visible in the downhole card when the lower right corner of the downhole card disappears. The Fill Control Level is the position above the bottom of the card where the Realift Rod Pump looks to calculate pump fill. The default is 35% and it should be set to this value. This means that the Realift Rod Pump will look 1/3rd of the way up from the bottom of the downhole card to measure pump fill. Pump fill is the width of the card 1/3rd of the way from the bottom.

•

The Fill Target is different from this. If the Actual Fill is more than the Fill Target, the Realift Rod Pump will speed up in an attempt to pump out oil so that actual fill matches the fill target. If the actual fill is less than the fill target the Realift Rod Pump will slow down so that the pump will fill back up. The Realift Rod Pump will slow down to minimum speed if necessary in order to match the fill target. If fill reaches the fill minimum, the Realift Rod Pump will stop for pump off time.

Operation i n “Downhole M ode” a nd P ump F ill Indicates 0 % Background: The Realift Rod Pump is operating in Downhole Mode and the pump fill indicates 0%. Solution: Verify that the “Downhole Control percent” on the status page is set correctly. 35% is the recommended value. This parameter is used for the calculation of downhole pump fill and is not the same thing as Fill Target or Fill Minimum that are found in the Fill Control Settings pane of the Pump Control Configuration page. See Setting the Downhole Fill Control Level on page 76.


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C

The Data Stored in Periodic and Stored Cards

C.1

Periodic Cards The data stored on periodic cards is divided into the following sections:

• • •

General

• • • •

Pump Control Configuration Well Data Configuration

Status Time and Network Configuration

Well Fault Detection ATV Drive.

General

• • • • •

Location Pump ID Card Type Server Clock (Time Downloaded from RPC) RPC Clock (Card Time Stamp)

Status

• • • •

RPC Status

• • • • • • • • • • • • • • • •

Card Frequency (Hz)

• •

Polished Rod Power (HHP) Pump Power (HHP)

1

Fill Status - Downhole (%) Reference Frequency (Hz) Output Frequency (Hz) Card Pump Rate (SPM) Pump Rate (SPM) Fluid Height in Casing (ft) Pump Intake Pressure (psi) Fluid Load (lbs) Belt Slip (%) Imbalance (%) Run Time Today (%) Production Today (bbl)1 Fill Control Level - Surface (lbs) Fill Control Level - Downhole (%) Surface Total Stroke (in) Downhole Total Stroke (in) Surface Effective Stroke (in) Downhole Effective Stroke (in)

The production today is calculated using the gross production and not the net production. In other words, water cut is not taken into consideration when calculating the production today.


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R e aRP liofutdmp C h a p t erC—T h eD at aSt o r e dinPe r io d ica n dSt o r edC ar d s

• • • • •

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Load Cell Filter Value (%) Fill Status Filter Value (%) Downhole Card Filter Value (%) Filter Method Control Enabled

Pump Control Configuration

• • •

Selected Control Mode

• • • • • • • • • • • • • • • • • • • • • • • •

Auto Off Time Adjust Off Time [non-Timed] (min)

Current Control Mode Produced Resource

Auto Adjust Maximum Off Time (min) Auto Adjust Minimum Off Time (min) Off Time [Timed Mode] (min) On Time [Timed Mode] (min) Startup Speed (Hz) Maximum Speed (Hz) Minimum Speed (Hz) Fill Control - Torque Minimum (%) Fill Control - Torque Target (%) Fill Status - Torque (%) Fill Control - Surface Minimum (%) Fill Control - Surface Target (%) Fill Status - Surface (%) Fill Control - Downhole Minimum (%) Fill Control - Downhole Target (%) Fill Status - Downhole (%) Power Cycle Start Delay (sec) Start Warning Time (sec) Start Reverse Time (sec) Pre-Control Strokes (str) Speed Change Strokes (str) Pump Off Count Limit (str)

Well Data Configuration

122

• • • • • • •

Stroke Length (in)

• • • •

Damping Factor

Stroke Length Method Direction of Rotation SPM:Hz Ratio (SPM/Hz) Proximity Angle (deg) Prox Debounce Time (msec) Load Cell Size (klbs) Rod String Speed of Sound (ft/sec) Tubing Fluid Gradient (psi/ft) Casing Fluid Gradient (psi/ft)


Version 3.0c 1 2 / 2 0 14


• • • • • • • • • •

Pump Diameter (in)

• • • • • • • • • • • • •

Rod Modulus Taper #1 (Mpsi) Rod Length Taper #2 (feet)

Pump Efficiency Factor (%) Include Buoyancy in Calculation Stuffing Box Friction (lbs) Casing Pressure at Surface (psi) Tubing Pressure at Surface (psi) Number of Tapers Rod Length Taper #1 (feet) Rod Diameter Taper #1 (in) Rod Weight Taper #1 (lbs/ft)

Rod Diameter Taper #2 (in) Rod Weight Taper #2 (lbs/ft) Rod Modulus Taper #2 (Mpsi) Rod Length Taper #3 (feet) Rod Diameter Taper #3 (in) Rod Weight Taper #3 (lbs/ft) Rod Modulus Taper #3 (Mpsi) Rod Length Taper #4 (feet) Rod Diameter Taper #4 (in) Rod Weight Taper #4 (lbs/ft) Rod Modulus Taper #4 (Mpsi)

Well Fault Detection

• • •

High Belt Slip - Detection Enabled

•

Belt Slip (%)

High Belt Slip - Startup Ignore (str) High Belt Slip - Threshold Value (%)

— High Belt Slip - Well Alarm Detection Limit Current Value (str) — High Belt Slip - Well Alarm Detection Count Current Value (str) — High Belt Slip - Well Fault Detection Limit Current Value — High Belt Slip - Well Fault Detection Count Current Value

• • •

High Imbalance - Detection Enabled

•

Imbalance (%)

High Imbalance - Startup Ignore (str) High Imbalance - Threshold Value (%)

— High Imbalance - Well Alarm Detection Limit Current Value (str) — High Imbalance - Well Alarm Detection Count Current Value (str)


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— High Imbalance - Well Fault Detec tion Limit Current Value — High Imbalance - Well Fa ult Detection Count Current Value

• • •

Low Max Card Load - Detection Enabled

•

Max Card Load (lbs)

Low Max Card Load - Startup Ignore (str) Low Max Card Load - Threshold Value (lbs)

— Low Max Card Load - Well Alarm Detection Limit Current Value (str) — Low Max Card Load - Well Alarm Detection Count Current Value (str) — Low Max Card Load - Well Fault Detection Limit Current Value — Low Max Card Load - Well Faul t Detection Count Current Value

• • •

Low Fluid Load - Detection Enabled

•

Fluid Load (lbs)

Low Fluid Load - Startup Ignore (str) Low Fluid Load - Threshold Value (lbs)

— Low Fluid Load - Well Alarm Detection Limit Current Value (str) — Low Fluid Load - Well Alarm Detection Count Current Value (str) — Low Fluid Load - Well Fault Detec tion Limit Current Value — Low Fluid Load - Well Fau lt Detection Count Current Value

• • •

High Torque - Detection Enabled

•

Torque (%)

High Torque - Startup Ignore (sec) High Torque - Threshold Value (%)

— High Torque - Well Alarm Detection Limit Current Value (sec) — High Torque - Well Alarm Det ection Count Current Value (sec) — High Torque - Well Fault Dete ction Limit Current Value — High Torque - Well Fault Det ection Count Current Value — Low Torque - Detection Enabled — Low Torque - Startup Ignore (sec) — Low Torque - Well Threshold Value (%)

•

Torque (%) — Low Torque - Well Alarm Detec tion Limit Current Value (sec) — Low Torque - Well Alarm Detec tion Count Current Value (sec) — Low Torque - Well Fault Detection Limit Current Value — Low Torque - Well Fault Detection Count Current Value

• • •

Low Output Frequency - Detection Enabled

•

Output Frequency (Hz)

Low Output Frequency - Startup Ignore (sec) Low Output Frequency - Well Threshold Value (Hz)

— Low Output Frequency - Well Alarm Detection Limit Current Value (sec) — Low Output Frequency - Well Alarm Detection Count Current Value (sec)

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— Low Output Frequency - Well Fault Detection Limit Current Value — Low Output Frequency - Well Fault Detection Count Current Value

• • •

High Motor Power - Detection Enabled

•

Motor Power (kW)

High Motor Power - Startup Ignore (sec) High Motor Power - Well Threshold Value (kW)

— High Motor Power - Well Alarm Detection Limit Current Value (sec) — High Motor Power - Well Alarm Detection Count Current Value (sec) — High Motor Power - Well Fault Detection Limit Current Value — High Motor Power - Well Fault Detection Count Current Value

• • •

High Load Cell - Detection Enabled

•

Load Cell (lbs)

High Load Cell - Startup Ignore (sec) High Load Cell - Well Threshold Value (lbs)

— High Load Cell - Well Alarm Detection Limit Current Value (sec) — High Load Cell - Well Alarm Dete ction Count Current Value (sec) — High Load Cell - Well Fault Det ection Limit Current Value — High Load Cell - Well Fault Detection Count Current Value — Low Load Cell - Detection Enabled — Low Load Cell - Startup Ignore (sec) — Low Load Cell - Well Threshold Value (lbs)

•

Load Cell (lbs) — Low Load Cell - Well Alarm Detection Limit Current Value (sec) — Low Load Cell - Well Alarm Detection Count Current Value (sec) — Low Load Cell - Well Fault Detection Limit Current Value — Low Load Cell - Well Fault Detection Count Current Value

• • • • •

Load Cell Status Proximity Sensor Status Missed Prox Count Well Alarm Status Well Fault Status

Time and Network Configuration

• • • • • • • •

Target IP Address

• • • •

Run-Time Since Reset (hours)

RPC Version RPC Version Type RPC HMI Version Parameter Set Most Recently Accessed Rod Stroke Count (str) Pump Stroke Count (str) Stroke Count Current Run (str) Run Time Current Run (hh:mm:ss) Run Time Total (hours) Energy Save Begin Time - Sunday


125


• • • • • • • • • •

Energy Save End Time - Sunday

• • •

Energy Save End Time - Friday Energy Save Begin Time - Saturday

Ve r s3io .0nc 12 / 2 0 14

Energy Save Begin Time - Monday Energy Save End Time - Monday Energy Save Begin Time - Tuesday Energy Save End Time - Tuesday Energy Save Begin Time - Wednesday Energy Save End Time - Wednesday Energy Save Begin Time - Thursday Energy Save End Time - Thursday Energy Save Begin Time - Friday

Energy Save End Time - Saturday

ATV Drive

• •

C.2

Motor Voltage (V) Motor Current (A)

Stored Cards The data stored on stored cards is divided into the following sections:

• • •

General Status Time and Network Configuration.

General

•

Location

• • •

Pump ID Card Type RPC Clock (Card Time Stamp)

Status

• •

Card Frequency (Hz) Card Pump Rate (SPM)

Time and Network Configuration

•

126

RPC HMI Version


Version 3.0c 1 2 / 2 0 14

D


User Privilege Levels

The user privilege levels of the three types of users described in Creating and Deleting Users on page 14 are described in the following table. For each parameter, a user’s privilege level can be Active, Disabled, or Read-only:

• • •

Active: The user has the right to modify this parameter. Disabled: The user does not have the right to modify this parameter. Read-only: This parameter is displayed but cannot be modified.

Ta bl e 1:

Us er P ri vi le ge Le v el s A d m in

C o n f ig

V ie w

Login Page Refresh List Navigate To Selected Pump

Active Active

Logout HMI Server IP Address Create new Pump Delete Selected Pump Manage Users

Active Active

Active Active

Active Active

Acknowledge Selected Alarm

Active Disabled

Active

Active Active

Disabled Disabled

Active Disabled Disabled Disabled

Disabled

Disabled

Active

Active

Active

Manage Users Create User

Active

Disabled

Disabled

Delete User

Active

Disabled

Disabled

Exit

Active

Active

Active

Status Page Run Pump

Active

Active

Disabled

RPC Status

Read-Only

Read-Only

Read-Only

Drive Status

Read-Only

Read-Only

Read-Only

Active Control Mode RunTimeCurrentRun/OffTimeRemaining/Elapsed Stroke CountCurrentRun

Read-Only Read-Only Read-Only



Fill Status

Read-Only

Read-Only

Read-Only

Frequency Command

Read-Only

Read-Only

Read-Only

Actual Frequency Pump Rate Fluid Height in Casing Pump Intake Pressure

Read-Only Read-Only Read-Only Read-Only



Fluid Load

Read-Only

Read-Only

Read-Only

Belt Slip

Read-Only

Read-Only

Read-Only

Imbalance Run Time Today Run Time Yesterday



Production Today

Read-Only

Read-Only

Production Yesterday

Read-Only

Read-Only

Surface Fill Control Level

Active

Active

Surface Total Stroke

Read-Only

Read-Only

Surface Effective Stroke

Read-Only

Read-Only

SurfacePolishedRodPower


Read-Only

Read-Only

Read-Only Read-Only Read-Only Read-Only Read-Only Disabled Read-Only Read-Only Read-Only

127

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Ta b l e 1 :

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Us er P ri vi le g e L ev e ls (continued) A d m in

Downhole Fill Control Level

Active

C o n f ig Active

Downhole Total Stroke

Read-Only

Read-Only

DownholeEffectiveStroke

Read-Only

Read-Only

Downhole Pump Power

Read-Only

Read-Only Read-Only

Read-Only

Read-Only

Card Interval

Active

Active

Card Age

Read-Only

Read-Only

Manually Initiate Card Transfer

Active

SetCurveVisibility Set Filtering Options Save Current Card View Card in Full Screen Mode

Active

Active Active Active Active

V ie w Disabled

Disabled Read-Only Active


Active Disabled Disabled Active

Status Page (Fullscreen Card View) Set Curve Visibility Return to Normal Status Page

Active Active

Active Active

Active Active

Trend Page Downhole Diagnostics

Active

Active

Surface Diagnostics

Active

Active

Active

Torque Diagnostics

Active

Active

Active

Counters and Timers Pump Fill and Pump Off

Active Active

Active Active

Active

Active Active

Downhole, Production and Power

Active

Active

Active

Speed Drive Parameters

Active

Active

Active

Natural Gas Production

Active

Active

On and Off Status Pump Rate Load Samples Run Time Max and Min Load Max Drive Power Polished Rod and Pump Power

Active Active Active Active Active

Reset RPC Values Clear Displayed Values Exit TransferStoredTrendsandEvents

Active Active Active

Active

Active

Active Active

Active

Disabled

Active

Active Active

Active Active

Active

Active

Active Active

Active

Active

Active

Active

Active

Active

Active

Active Active

Active

Active

Production Estimate Events and Start Stop Log

Active

Disabled

Active Active

Active Disabled

History Page Set Curve Visibility

Active

Refresh One Up Level

Active

Active

Active Active

Active

Active

Active Folder

Active

Active

Active

Active

Active

Home

Transfer Stored Cards

Active


Card Interval

Active

Active

Disabled

Card Transfer Status

Read-only

Read-only

Read-only

CSV File Storage Info

128

Active

Active

Active

Active

Active


Version 3.0c 1 2 / 2 0 14


Tab le 1 :

U s er P r i v i l e g e L e v e l(continued) s A d m in

C o n f ig

V ie w

CSV File Storage Info Sub-Page Root Directory

Active

Disabled

Disabled

CurrentStorageDirectory

Read-Only

Read-Only

Read-Only

Card Transfer Status MaxNumberofCardsPerDirectory

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

NumberofCardsinCurrentDirectory

Read-Only

Read-Only

Read-Only

Manually Create New Directory

Active

Active

Read-Only

Exit

Active

Active

Active

Pump Control Configuration Selected Control Mode

Active

Active

Disabled

Current Control Mode

Read-Only

Read-Only

Read-Only

GDT Password

Hidden

Hidden

Hidden

Produced Resource

Read-Only

Read-Only

Active

Active

Auto Off-Time Adjust – Yes/No Off Time (non Timed)

Active

Active

Read-Only Disabled Disabled

Auto Adjust Max Off-Time

Active

Active

Disabled

Auto Adjust Min Off-Time

Active

Active

Disabled

Off Time (Timed Mode)

Active

Active

Disabled

On Time (Timed Mode)

Active

Active

Disabled

Startup Speed

Active

Max Speed Min Speed Units for Speed Settings SPM Hz Ratio :



Disabled Disabled Disabled Active Read-Only

Torque Fill Minimum

Active

Active

Disabled

Torque Fill Target

Active

Active

Disabled

Torque Fill Status

Read-Only

Read-Only

Read-Only

Surface Fill Minimum

Active

Active

Disabled

Surface Fill Target

Active

Active

Disabled

Surface Fill Status

Read-Only

Read-Only

Read-Only

Downhole Fill Minimum

Active

Active

Disabled

Downhole Fill Target

Active

Active

Disabled

Downhole Fill Status Power Cycle Start Delay

Read-Only Active

Read-Only Active

Read-Only Disabled

Start Warning Time

Active

Active

Disabled

Start Reverse Time

Active

Active

Disabled

Pre-Control Strokes Speed Change Strokes Pump Off Count Limit



Disabled Disabled Disabled

Well Data Configuration Stroke Length

Active

Active

Disabled

Stroke Length Method

Read-Only

Read-Only

Disabled

Enter API Dimensions

Active

Active

Active

Pumping Unit Type

Active

Active

Disabled

Direction of Rotation SPM Ratio Hz :


Active Active

Active Active

Disabled Disabled

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C o n f ig

Active

Active

Calibrate Proximity Angle Prox Debounce Time Load Cell Size



Read-Only

Read-Only

Load Status

Read-Only

Read-Only

Damping Factor

Active

Active

Active


Prox Status

Rod String Speed of Sound

V ie w Disabled

Active

Read-Only Read-Only Disabled Disabled

Tubing Fluid Gradient

Active

Active

Disabled

Casing Fluid Gradient

Active

Active

Disabled

Pump Diameter

Active

Active

Disabled

Pump Efficiency Factor

Active

Active

Disabled

Include Buoyancy in Calculation

Active

Active

Disabled

Stuffing Box Friction

Active

Active

Disabled

Casing Pressure at Surface

Active

Active

Disabled

Tubing Pressure at Surface

Active

Active

Disabled

Number Tapers of

Active

Active

Disabled

Taper Length 1

Active

Active

Disabled

Taper Diameter 1

Active

Active

Disabled

Taper Weight 1

Active

Active

Disabled

Taper Modulus 1

Active

Active

Disabled

Taper Length 2

Active

Active

Disabled

Taper Diameter 2

Active

Active

Disabled

Taper Weight 2

Active

Active

Disabled

Taper Modulus 2

Active

Active

Disabled

Taper Length 3

Active

Active

Disabled

Taper Diameter 3

Active

Active

Disabled

Taper Weight 3 Taper Modulus 3

Active Active

Active Active

Disabled Disabled

Taper Length 4

Active

Active

Disabled

Taper Diameter 4

Active

Active

Disabled

Taper Weight 4

Active

Active

Disabled

Taper Modulus 4

Active

Active

Disabled

Taper Length 5

Active

Active

Disabled

Taper Diameter 5

Active

Active

Disabled

Taper Weight 5

Active

Active

Disabled

Taper Modulus 5

Active

Active

Disabled

Taper Length 6

Active

Active

Disabled

Taper Diameter 6

Active

Active

Disabled

Taper Weight 6

Active

Active

Disabled

Taper Modulus 6

Active

Active

Disabled

API Dimensions Stroke Length Stroke Length Method Pumping Unit Type Direction of Rotation

130

Active

Active

Disabled

Active

Active

Disabled

Active Active

Active Active

Disabled Disabled

R

Active

Active

Disabled

K

Active

Active

Disabled

C

Active

Active

Disabled


Version 3.0c 1 2 / 2 0 14


Tab le 1 :


C o n f ig

P

Active

Active

Disabled

V ie w

A

Active

Active

Disabled

I

Active

Active

Disabled

WELL FAULT DETECTION Trend Hyperlinks High Belt Slip High Imbalance Low Max Card Load Low Fluid Load




High Torque

Active

Active

Active

Low Torque

Active

Active

Active

Low Output Frequency High Motor Power

Active Active

Active Active

Active Active

High Load Cell

Active

Active

Active

Low Load Cell

Active

Active

Active

Active

Active

Disabled

Detection Enable Check Boxes High Belt Slip High Imbalance Low Max Card Load Low Fluid Load




High Torque

Active

Active

Disabled

Low Torque

Active

Active

Disabled


Active Active

Active Active

Disabled Disabled

High Load Cell

Active

Active

Disabled

Low Load Cell

Active

Active

Disabled

Active

Active

Disabled

Startup-Ignore High Belt Slip High Imbalance Low Max Card Load Low Fluid Load




High Torque

Active

Active

Disabled

Low Torque

Active

Active

Disabled


Active Active

Active Active

Disabled Disabled

High Load Cell

Active

Active

Disabled

Low Load Cell

Active

Active

Disabled

Active

Active

Disabled

Threshold-Value High Belt Slip High Imbalance Low Max Card Load Low Fluid Load




High Torque

Active

Active

Disabled

Low Torque

Active

Active

Disabled


Active Active

Active Active

Disabled Disabled

High Load Cell

Active

Active

Disabled

Low Load Cell

Active

Active

Disabled


131


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C o n f ig

V ie w

Alarm-Limit High Belt Slip High Imbalance Low Max Card Load Low Fluid Load

Active

Active

Active Active

Active Active

Active

Active

Disabled Disabled Disabled Disabled

High Torque

Active

Active

Disabled

Low Torque

Active

Active

Disabled


Active Active

Active Active

Disabled Disabled

High Load Cell

Active

Active

Disabled

Low Load Cell

Active

Active

Disabled

Active

Active

Disabled

Fault-Limit High Belt Slip High Imbalance Low Max Card Load Low Fluid Load

Active Active

Active Active

Active

Active


High Torque

Active

Active

Disabled

Low Torque

Active

Active

Disabled


Active Active

Active Active

Disabled Disabled

High Load Cell

Active

Active

Disabled

Low Load Cell

Active

Active

Disabled

Current Value of Parameter High Belt Slip High Imbalance Low Max Card Load




Low Fluid Load High Torque

Read-Only Read-Only

Read-Only Read-Only

Read-Only Read-Only

Low Torque

Read-Only

Read-Only

Read-Only

Low Output Frequency

Read-Only

Read-Only

Read-Only

High Motor Power

Read-Only

Read-Only

Read-Only

High Load Cell

Read-Only

Read-Only

Read-Only

Low Load Cell

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

Current Value - Alarm Count High Belt Slip High Imbalance Low Max Card Load Low Fluid Load

Read-Only Read-Only

Read-Only Read-Only

Read-Only Read-Only

Read-Only

Read-Only

High Torque

Read-Only

Read-Only

Read-Only Read-Only

Low Torque

Read-Only

Read-Only

Read-Only

Low Output Frequency

Read-Only

Read-Only

Read-Only

High Motor Power

Read-Only

Read-Only

Read-Only

High Load Cell

Read-Only

Read-Only

Read-Only

Low Load Cell

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

Current Value - Retry Count High Belt Slip High Imbalance Low Max Card Load Low Fluid Load

132





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Tab le 1 :


C o n f ig

V ie w

High Torque

Read-Only

Read-Only

Read-Only

Low Torque

Read-Only

Read-Only

Read-Only

Low OutputFrequency

Read-Only

Read-Only

Read-Only

High Motor Power

Read-Only

Read-Only

Read-Only

High Load Cell

Read-Only

Read-Only

Read-Only

Low Load Cell

Read-Only

Read-Only

Read-Only

Load Cell Sensor Status

Read-Only

Proximity Sensor Status Missed Prox Count Missed Prox Count Reset ResetDetection for Well and Drive

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

Active

Read-Only

Active

Active

RunTimeCurrentRun/OffTimeRemaining/Elapsed Stroke CountCurrentRun

Read-Only

Active

Active

Read-Only

Active

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

Time and Network Configuration Location Pump (or Well) ID

Active

RPC HMI Version

Read-Only Active

Read-Only Read-Only

Communication Settings

Read-Only Read-Only

Active

Detailed Settings Card Interval (hh:mm:ss)

Disabled

Read-Only Active

RPC Version

Disabled

Active

Communication State Target Address IP

Active

Active

Read-Only Read-Only

Active

Active Active

Read-Only Disabled

Active Active

Disabled Active Disabled

Parameter Set Admin Open –

Active

Active

Disabled

Parameter Set Admin Save –

Active

Active

Disabled

Parameter Set Admin Delete –

Active

Active

Disabled

Parameter Set Admin View –

Active

Active

Disabled

Reset RPC To Factory Settings Time of New Day (24h Format) Server Date & Time RPC Date Time &

Active Active Read-Only Read-Only

Active Active Read-Only Read-Only

Disabled Disabled Read-Only Read-Only

Time Set

Active

Active

Disabled

Rod Stroke Count

Read-Only

Read-Only

Read-Only

Rod Stroke Count Reset Pump Stroke Count Pump Stroke Count Reset Stroke CountCurrentRun Run Time Since Reset Run Time SinceReset,ResetButton

Active Read-Only Active Read-Only Read-Only Active

Active Read-Only Active Read-Only Read-Only Active

RunTimeCurrentRun/OffTimeRemaining/Elapsed

Active

Active

Run Time Total

Read-Only

Read-Only

Active Read-Only Active Read-Only Read-Only Active Active Read-Only

Energy Save Sunday Begin Time

Active

Active

Disabled

Energy Save Sunday End Time

Active

Active

Disabled

Energy Save Monday Begin Time

Active

Active

Disabled

Energy Save Monday End Time Energy Save Tuesday Begin Time

Active Active

Active Active

Disabled Disabled

Energy Save Tuesday End Time

Active

Active

Disabled

EnergySaveWednesdayBeginTime

Active

Active

Disabled

Energy Save Wednesday End Time

Active

Active

Disabled


133


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Energy Save Thursday Begin Time

Active

C o n f ig Active

V ie w Disabled

Energy Save Thursday End Time

Active

Active

Disabled

Energy Save Friday Begin Time

Active

Active

Disabled

Energy Save Friday End Time

Active

Active

Disabled

Energy Save Saturday Begin Time

Active

Active

Disabled

Energy Save Saturday End Time

Active

Active

Disabled

Detailed Communications Settings Communications State Comm Timeout Count Comm Timeout Count Reset

Read-Only Read-Only Active

Read-Only Read-Only Active

Disabled

Communication Settings

Active

Active

Reestablishment Interval

Active

Active

Data Reply Time Set Value DataReplyTimeCurrentValue Data Collection Time Set Value DataCollectionTimeCurrentValue Card Transfer Time Set Value CardTransferTimeCurrentValue RodPump Controller (RPC)Active ATV Config via RPC Active

Active

Active

Read-Only Active Read-Only

Read-Only

Read-Only

Read-Only

Read-Only

Read-Only Disabled

Read-Only Active

Active

Disabled

Disabled

Active

Active

Disabled

Disabled

Active

Active

Read-Only Read-Only

Read-Only Disabled

Active

Disabled

Drive Configuration Min Speed

Active

Active

Max Speed

Active

Active

Drive Interface Type Drive Address Set Drive Defaults needed… Bypass Contactor External Fault Trigger

134



Disabled Disabled Disabled Disabled Disabled Disabled Disabled


Version 3.0c 1 2 / 2 0 14

E


Resetting the SCADAPack 535 E

The SCADAPack 535 E was configured when it was delivered as part of the Realift Rod Pump. However, under certain circumstances, for example, when the SCADAPack battery has been replaced, it is necessary to reset the SCADAPack 535 E. When you installed the Realift Rod Pump HMI software, copies of the configuration file and the application package file were installed on your computer. You can use these c opies to reset the SCADAPack 535 E. The process of resetting the SCADAPack 535 E takes place in two steps:

E.1

•

Reinstalling the SCADAPack 535 E Firmware

•

Reinstalling the Application Package File.

Reinstalling t he S CADAPack 5 35 E Firmware To reinstall the SCADAPack 535 E firmware: 1. Start the SCADAPack in cold boot mode: a. Remove power from the RTU. b. Hold down the Select button on the top of the S CADAPack 535 E (see Fi gure E.1). c. Apply power to the RTU. d. Continue holding the Select button down for 20 seconds, until the Status LED begins blinking on and off. e. Release the Select button. If you release the Select button before the Status LED begins blinking on and off, the RTU will start in Service mode and you will have to start over at step a. 2. Connect your computer to the SCADAPack 535 E USB device port (see Figure E.1).


135

R e aRP liofutdmp C h a p t eE — rR e s e t t in g t hS e C AD A Pa c5 k3E 5

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Figu re E.1: SCADAPack 535 E USB Ports

3. Select Start > All Programs > Schneider Electric SCADAPack E > SCADAPack E Configurator. The SCADAPack E Configurator opens (see Figure E.2).

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Version 3.0c 1 2 / 2 0 14


Figure E.2: SCADAPack E Configurat or

4. When SCADAPack E Configurator opens, select Open an existing RTU configuration file and click Finish. The Open dialog box appears. 5. In the Open dialog box, navigate to the following folder on your computer: — On 32-bit Windows (x86): C:\Program Files\Schneider Electric\Realift Rod Pump\ConfigurationFiles — On 64-bit Windows (x64): C:\Program Files (x86)\Schneider Electric\Realift Rod Pump\ConfigurationFiles. 6. In the ConfigurationFiles folder, select CONFIGFILE.rtu and click Open. 7. In the tree control displayed on the left-hand side of the SCADAPack E Configurator main window, expand the General folder and select Controller Status. 8. Click the Refresh button (

) in the toolbar.

9. On the Controller Status property page, verify that you have communication with the SCADAPack 535 E. 10. Select File > Write RTU Configuration. A message appears asking you to confirm that you want to write the configuration to the RTU. Figu re E.3 : Confirm Wri ting th e Confi guration to t he RTU

11. Click Yes. A message is displayed, indicating the progress of writing the configuration to the SCADAPack 535 E.


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Ve r s3io .0nc 12 / 2 0 14

Figu re E.4: Progress o f Writi ng the Configurat ion

When SCADAPack E Configurator has completed writing the configuration to the SCADAPack 535 E, you are asked to restart it (see Figure E.5). Fig ure E.5: Res tar tin g the RTU

12. Click Yes to restart the SCADAPack 535 E. SCADAPack E Configurator informs you that the SCADAPack 535 E will be unavailable while it restarts (see Figure E.6). Figu re E.6: SCADA Pack 535 E Unavailable

13. Click OK. The SCADAPack 535 E is restarted. Once the SCADAPack 535 E has restarted. The next step is reinstalling the application package file.

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Version 3.0c 1 2 / 2 0 14

E.2


Reinstalling the Application Package File To reinstall the application package file: 1. In the SCADAPack E Configurator, make the following connection settings in the toolbar (see Figure : — Select TCP from the list — Enter “11” in the Target DNP3 Address box. Figure E .7: Con nec tin g Usi ng TC P

2. Select Communication > Communication Settings. The DNP3 TCP Configuration dialog box appears. 3. In the DNP3 TCP Configuration dialog box, verify that IP address is set to 192.168.0.101, the factory default IP address for the Realift Rod Pump. 4. In the toolbar, click the Refresh button (

).

5. On the Controller Status property page, verify that you have communication with the SCADAPack 535 E. 6. Select IEC 61131-3 > Write Application. The Write IEC 61131-3 Application to the RTU dialog box appears (see Figure E.8). Figu re E.8: The Wri te IEC 611 31-3 App licat ion to the RT U Dialo g Box


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Ve r s3io .0nc 12 / 2 0 14

7. In the Write IEC 61131-3 Application to the RTU dialog box, navigate to the following folder on your computer: — On 32-bit Windows (x86): C:\Program Files\Schneider Electric\Realift Rod Pump\ConfigurationFiles — On 64-bit Windows (x64): C:\Program Files (x86)\Schneider Electric\Realift Rod Pump\ConfigurationFiles. 8. In the ConfigurationFiles folder, select SCADAPack535E.I5P and click Open. A message is displayed, indicating the progress of writing the application package file to the SCADAPack 535 E. When the SCADAPack E Configurator has completed writing the configuration, a dialog box is displayed, indicating that the application package file was successfully loaded onto the SCADAPack 535 E. 9. Click OK. 10. In the tree control displayed on the left-hand side of the SCADAPack E Configurator main window, expand the Logic folder and select IEC 61131-3. 11. In the toolbar, click the Refresh button (

).

12. On the IEC 61131-3 property page, verify that both resources on the SCADAPack 535 E are running (see Figure E.9). Fig ure E.9: IEC 611 31- 3 Tar get

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Realift Rod Pump - Controller - Commissioning Manual.pdf

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