Revised 20 September 05
Table of Contents Section
Rev #
Date
TABLE OF CONTENTS
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20Sep05
i
1.0
REAE ME FIRST
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20Sep05
1
2.0
INTRODUCTION
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20Sep05
2
3.0
GENERAL INFORMATION
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20Sep05
3
4.0
UNIT SPECIFICATIONS
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20Sep05
4
5.0
“PRACTICE SAFETY FIRST”
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20Sep05
5
6.0
INSTALLATION
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20Sep05
6
6.1
WELL SITE PREPARATION
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20Sep05
8
6.2
FOUNDATION
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20Sep05
10
6.3
ELECTRICAL
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20Sep05
11
6.4
ON-SITE ASSEMBLY
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20Sep05
12
6.5
LUBRICATION
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20Sep05
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6.6
BRAKE OPERATION
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20
6.7
SPEED-SENTRY WIRING DIAGRAM
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6.8
SPEED-SENTRY SETTINGS
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OPERATING ROTAFLEX
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7.1
COUNTERBALANCE ADJUSTMENT
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7.2
BEFORE WELL SERVICE
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7.3
AFTER WELL SERVICE
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PREVENTATIVE MAINTENANCE
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51
8.1
CHECKING TOWER CHAIN TENSION
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8.2
ADJUSTING THE TOWER ROLLER CHAIN
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7.0
8.0
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Title
Date 20 Sept 05
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Table of Contents Section
Title
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Date
Page #
8.3
ADJUSTING WEIGHT BOX GUIDE WHEELS
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8.4
TOP IDLER DRUM INSPECTION
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57
9.0
REPLACING THE LOAD BELT
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10.0
MOVING THE UNIT
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63
11.0
PRODUCTION IMPROVEMENT
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66
FORMS PRODUCT PERFORMANCE REPORT
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PPR20041022
iii
1.0 READ ME FIRST Read these instructions prior to assembly or operation. The manufacturer of this Rotaflex Pumping Unit has taken all reasonable precautions to insure quality and safety as associated with the operation of this equipment. The manufacturer is not responsible for any damage done during the installation unless it is installed under the supervision of factory-authorized personnel. Failure to follow manufacturer’s installation instructions, specifications for unit sizing, and installation and safety procedures will void the manufacturer of any responsibility for damage to property or individuals. WARNING: This symbol is used throughout this manual to point out information that involves your safety. Read and understand all assembly and operating instructions and precautions before attempting to assemble and operate the Rotaflex Pumping Unit. WARNING: Some illustrations in the manual show the Rotaflex Pumping Unit with safety shields removed for assembly or for a better view of the subject. NEVER OPERATE THE PUMPING UNIT WITH ANY SAFETY SHIELDS REMOVED.
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2.0 INTRODUCTION Rotaflex Pumping Units are designed to give many years of trouble-free service if properly installed, operated within rated capacity, and serviced as specified. The purpose of this manual is to provide instruction on the installation, operation, and maintenance of a Rotaflex Pumping Unit. Become familiar with the contents of this manual, it will provide the means for a safe and efficient installation and operation. Due to the size of the pumping unit and it’s components, safety must be stressed during installation, at start up and any time maintenance is performed. SAFETY MUST NOT BE SACRIFICED FOR EXPEDIENCY. Before beginning installation, operation or maintenance, review basic safety practices with all the personnel involved with the Rotaflex Pumping Unit. The information presented in this manual was current at the time of printing. The illustrations used may not look exactly like your pumping unit but are representative and specify the correct parts and instructions required to properly install, maintain, and operate your particular pumping unit. The manufacturer reserves the right to redesign and change the machine as may be necessary without notification.
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3.0 GENERAL INFORMATION The Rotaflex Pumping Unit is a long, slow stroke Pumping Unit. Development of this unique unit began in 1983 and is manufactured and marketed by Weatherford Artificial Lift Systems at Odessa, Texas. Information about the unit can be obtained by calling (432) 334-4500 or any Weatherford International Ltd office or Weatherford Service Center.
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4.0 UNIT SPECIFICATIONS 800DX
900
1100
Unit Model Number
R228-300-288
R320-360-288
R320-500-306
Stroke Length ( in.)
288
288
306
30,000
36,000
50,000
Counterweight - minimum ( lbs.)
9,400
9,400
9,800
Counterweight - auxiliary ( lbs.)
12,100
21,980
25,300
Counterweight - maximum ( lbs.)
21,500
31,380
35,100
30
42
50
Load Belt - Length
32 ft. 6 in.
32 ft. 6 in.
33 ft. 10 in.
Load Belt - Tensile Strength (PIW)
10,000 lbs.
10,000 lbs.
10,000 lbs.
Gearbox Size ( x 1000 in./lbs.)
228
320
320
Speed - Maximum ( SPM )
4.5
4.5
4.5
Peak Polished Rod Load ( lbs.)
Load Belt - Width ( in.)
Speed - Minimum ( SPM )
No Absolute Minimum
Working Temperature Range
-40F to 140F
Unit Height
40 ft. 6 in.
40 ft. 6 in.
44 ft. 6 in.
Unit Width
8 ft. 6 in.
8 ft. 6 in.
8 ft. 6 in.
46,000
46,000
54,800
Shipping Height
9 ft. 0 in.
9 ft. 0 in.
10 ft. 6 in.
Shipping Width
7 ft. 8 in.
7 ft. 8 in.
8 ft. 6 in.
Shipping Length
40 ft. 6 in.
40 ft. 6 in.
44 ft. 6 in.
29,000
29,000
29,000
Base Length
24 ft. 0 in.
24 ft. 0 in.
24 ft. 0 in.
Base Width
8 ft. 6 in.
8 ft. 6 in.
8 ft. 6 in.
Shipping Weight ( lbs.)
Base Weight ( lbs.)
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5.0 “PRACTICE SAFETY FIRST” Be prepared for fire, mechanical failure and other emergency in the event that an accident does happen. Rotaflex Pumping Units are constructed of large and heavy moving parts. It is essential that all personnel involved with the installation, assembly, operation and maintenance of the Rotaflex Pumping Unit use extreme care and good safety practices at all times. Wear proper clothing, footwear and head gear. Failure to use extreme care when working with heavy equipment can cause severe bodily injury or death. During installation of the pumping unit, a hoisting supervisor should give directions for all hoisting operations. It is suggested that all personnel be briefed on safety procedures and the installation prior to beginning the actual installation. The supervisor also should be readily visible to the hoist or crane operator and able to view all the hoisting operations. All personnel should exercise extreme caution and stay clear of all objects being hoisted. Cables, chains and slings should be inspected prior to use and replaced if worn or damaged. The Rotaflex Pumping Unit has components that can start moving due to gravity. All personnel should stay clear of any elements that may start moving. Times of particular danger from moving parts would be during installation, counterbalance change, general maintenance, well servicing and conducting dynamometer evaluations. It is essential to prevent accidental movement of any kind during service or maintenance. The Rotaflex Pumping Unit is equipped with two braking systems and a positive lock-out bolt for the brake disk is provided. The operator should provide safety stops from timbers, metal tubing or similar bracing material to support the counterweight box if personnel have to work where injury could occur from movement of the equipment. WARNING: Do not operate the Rotaflex Pumping Unit unless all safety shields and guards are securely fastened in place. WARNING: Do not try to operate the Rotaflex Pumping Unit while any access doors are loose or open. WARNING: Adjust the Caliper Pads on both the manual and automatic braking systems calipers before every incident of service action that might be necessary.
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6.0 INSTALLATION In addition to the equipment and parts supplied and shipped with the Rotaflex Pumping Unit, the operator will need to furnish these additional items and services to complete the installation of the unit: 1 – For the 800DX & 900 units a 50 ton crane with 65’ mast height capability is require. For the 1100 unit a 70 ton crane with 75’ mast height capability is required. Crane should be equipped with: a) 4 - 20’ wire line cables b) 1 - spreader bar (8’ between holes) c) 2 - 3’ wire line cables, and shackles of sufficient size to work with 2” thick pad eyes. The crane will be used to unload the concrete base and the pumping unit, and stand the pumping unit upright. The base weighs approximately 29,000 pounds and the 900 & 800DX units weigh approximately 43,000 pounds, the 1100 unit weighs 58,000 pounds. 1 - 3-man roustabout crew with truck and tools. 1 - backhoe/front-end loader with operator. 12 - yards material suitable for earthen base (amount of material may vary from installation to installation). 1 - 36’ (min.) polished rod with 28’ (min.) liner. 2 - polished rod clamps. 1 - prime mover with hub, sheave, and mounting bolts. 1 - power band belt for prime mover sheave to gear reducer sheave. 1 - electric panel and electrical service for prime mover. 1 - 22.5 ton hydraulic jack. 1 - electrician w/tools and equipment for installation of the prime mover and SPEEDSENTRY. In addition, the operator needs to furnish all well head and downhole equipment. Prior to installing the Rotaflex Pumping Unit, the well should be serviced with the pump and sucker rods. Space the pump off the bottom as recommended by a well design computer predictive for the pumping installation or as recommended by a ROTAFLEX service representative. Leave the top of the polished rod approximately 72 inches above the stuffing box Rev -F
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for 800DX & 900 units, 96 inches for 1100 units, and clamp the polished rod just above the stuffing box. The top of the stuffing box should not be more than 36 inches higher than the earthen pad. If the stuffing box is more than 36 inches higher than the earthen pad, the operator should contact a ROTAFLEX service representative for instructions for proper polished rod/carrier bar attachment as shown in Figure 1. Anticipate new load belts stretching approximately 12 to 18 inches depending upon peak load of the unit. Alternate method: Measuring from the anticipated set height of the top of the concrete base pad, leave the top of the polished rod extended above the stuffing box. The polished rod should extend approximately 96 inches for 800DX & 900 units, 120 inches for 1100 units from the top of the concrete base. Clamp the polished rod just above the stuffing box as shown in Figure 1.
Figure. 1 Polished Rod/Carrier Bar Attachment
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6.1 WELL SITE PREPARATION Because of the geometry of the Rotaflex Pumping Unit, the unit must be placed so the load belt is directly over the center of the well. The earthen base or bed should be of suitable material to carry (without undue settling) a minimum of 125,000 pounds and should extend three feet beyond the concrete portable pad in all directions as shown in Figure 2. If the material in the cellar around the well head cannot support this weight, the material should be replaced with a suitable material that can be properly packed. If the Rotaflex is to be placed over a wellhead cellar, consult with your Weatherford ALS Rotaflex representative for installation recommendations.
Figure. 2
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Concrete Base Setting
8
The pad should be perfectly level from side to side and should be slightly tapered from the well head to the back. The manufacturer recommends the pad be 4 inches higher at the well head. as shown in Figure 3. Since most of the weight is near the well head, the slight taper will allow for some settling that normally occurs. An optional use of a auxiliary base pad may be used to provide additional support. This “nose pad” is approximately 10 ft. x 4 ft. x 1 ft. and is placed perpendicular to the base pad as close to the wellhead as possible.
NOTE: With the use of the nose pad the unit base may be set with little or no elevation taper to account for earthen settling.
Figure 3. Concrete Base Elevation
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6.2 FOUNDATION The portable concrete base supplied by the manufacturer as shown in Figure 4, is of sufficient size and weight to support the Rotaflex Pumping Unit. The base must be properly aligned and positioned beside the well. The front of the base is notched to fit around the casing head. The well alignment brackets attached to the metal rails on the concrete base should be perfectly aligned with the pumping tee as shown in Figure 4. The pad should be perfectly level from side to side. Since it is critical the pad be positioned properly, check all measurements, alignment and level as described on previous pages.
Figure 4. Concrete Base Setup
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6.3 ELECTRICAL Rotaflex Pumping Units can be operated with multi-cylinder gas engines or electric motors. Usually a motor of adequate size is recommended. The operator will need to provide a standard control panel similar to that used with other rod pumping systems. To operate the SPEEDSENTRY, 110V. AC 5 A power supply is needed. The operator will provide from 4 to 6 wires (check SPEED SENTRY model) from the motor control panel to the SPEED SENTRY control box. For more detail, please refer to the Section 6.6, 6.7 and 6.8. If a gas engine is used to operate the unit, alternate provisions had been made to operate on DC power.
Single cylinder gas engines are not recommended to power the Rotaflex pumping unit due to the long stroke and low rotational inertia of the drive components in the Rotaflex pumping unit. The single cylinder engine relies upon high rotational inertia of the engine flywheel and cranks arms with counterweights to assist in lifting the high loads for a brief moment in faster SPM operation of a conventional beam unit. The slower pumping speed of the Rotaflex without the high rotational inertia will cause the single cylinder engine to stall and shutdown.
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6.4 ON-SITE ASSEMBLY The Rotaflex Pumping Unit is shipped 95% assembled. Position the 50-ton (or larger) crane perpendicular to, and near the middle of the concrete base. Position the truck with the unit parallel to the crane. Using four 20-foot wireline cables attached to the lifting eyes on the Rotaflex Pumping Unit as shown in Figure 5, lift the unit off the truck and position it on the concrete base with the front of the Rotaflex Pumping Unit skid 84 inches from the alignment brackets as shown in Figure 6.
Model 800DX 900 1100
Approx. Unit Weight (lbs) 46,000 46,000 54,800
Figure 5. Transporting Unit
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Figure 6. Aligning Rotaflex Unit 1. Install both tie-down bolts and tighten securely. 2. Remove the four 20-foot wireline cables from the lifting eyes. 3. Attach the bridle and carrier bar to the belt bar. The carrier bar has a gate held in place with a 1/2-inch bolt. Orient the carrier bar so the bolt is at the top. The gate is inserted in the prepared slot from the top and should be removed from the top of the carrier bar. There is a 1/2-inch rope attached to the belt bar. It should be untied and reattached to the carrier bar. 4. Using an 8 foot spreader bar, attach two 3-foot wireline cables to the spreader bar and to the pad eyes located on either side of the tower near the crown hood as shown in Figure 7.
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Figure 7. Lifting Rotaflex Unit 5. Remove two bolts attaching each of the shipping supports to the Rotaflex Pumping Unit skid. 6. The crane operator will begin lifting the tower on the hinged skid and when there is sufficient clearance, remove the pin from the shipping support and attach the Rotaflex Pumping Unit standing struts in their place as shown in Figure 8.
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Figure 8. Prepare For Standing Rotaflex 7. Stand the unit up slowly until it breaks-over in the upright position. Bolt the tower beams and Rotaflex Pumping Unit skid together using the 4 bolts and nuts, 2 for each side. Pin the end of the standing struts to the guide shoes, slide the guide shoe forward to lock the strut into place and tighten the guide shoe bolts. Loosen the tie-down bolts and move the unit forward until the unit is against the well alignment brackets. Re-tighten the tie-down bolts as shown in Figures 9 & 10).
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Figure 9. Before Sliding
Figure 10. After Sliding
8.
Remove the wireline cables and spreader bar from the unit.
9.
If the gear reducer does not have a breather filter already installed, remove the oil plug located on top of the gear reducer and replace it with the vented breather filter.
10. Install the prime mover, sheaves, belts and guards. Wire the SPEED-SENTRY into the Motor Control panel. (Refer to SPEED-SENTRY section 6.7). 11. Open the valve on nitrogen bottle to activate the Gas emergency brake system if used on this unit as shown in Figure 11. Ignore this instruction if: the unit has a Linear Actuator emergency brake system.
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Figure 11. Nitrogen Operated Braking System 12. The manual brake has been set at the factory and the brake handle has been positioned against the unit for shipment. Remove the bolt securing the brake handle, reposition the handle and replace the bolt. With the manual brake engaged the handle should extend horizontally away from the unit. 13. Adjust brake pads on the manual brake by removing lock pin and tightening the caliper adjustment nut. Adjust the manual brake to allow for minimal play in the brake handle. Replace the lock pin as shown in Figure 12.
Figure 12. Brake Adjustment
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Note: Remove the four shipping blocks located at each corner of the counterweight box before starting the unit. 14. When power is available, open the front doors and lift the internal counterweight box high enough to install half of the auxiliary counterweight. Close and fasten the doors. 15. Raise the weight box (lower the lifting belt) while pulling down on the rope attached to the carrier bar. This assists the load belt to fall as fast as the weight box is being raised. Apply the brake and turn off the motor when the carrier bar is at the lowest point. WARNING: DO NOT LET ROPE GET WRAPPED AROUND HANDS OR FEET! 16. Attach the carrier bar to the polished rod and replace the gate and 1/2” bolt. 17. Attach the polished rod clamp above the carrier bar. 18. Release the brake slowly and allow the load belt to pick up the polished rod load. Remove the clamp at the stuffing box. 19. Lower the weight box, open the front doors and install enough auxiliary counterweight to balance the unit. (Do not let the unit and well load get over 10 amps out of balance. When fluid has stabilized, the unit and well load should be within 2 or 3 amps for best results.) 20. Close and fasten the front doors. 21. There is a belt retainer bar located at the top of the tower, between the idler drum and the hood hinge, that needs to be inspected to assure the load belt is not rubbing on it. The bar should be adjusted if the belt is rubbing. WARNING: Personnel climbing to the top of the tower for the belt retainer inspection must use a safety harness with lanyard securely attached to the pumping unit.
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6.5 LUBRICATION The recommended oils and oil capacities are as follows: Gearbox Units (by serial no.) before 0655 0655 & after
Amount 37 gallons 63 gallons
Ambient Temperatures -20 - +60 F +10 & above F ISO EP150 ISO EP220 ISO EP150 ISO EP220
Chain and Sprockets Unit (by serial no.) Before 0483 0483 – 0761 * 0762 & after
Oiling system Oil bath Dry Sump Oil Bath
Amount 37 gallons 2 gallons 37 gallons
Oil ISO EP100 Rotack ISO EP100
* Except 0484, 0486-0489, 0494, 0495, 0501, 0502, 0506-0510, 0513-0521, 0523-0525, and 0528-0534. All of these should be converted to the wet sump system. Recommended oil
ISO EP150 Mobilgear 629 Gear Compound EP 150
ISO EP220 Mobilgear 630 Gear Compound EP 220
Supplier Mobil Chevron
Lubrication service is as follows: Gearbox - Check the fluid level at the sight glass regularly. Catch a sample and make a visual inspection of the lubrication every 6 months. Analysis should be made for discoloration of the fluid, or contamination of water or metal particles as necessary and oil changed as needed. Check gear tooth condition for abnormal wear. Change the lubrication in the gear reducer after the first 1,000 hours and once a year thereafter. Routinely check for leaks. Seal replacement is required if a leak develops that exceeds one cup per week. Chain and Sprockets – Oil Bath system - The chain and sprockets are pre-lubricated at the factory. The chain reservoir is fitted with a drain plug to be emptied when needed. Application of oil at startup is serviced from either the outside or the inside of the unit. From the outside, pour oil into filler port located on front of oil collector on tower. From the inside, pour oil into oil collector when the counterweight doors are open and the weight box is raised up at least 6’ out of the way. It is recommended to change the lubrication in the sump once a year.
WARNING: The weight box must be blocked and/or chained before personnel climbs inside the tower! Chain and Sprockets – Dry Sump system – It is recommended to convert these units to a wet sump system. The chain and sprockets are prelubricated at the factory. The chain reservoir is fitted with a drain plug to be emptied when needed. The chain and sprocket MUST be serviced initially at start-up AND every 3 months with an application of 2 gallons of Rotack chain lubrication oil Rotaflex part number 750082. The unit MUST be running for minimum of 6 hours at the time of application of oil to insure distribution of oil to the total length of chain. Application of oil is serviced from the outside of the unit. Pour oil into filler tube located on center of backside of tower, above gearbox sprocket split cover. The components requiring grease and periodic service are: Component Grease Top Drum Grease meeting spec AAR M-942 Top Sprocket Grease meeting spec AAR M-942 The periodic SERVICE requirements are: Grease every six months until part of the old grease is purged out of the grease relief fitting. This is to insure that a certain amount of new grease has entered the bearing cavity. The pre-lubricated, sealed-for-life components and periodic service are: Component Grease Swivel Shaft Grease meeting spec AAR M-942 Carriage Wheels Grease meeting spec AAR M-942 Weight Box Wheels Grease meeting spec AAR M-942 These anti-friction roller bearings have been lubricated at the factory. No re-lubrication is necessary. The periodic SERVICE requirements are: Inspect the seals every 6 months to insure no loss of grease and these seals have not lost their sealing capability.
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6.6 BRAKE OPERATION – MANUAL & AUTOMATIC The Rotaflex unit is equipped with both a manually operated brake and an automatically operated brake. These braking systems are caliper/disk systems mounted on the input shaft of the gear reducer. The operation of each system is independent of each other. The 2 separate calipers are mounted on a single rotor disk. The 2 calipers are identical except the manual caliper on earlier unit is a cast aluminum unit, whereas later was change to a cast iron unit like the automatic caliper. The braking capability of either system is lost if the pad adjustment is too loose. See Adjusting the Caliper. The caliper pad adjustment must be maintained to insure that the capability of Warning: these braking system is safe for the necessary braking action needed. It is the responsibility of the customer to maintain this adjustment. It is recommended that this adjustment be performed every time a service action is required on the unit. This will insure that the caliper is ready to deliver the full braking force needed when needed. The caliper pad adjusting nut is located on the caliper. It is a castle Adjusting the Caliper: nut holding the actuating lever and has a cotter pin thru the slots of the castle nut. Remove the cotter pin. To increase brake holding force, turn the castle nut clock-wise. To adjust, place a 0.050” spacer shim between the caliper pad and the brake rotor, tighten the castle nut finger tight and remove the spacer shim and replace cotter pin to retain this setting. The Manual Braking System The manual brake system is actuated by means of a brake lever handle located on the right side of the Rotaflex pumping unit. It is directly linked to the manual caliper through a “spring tube” which provides a very smooth brake action. The brake lever in the disengaged position will hold the caliper in the released position without allowing the pads to ride on the brake rotor, if the pad adjustment castle nut on the caliper is adjusted to the correct specifications. See Adjusting the Caliper. The brake lever linkage will hold the brake in the engaged state by means of an “over center” geometry. The Automatic Braking System - or Speed Sentry The automatic braking system will protect the unit from damage in case of certain conditions that would allow the Counterweight Box to free-fall. It will also protect the unit from damage in case of conditions that would cause overloading of the unit. It is controlled by the Speed Sentry which constantly monitors the speed of the unit. For UNDERSPEED conditions such as a seized pump, causing the speed of the unit to slow down below a predetermined minimum SPM speed, the Speed Sentry will initiate a shutdown process. The brake will be actuated and electrical power to the prime mover will be disconnected. For OVERSPEED conditions such as a sucker rod failure, causing the speed of the unit to speed up above a predetermined maximum SPM speed, the Speed Sentry will initiate a shutdown process. The brake will be actuated and electrical power to the prime mover will be disconnected. If the speed increases above the synchronous speed of the motor, the power to the prime mover will be retained until the speed falls below the synchronous speed of the motor. This “dynamic braking” greatly increases the efficiency of the auto braking system.
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The Automatic Braking System may come in either of two versions, older models are equipped with a pneumatic version and newer models with a electrical linear actuator. The Pneumatic version uses an electrically controlled solenoid valve to withhold the pressure from actuating the brake caliper and will allow pressure to the brake caliper when the automatic braking system is activated or when electric power is removed. This version provides an “EMERGENCY STOP” Button in close proximity to the OFF-ON Switch and Manual Brake Handle. When this button is pushed or the Speed Sentry activates the brake, power to the prime mover will be disconnected and the brake will be engaged. This braking will be smooth and controlled to minimize trauma to the pumping system. This version is protected from the elements and all high-pressure components are contained behind a 1/4-inch steel plate with a sight hole for visual access to the gauges. It is important to monitor the pressure on these gauges. A full bottle will supply a sufficient amount of nitrogen to apply the brake in excess of 100 operations and should register only a small change in the pressure. If there is an unusual drop in pressure it may indicate a leak in the nitrogen portion of the braking system. The 0-3000 PSI gauge shows the nitrogen charge in the bottle. The 0-160 PSI gauge shows the regulated pressure that will activate the emergency brake. WARNING: When the pressure drops below 100 PSI on the 0-3000 PSI gauge, refill the nitrogen cylinder! The pressure should show a minimum of 70 PSI on the 0-160 PSI gauge to properly activate the emergency brake. The Electrical Linear Actuator version is an electrical motor with a gear drive linear actuated tube which retracts in to set the brake and extends out to release the brake. The 3 position RESET-OFF-ON switch resets the brake. This version does not SET the brake when power is removed. This version provides an “EMERGENCY STOP” Button in close proximity to the RESET-OFF-ON Switch and Manual Brake Handle. When this button is pushed or the Speed Sentry activates the brake, power to the prime mover will be disconnected and the brake will be engaged. This braking will be smooth and controlled to minimize trauma to the pumping system.
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6.7 SPEED SENTRY WIRING DIAGRAM The Speed Sentry control box is fully wired at the factory to the pumping unit through terminal block one (TB1) and is recommended to be mounted next to the motor control panel. Customer connections to terminal block TB2 differ slightly depending on which Model ROTAFLEX Speed Sentry is being used. A minimum of four and a maximum of fourteen wires are possible depending on the Speed Sentry model used. These connections are made to the motor control panel for HAND-OFF-AUTO control and power to the Speed Sentry on units with electric prime movers. On units operating on a gas engine, Speed Sentry power and battery/alternator connections are made directly. Beginning with Figure 13 below, complete customer interconnect diagrams for the various ROTAFLEX control models follow. A complete wiring diagram is either permanently mounted on the inside door of each Speed Sentry, or enclosed in the envelope which also contains complete instructions for programming the Durant tachometer. NOTE: All interconnect wiring to TB1 will normally be done at the factory. The connections to TB2 will be made on site.
Figure 13. Model 6 SPEED-SENTRY Gas Engine Driven- Customer Connections Diagram Rev -F
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Figure 14. Model 6 Schematic Wiring Diagram - Gas Engine Driven
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Figure 15. Model 7 - Customer Connections Diagram - Electric Motor Driven
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Figure 16. Model 7 Schematic Wiring Diagram - Electric Motor Driven
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Figure 17. Model 8 Speed Sentry - Customer Connections Diagram
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Figure 18. Model 8 Speed Sentry Schematic Wiring Diagram
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Figure 19. Model 9 - Customer Connections Diagram - Electric Motor Driven
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Figure 20. Model 9 Speed Sentry Schematic Wiring Diagram
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Figure 21. Model 10 - Customer Connections Diagram - Electric Motor Driven
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Figure 22. Model 10 Schematic Wiring Diagram - Electric Motor Driven
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Figure 23. Model 10 - Customer Connections Diagram - Gas Engine Driven
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Figure 24. Model 10 - Schematic Wiring Diagram Gas Engine Driven
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Figure 24-A. Model P1 Speed Sentry Wiring Diagram – Gas Engine or Electric Motor
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Figure 24-B. Model P2 Speed Sentry Wiring Diagram – both Gas Engine and Electric Motor.
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6.8 SPEED SENTRY – (Automatic Braking System) The purpose of the Speed Sentry is to provide the electrical control for an automatic braking system that will protect the unit from damage in the case of a high rod part or any other condition that would allow the Counterweight Box to free-fall. On units which utilize a target wheel, the target wheel and proximity sensor are mounted on the input shaft of the gear reducer, the proximity switch obtains its’ pulsed signal from gaps in the 24-tooth wheel. Later units have the proximity switch mounted on the brake mounting plate and obtain the pulsed signal from holes in the face of the brake rotor. On units with the target wheel, care should be taken to insure that the proximity switch face is parallel with the target wheel teeth and centered as closely as possible. An air gap of .025” is recommended for the best performance. On units utilizing the brake rotor face and the proximity switch # II3010, the proximity switch should be parallel with the rotor maintaining an air gap of between 0.25” and 0.32” inches. On units utilizing the brake rotor face and the Proximity Switch # II3015, the proximity switch should be parallel with the rotor maintaining an air gap of between 0.56” and 0.69” inches. The proper functioning of the Speed Sentry depends on the “gap” adjustment of the proximity switch and the “overspeed and underspeed” settings. To ensure proper operation of the Speed Sentry, initial settings must be made to obtain reliable Overspeed and Underspeed protection. It is the responsibility of the operator to select the appropriate Overspeed and Underspeed Set-Point SETTINGS. This manufacturer strongly recommends not to set the Overspeed setpoint setting higher than .5 SPM over the maximum SPM speed shown on the digital readout during normal operation. The Underspeed set-point setting should not be set less than .5 SPM lower than the minimum SPM speed shown on the digital readout during normal operation. WARNING:
Failure to set the appropriate Overspeed and Underspeed set-point settings in the Speed Sentry, resulting in damage to the Rotaflex pumping unit, will void the Rotaflex Warranty.
NOTICE:
If the SPM of the Rotaflex pumping unit is changed for any reason, new Overspeed and Underspeed set-point settings are required.
The operations of the Speed Sentry and the automatic braking system should be tested occasionally to insure the system is operating satisfactorily. To test the Overspeed alarm condition, lower the overspeed set-point setting to a value less than the maximum operating SPM. The Speed Sentry should turn off the motor, set the brake and the overspeed flag should be visible. To test the Underspeed alarm condition, raise the underspeed set-point setting to a value higher than the minimum operating SPM. The Speed Sentry should turn off the motor, set the brake and the underspeed flag should be visible. After these tests, reset the overspeed and under-speed set-point settings to the correct values.
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All Speed Sentrys up to and including the Model 10 The following procedure outlines steps for monitoring and setting the overspeed and underspeed set-points with the Durant tachometer or rate indicator. All instructions will be initiated from the run state. The key to press on the tachometer is indicated in BOLD. TO MONITOR OVERSPEED AND UNDERSPEED SET POINTS ALM + or EXIT
Show the HIGH or LOW setting Change the display from HIGH to LOW and vice versa Returns to RUN mode TO CHANGE OVERSPEED AND UNDERSPEED SETTINGS
ALM + or SEL + or SEL + or ENT EXIT
The display will show the HIGH or LOW setting This will change the display from HIGH to LOW or vice versa Selects HIGH or LOW which is on display for programming Changes value of character flashing Advances to next character Changes value of character flashing, continue until desired setting is displayed Enters data into program memory Returns tachometer to RUN mode
TO MONITOR PROGRAM SETTINGS PGM PGM+ + or -
SEL + or EXIT-RUN
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Selects program mode for 5 seconds, returns to RUN mode Selects program for monitoring and steps through the six programs 1. PROGRAM SCALER 2. PROGRAM RATE ALARM 3. PROGRAM INPUTS 4. PROGRAM OUTPUTS 5. PROGRAM SET POINTS 6. PROGRAM OPTIONS To monitor data in each of the programs Terminates monitoring and returns control to RUN mode
Date 20 Sept 05
37
PROGRAM SETTINGS FOR SPEED SENTRY (MODELS 6 - 9) (Units utilizing the 24-tooth target wheel) Note: The ZERO TIME for all units with 24-tooth target wheel is set to 1.0 and the AVE TIME is set to 0.5. 1.
PROGRAM SCALERS
ITEMS SCALER
DEC PT ZERO TIME AVE TIME
DATA 1.301 (800DX) 1.4317 (900) 1.3041 (1100) 1.2383 (1200) --.-0.3 SEC 0.1 SEC
PROGRAM SETTINGS FOR SPEED SENTRY (Model 10 - LA BRAKE) No 1.
Program SCALERS
Items SCALER DEC PT ZERO TIME AVE TIME
Data see Table 1 --.-0.3 SEC 0.1 SEC
Note: Programs 2 - 6 on following page are identical for all units No 2.
Program RATE ALM
Items ALM 1 ALM 2
Data LOW HIGH
3.
INPUTS
RATE IN INHIB LOW LOCK
SOLID STATE FOLLOWS ALL
4.
OUTPUTS
ALM 1 OUT ALM 1 OUT PUL ALM 2 OUT ALM 2 OUT PUL
PULSED 1.0 SEC PULSED 1.0 SEC
5.
SER PORT
SER PORT ID BAUD PARITY TX DELAY
0 1200 NONE 0.100 SEC
Note: Rotaflex does not use the serial port. 6.
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OPTIONS
Date 20 Sept 05
UNL KEY UNITS PROGRAM
DISABLED S/M USER
38
All the program data shown above are programmed by this manufacturer. It is important that the program data is not changed. If for some reason the program is changed, it must be entered as shown, dependent on Rotaflex size. TO ENTER DATA INTO THE TACHOMETER MEMORY PRO-ENT + or SEL + or SEL
To monitor program. To step through the programs To select program items to monitor Steps through and displays program items Places displayed item in program change mode, items available for changing will be blinking + or Changes value of blinking characters ENT-EXIT-RUN Put displayed value into tachometer memory and returns control to RUN mode Use caution when SEL is pushed the second time, this places the displayed data into the tachometer memory and may result in improper memory storage. Table 1.
SCALING FACTORS FOR ALL UNITS WITH LA BRAKES Model 800 800DX 800DX 900 900 1100 1200
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Date 20 Sept 05
Gearbox 228 OILWELL 228 D 228 FAIRFIELD 320 D 320 FAIRFIELD 320 D 456 OILWELL
Scaling Factor 10.408 10.365 11.315 10.902 11.839 10.399 9.907
39
Speed Sentrys – P1 and P2 The Speed Sentry P1 and P2 utilize PLC components that replace the Speed Sentry model 10. All of the functions previously provided in the model 10 are covered in these models. Dynamic Braking has been added for use on all electric motor applications. This feature has been added to provide a more reliable automatic braking system. Proper functioning of the Speed Sentry depends on the proximity switch and the overspeed and underspeed set-point SETTINGS “entered” in the display. Units have the proximity switch mounted on the brake plate and obtain the pulsed signal from holes in the face of the brake rotor. The proximity switch should be parallel with the rotor maintaining an air gap of between 0.56” to 0.69”. DISPLAY MEMORY SETTINGS PROCEDURE Upon initial power-up, the Display will perform a self-test procedure, which lasts about 10 seconds. CHANGING SCREENS: All 11 Screens are accessible via the Right and Left Arrow Keys. Right Arrow = Page Down, Left Arrow = Page Up. CHANGING VALUES: Depressing the F1 key will cause the stored numerical value to flash. Use of the Arrow Keys will change the settings: LEFT ARROW RIGHT ARROW UP ARROW DOWN ARROW
-
Increments by 100 (3rd digit, if applicable) Decrements by 100 (3rd digit, if applicable) Increments by 1 (1st digit) Decrements by 1 (1st digit)
When desired value is reached, pressing the ENTER Key will download the value into memory. Pressing the Right Arrow Key while any screen is displayed will advances to the next screen. Pressing the Left Arrow Key while any screen is displayed will return to the 1st screen. SCREEN #
Description
1
STROKES PER MINUTE (read only) Normal screens. Displays actual strokes per minute (SPM).
2
MOTOR RPM (read only) Displays actual revolutions per minute (RPM).
3
ENTER GEARBOX RATIO (adjustable) Programmed during unit run-out. Displays ratio of gear reducer. (example : 31.069)
4
ENTER CHAIN RATIO (adjustable) Programmed during unit run-out. Displays ratio of chain to sprocket (example : 5.9048 - 900) (6.1985 – 1100) (7.3333 – 1150)
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40
5
ENTER UNIT SHEAVE DIAMETER (adjustable) Programmed in the field. Displays diameter in inches of v-belt sheave on gearbox. (example : 24)
6
ENTER MOTOR SHEAVE DIAMETER (adjustable) Programmed in the field. Displays diameter in inches of v-belt sheave on motor. (example : 13)
7
ENTER MOTOR SYN RPM (adjustable) default=1200 Displays synchronous speed (rpm) of motor.
8 ENTER OVERSPEED SET POINT (adjustable) .5 SPM above normal speed is recommended. 9 ENTER UNDERSPEED SET-POINT (adjustable) .5 SPM below normal speed is recommended. 10
UNDERSPEED DELAY TIME (adjustable) Displays the delay time (seconds) for disabling the UNDERSPEED alarm on start-up. Up to a maximum of 3276.7 seconds (50+ minutes).
11
EVENT LIST (non-adjustable) List the Event History beginning with the latest logged. To view past Events - Press F4, Latest Event is displayed. Up Arrow - Scrolls back through Event List History Down Arrow - Scrolls back toward latest Event Right Arrow - Depressed at any time during Event List will display the date/time. // Key Returns user to Event List. Important Note: The Event List history is lost when power is removed, also the Date/Time will have to be reset as follows Enter Press and Hold until display changes to the Configuration Mode Left Arrow - Press twice until TIMe is highlighted. Enter Press to begin Time/Date change mode Use the UP/DOWN Arrow keys to select time and date, follow each selection with the ENTER key. The Date/Time format is viewed as follows: (AM/PM is selected through changes made during setting the HOUR digits) DAY MONTH YEAR HOUR MINUTE SECOND AM/PM When all selections are correct, Press the // Key to return to the EVENT LIST screen. To return to the STROKES PER MINUTE screen, press the LEFT ARROW key until it is displayed, also by scrolling back toward the STROKES PER MINUTE screen all user setpoints may be rechecked.
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Date 20 Sept 05
41
7.0 OPERATING ROTAFLEX Starting the Rotaflex Pumping Unit for the first time: Your Rotaflex Pumping Unit was erected and run at the factory. Necessary adjustments were made and the unit is in good working order. However, additional adjustments may be required after erecting the unit at the well site. After assembling the unit and performing maintenance, perform each of the following steps before starting the unit for the first time. 1. Remove all tools or articles of obstruction from the foundation and around the unit. 2. Check to be certain that all safety guards and shields are properly installed. 3. Remove the wooden shipping blocks located at the back of the weightbox. The wooden shipping block is used to protect the back wheels from being flattened after prolong periods of the unit laying down. 4. Check for proper lubricant levels in the gear reducer and chain reservoir. The gear reducer has been pre-lubricated at the factory, but should be checked prior to operation. The vented breather filter should replace the shipping plug at the top of the gear reducer prior to start-up. The chain should be lubricated with 40 gallons of chain lubrication oil. For more information, please refer to the LUBRICATION section. 5. Check that the prime mover is properly installed and mounting bolts are properly tightened. 6. Check that belts are aligned and properly tensioned and belt guard is in place. 7. Remove all safety stops and disengage the manual brake. 8. Make the first stroke as slow as possible to properly check the clearance between the belt guards, railings and any safety structure installed around the Rotaflex Pumping Unit. Be sure the polished rod and the downhole pump have clearance on the down stroke and upstroke. WARNING: To prevent personal injury, stay clear of any moving parts!
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42
7.1 COUNTERBALANCE ADJUSTMENT Efficient operation, minimum torque loading and maximum life of a pumping unit are all a result of proper counterbalance. The auxiliary counter weight is supplied in properly dimensioned metal blocks of varying thickness. To calculate the weight of the auxiliary counterweight, measure the stacked block of metal. Measure the height, width and depth in inches of the auxiliary counterweight stack. H x W x D x .2833 will calculate the weight of the auxiliary counterweight in pounds. This number in pounds added to the built-in weight of the weightbox is the counter balance weight. See Section 4.0 Unit Specifications for built-in weight..
AMMETER A clip-on ammeter may be used to compare the up stroke and down stroke current on electrically powered units. Balance the counterweight so that the current peaks are equal within plus or minus 5%.
VACUUM GAUGE A vacuum gauge may be used to compare torque peaks on engine-driven units much as the ammeter is used on electrically driven units. Vacuum pressure decreases as engine output increases.
SOUND OF THE POWER UNIT A rough estimate of balance can be made by listening to the characteristic sound of the PRIME MOVER as it drives the Rotaflex Pumping Unit. Some speed change will occur as the peak loads are approached; this speed change will cause the sound of the PRIME MOVER to change.
POLISHED ROD DYNAMOMETER TEST Dynamometer card analysis is the most accurate method used to determine loading and counterbalance. This involves using a dynamometer to record the well load through a stroke cycle and then using torque factors to determine the gear reducer torque required for balanced conditions. The stroke length of the Rotaflex Model 800DX and 900 is 288 inches, 306 inches for the 1100 unit. If the position transducer does not have sufficient capability to measure the full stroke length, an auxiliary string and pulley attached to the unit will reduce the required stroke length measurement of the transducer to 1/2 the stroke length. Figure 25 shows a string and pulley configuration to obtain dynamometer card from Rotaflex with a 200” position transducer. To do so, tie one end of string to eye on crown at top of tower. Tie the other end of the string to the Belt Bar after passing it around the traveling pulley. The traveling pulley will provide a 144” of travel from the 288” stroke of the Rotaflex.
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Date 20 Sept 05
43
Figure 25. String & Pulley Configuration to obtain Rotaflex Dynamometer Card
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Date 20 Sept 05
44
SPM vs. Sheave Size for ROTAFLEX 800DX Motor RPM X Motor Sheave Gearbox Ratio X Chain Ratio X Unit Sheave
SPM =
for Motor RPM = use 1150, Gearbox Ratio = 32.67, Chain Ratio = 5.9048 SPM = 5.96 X
Motor Sheave Unit Sheave
7” 8.5
Motor Sheave 8” 8.5” 9” 11.1 12.3 13.5
HP/Belt
7.5” 9.8
9.5” 14.7
10” 15.9
11” 17.1
Recommended Belt : 4 Groove, C section PowerBand Belt Selection is based on 65 HP Select designed SPM from Table 2: Table 2
Rotaflex 800DX SPM Selection Table
Motor Sheaves
Unit sheave Size / V-Belt size (50” – 60” Centers) 20* 24 27
7 7.5 8 8.5
2.1 2.2 2.4 2.5
C-158 C-158 C-158 C-158
1.7 1.6 2.0 2.1
C-162 C-162 C-162 C-162
1.5 1.7 1.8 1.9
30
36
C-162 C-162 C-162 C-162
1.4 1.5 1.6 1.7
C-162 C-173 C-173 C-173
1.2 1.2 1.3 1.4
C-180 C-180 C-180 C-180
C-162 C-162 C-162 C-173 C-173 C-173 C-173 C-180 C-180
1.8 1.9 2.0 2.2 2.4 2.6 2.8 3.2 3.6 4.0 4.8
C-173 C-173 C-173 C-173 C-173 C-180 C-180 C-180 C-180 C-190
1.5 1.6 1.7 1.8 2.0 2.2 2.3 2.6 3.0 3.3 4.0
C-180 C-180 C-180 C-180 C-190 C-190 C-190 C-195 C-195 C-195 C-195
Motor Sheaves 8.5” & smaller not recommended. 9 9.5 10 11 12 13 14 16 18 20 24
2.7 2.8 3.0 3.3 3.6 3.9 4.2 4.8 5.4 6.0 7.2
C-158 C-158 C-162 C-162 C-162 C-162 C-162
2.2 2.4 2.6 2.7 3.0 3.2 3.5 4.0
4.5
C-162 C-162 C-162 C-162 C-162 C-162 C-162 C-173 C-173
5.0 6.0
2.0 2.1 2.2 2.4 2.6 2.9 3.1 3.5 4.0 4.4 5.3
Note: SPM’s indicated in Bold are above the maximum allowable SPM. Recommended 20” 4 C standard sheave. EXAMPLE: Desired SPM is 3.6 - For 20” unit sheave, select 12” motor sheave.
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Date 20 Sept 05
45
SPM vs. Sheave Size for ROTAFLEX 900 Motor RPM X Motor Sheave Gearbox Ratio X Chain Ratio X Unit Sheave
SPM =
for Motor RPM = use 1150, Gearbox Ratio = 31.06, Chain Ratio = 5.9048 (5.00” chain) 5.6796 (4.09” chain) SPM =
7” 8.5
HP/Belt
Motor Sheave Unit Sheave
6.27 X
Motor Sheave 7.5” 8” 8.5” 9.8 11.1 12.3
9” 13.5
9.5” 14.7
10” 15.9
11” 17.1
Recommended Belt : 4 Groove, C section PowerBand Belt Selection is based on 65 HP Select designed SPM from Table 3: Table 3
Rotaflex 900 SPM Selection Table
Motor Sheaves
Unit sheave Size / V-Belt size (50” - 60”Centers) 20* 24 27
7 7.5 8 8.5
2.2 2.4 2.5 2.7
C-158 C-158 C-158 C-158
1.8 2.0 2.1 2.2
C-162 C-162 C-162 C-162
1.6 1.7 1.9 2.0
30
36
C-162 C-162 C-162 C-162
1.5 1.6 1.7 1.8
C-162 C-173 C-173 C-173
1.2 1.3 1.4 1.5
C-180 C-180 C-180 C-180
C-162 C-162 C-162 C-173 C-173 C-173 C-173 C-173 C-173
1.9 2.0 2.1 2.3 2.5 2.7 2.9 3.3 3.8 4.2 5.0
C-173 C-173 C-173 C-173 C-173 C-180 C-180 C-180 C-180 C-180
1.6 1.7 1.7 1.9 2.1 2.3 2.4 2.8 3.1 3.5 4.2
C-180 C-180 C-180 C-180 C-180 C-180 C-195 C-195 C-195 C-195 C-195
Motor Sheaves 8.5” & smaller not recommended. 9 9.5 10 11 12 13 14 16 18 20 24
2.8 3.0 3.1 3.4 3.8 4.1 4.4 5.0 5.6 6.3 7.5
C-158 C-158 C-162 C-162 C-162 C-162 C-162
2.4 2.5 2.6 2.9 3.1 3.4 3.7 4.2 4.7 5.2 6.3
C-162 C-162 C-162 C-162 C-162 C-162 C-162 C-162
2.1 2.2 2.3 2.6 2.8 3.0 3.3 3.7 4.2 4.6 5.6
Note: SPM’s indicated in Bold are above the maximum allowable SPM. *Recommended 20” 4 C standard sheave. EXAMPLE: Desired SPM is 3.4 - For 20” unit sheave, select 11” motor sheave.
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Date 20 Sept 05
46
SPM vs. Sheave Size for ROTAFLEX 1100 Motor RPM X Motor Sheave Gearbox Ratio X Chain Ratio X Unit Sheave
SPM =
for Motor RPM = use 1150, Gearbox Ratio = 31.06, Chain Ratio = 6.1985 SPM =
HP/Belt
7” 8.5
Motor Sheave Unit Sheave
5.98 X
Motor Sheave 8” 8.5” 9” 11.1 12.3 13.5
7.5” 9.8
9.5” 14.7
10” 15.9
11” 17.1
Recommended Belt : 5 Groove, C section PowerBand Belt Selection is based on 65 HP Select designed SPM from Table 4: Table 4
Rotaflex 1100 SPM Selection Table
Motor Sheaves
Unit sheave Size / V-Belt size (50” - 60”Centers) 20* 24 27
7 7.5 8 8.5
2.1 2.2 2.4 2.5
C-158 C-158 C-158 C-158
1.7 1.9 2.0 2.1
C-162 C-162 C-162 C-162
1.6 1.7 1.8 1.9
30
36
C-162 C-162 C-162 C-162
1.4 1.5 1.6 1.7
C-173 C-173 C-173 C-173
1.2 1.2 1.3 1.4
C-180 C-180 C-180 C-180
C-162 C-162 C-162 C-173 C-173 C-173 C-173 C-173 C-173 C-173
1.8 1.9 2.0 2.2 2.4 2.6 2.8 3.2 3.6 4.0 4.8
C-173 C-173 C-173 C-173 C-173 C-173 C-173 C-180 C-180 C-180
1.5 1.6 1.7 1.8 2.0 2.2 2.3 2.7 3.0 3.3 4.0
C-180 C-180 C-180 C-180 C-180 C-180 C-195 C-195 C-195 C-195 C-195
Motor Sheaves 8.5” & smaller not recommended. 9 9.5 10 11 12 13 14 16 18 20 24
2.7 2.8 3.0 3.3 3.6 3.9 4.2 4.8 5.4 6.0 7.2
C-158 C-158 C-162 C-162 C-162 C-162 C-162
2.2 2.4 2.5 2.7 3.0 3.2 3.5 4.0
4.5
C-162 C-162 C-162 C-162 C-162 C-162 C-162 C-162 C-173
5.0 6.0
2.0 2.1 2.2 2.4 2.7 2.9 3.1 3.5 4.0
4.4 5.3
Note: SPM’s indicated in Bold are above the maximum allowable SPM. Recommended 24” 5 C standard sheave. EXAMPLE: Desired SPM is 3.5 – For 24” unit sheave, select 14” motor sheave.
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Date 20 Sept 05
47
7.2 BEFORE WELL SERVICE Rotaflex is designed with the ease of well service in mind, the Rotaflex pumping unit can be rolled back “away” from the well for servicing. The following is the procedure for rolling back the Rotaflex Unit: 1. Run the rod string down to within 6 to 12 inches from the bottom of the stroke. WARNING: The manual brake caliper must be adjusted sufficiently to hold the weight box without the well load attached. 2. Clamp off the polished rod above the stuffing box. 3. Disconnect the carrier bar from the polished rod. 4. Tie a 1/2-inch rope 35 feet long to the carrier bar. 5. Keep the load belt centered on the idler drum. 6. Lower the weight box (raise the load belt) slowly with the manual brake while holding tension on the rope. WARNING: Do not let rope get wrapped around hands or feet! WARNING: Weight box MUST be lowered before sliding unit back for well servicing. WARRANTY may be void if weight box falls while servicing the well. Consult with a ROTAFLEX service representative for exceptions. 7. Tie off the rope. 8. Remove the tie-down bolt and plate nearest the well head and loosen, but do not remove, the tie down bolt nearest to the back of the Rotaflex Pumping Unit. 9. Lubricate the pin and the inside of the roll-back wheel.
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48
10. Using a 22-ton hydraulic jack under the pack pads lift one side of the unit and install the roll-back wheel and pin as shown in Figure 26. 11. Release the jack slowly and repeat the procedure on the opposite side. 12. With steps 9, 10, 11, and 12 completed, the unit is designed to slide back on the rails mounted to the special concrete base using a winch line from a 2-ton or larger truck OR a hydraulic unit similar to a backhoe, to slide the unit back 10 feet. The winch line should be as near horizontal as possible and attached to the pad eye at the rear of the skid. 13. Tighten the tie-down bolt to secure the unit while the well is being serviced.
Figure 26. Rolling Back Rotaflex
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Date 20 Sept 05
49
7.3 AFTER WELL SERVICE When the Rotaflex Unit has been rolled back for well service, the following procedure must be followed to “roll” the Rotaflex unit back to position and hook-up for production: 1. Loosen, but do not remove the tie-down bolt. 2. To pull the unit forward after the workover, a yoke should be in front of the well head as shown in Figure 27. Slide the unit forward until it is against the well alignment brackets. 3. Use the hydraulic jack to raise one side and remove the pin from the roll-back wheel. Release the jack slowly and repeat the procedure on the opposite side. 4. Re-install the tie-down bolt and tighten both tie-down bolts. 5. Raise the weight box (lower the lifting belt) while pulling down on the rope attached to the carrier bar. This assists the load belt to fall as fast as the weight box is being raised. Apply the brake and turn off the motor when the carrier bar is at the lowest point. Activate the emergency brake. WARNING: Do not let the rope wrap around hands or feet! 6. Re-attach the carrier bar the polished rod and attach the polished rod clamp above the carrier bar. 7. Release the brake slowly and allow the load belt to pick up the polished rod load. Remove the clamp at the stuffing box.
Figure 27. Rolling Rotaflex Forward
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Date 20 Sept 05
50
8.0 PREVENTATIVE MAINTENANCE With periodical preventive maintenance according to the recommended schedule, the life of the unit will be prolonged and costly down time will be prevented. Visual and audio inspections can be made routinely. MONTHLY MAINTENANCE CHECK LIST
Inside Counterweight DOORS 1. 2. 3. 4. 5. 6. 7.
Check all 12 weight box Wheels for any wear or cracking and clearance to tower beam Check position of auxiliary counterweight blocks if equipped Check chain tension Check and clean oil Drip Tray above drive sprocket Check Clips between load belt and belt bar Check load belt pin Retainer between belt bar and weight box Inspect Carriage wheel-to-Rail contact, especially the flanges Associate the following comments with above inspection items.
1. See section 8.3 2. These are the extra counterweight pieces contained inside the weight box. Make sure the position has not changed which might cause interference with other components. 3. See section 8.1 4. The oil is directed on the chain and sprocket and the carrier frame when the weight box is in the down position. This oiling is impaired if the holes in the drip tray are stopped up. The screen wire across the top is to keep out insects and bugs that can plug oiling holes. Clean out tray and unplug any stopped up holes. 5. The clips carry the rivets, which attach the load belt to the belt bar. This is the same on both ends of the load belt. Look for combing of the load belt material in the area of the rivets. 6. The 3” pin links the load belt to the counterweight box. Loss of this pin or its retaining devices would cause a catastrophic condition similar to broken polished rod. 7.
The carriage wheels are adjusted to contact the upper rail at the factory. The inside flange dimension of the wheels is matched to the rail to rail dimension of the carrier frame. Any excess clearance in either of these areas will result in excessive wear to the wheels. Lack of oil on the surfaces will result in wearing and noise. If the clearance appears ok and the surfaces appear dry, apply a film of oil on rail surface. This will reduce incidence of wear on wheels.
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Date 20 Sept 05
51
GROUND LEVEL 1. 2. 3. 4. 5. 6. 7. 8. 9.
Check oil level in gear reducer Check brake pads on both sets of brake calipers Check caliper pad adjustment Check brake rotor Check tension of prime mover belts Check belt guard and target wheel guard Check ladder and safety shroud bolts Check all controls provided with SPEED-SENTRY for proper function Check both gauges on nitrogen bottle (if present)
Associate the following comments with above inspection items. 1. No oil in sight glass may indicate need for replacement of oil seal(s) or drain plug. See section 6.5 2. Excessive wear of brake pad material will result in slow or no response in braking when needed. Replace worn pad with replacement pad kit, either 830192 for Alum. Caliper & 830232 for Cast Iron Caliper, when pad thickness is 1/16” minimum. 3. Excessive wear of brake pad material will result in slow or no response in braking when needed. This is most important in the automatic brake caliper. Adjust by turning the hex nut clockwise to reduce clearance 4. Brake rotor must run true without wobble. Frequent adjustment of pad clearance may indicate need to replace rotor. 5. Correct tension of v-belt(s) or power-band will greatly increase the effectiveness of the prime mover power and the operation of the unit during normal operation. 6. The safety of the personnel around the unit requires that the v-belt and target wheel guard be in place, operating as designed and not broken or bent out of place. 7. The safety of the personnel ascending to the top of the unit requires that the ladder and cages be of sound structure and not broken. Replace any broken bolts. 8. The safe operation of the Rotaflex unit as designed will not allow the counterweight box to fall completely to the bottom of the tower without actuating the automatic braking system. The Speed Sentry controls this automatic braking system. Check the operation of the Speed Sentry by testing the UNDER-SPEED and the OVER-SPEED operation referred to in section 6.8. 9. On those units equipped with the nitrogen powered automatic braking systems, check the high pressure gauge for a pressure of 100 Lbs. Minimum and the low pressure gauge for a pressure of 70 Lbs. minimum. If needed, replace the empty cylinder with a full cylinder.
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Date 20 Sept 05
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INSIDE MID-TOWER 1. Check locking bolts and nuts 2. Check chain pin Retaining Plug or Keeper on swivel shaft 3. Inspection of the Chain Pin inside the swivel shaft Associate the following comments with above inspection items. 1. Loose locking bolts will allow Top Sprocket misalignment. 2. Loose Retainer or Keeper will allow chain failure. 3. On those units with a Retainer Plug, remove plug to allow visual access of the end of the chain pin. The chain pin hole must not be elongated, which would indicate pin rotation wear in the Swivel Shaft. Replace Retainer Plug.
TOP OF TOWER 1. Check end plates of idler drum 2. Check grease level in pillow block bearing housings (For all 1100’s and certain 800DX and 900 units without poly-pak bearings.) 3. Check grease seals on inside of bearing housings. Associate the following comments with above inspection items. 1. Visual inspection of end plate will give indication of any abnormal “load” cracks, either in the plates or any weld area. 2. See section 8.4 3. Excessive amount of grease on the shaft just inside the pillow block may indicate a leaking pillow block grease seal.
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8.1 CHECKING TOWER CHAIN TENSION The heavy duty tower roller chain is designed to give many years of service with proper maintenance. The Rotaflex Pumping Unit’s unique lubrication system provides adequate lubrication, but the chain should be routinely examined for excessive wear and proper tensioning. To check the tension on the Rotaflex Pumping Unit chain, please follow these procedures. 1. Turn the unit off with the bottom of the counterweight box approximately 2 feet above the top of the front opening. Note the position of the drive sprocket. Using a 4 or 5 foot probing device, such as a shovel handle, push against the chain, trying to move it from left to right, not front to back. Push first on one side and then against the other (one side will be extremely tight), noting the amount of side to side movement on the loose side of the chain. 2. There is a possibility that the chain may experience more or less tension as the drive sprocket and the idler sprocket rotate, it is imperative to check the tension a minimum of four different sprocket positions. 3. Allow the drive sprocket to make a quarter revolution (or 90 degrees turn) and check the tension of the chain again. Note the side to side movement of the chain. 4. Allow the drive sprocket to make another quarter revolution (180 degree rotation from original position) in the same direction as before and check the tension of the chain again. Note the side to side movement of the chain. 5. Allow the drive sprocket to make an additional quarter revolution (270 degrees rotation from original position) in the same direction as before and check the tension of the chain again. Note the side to side movement of the chain. 6. If the side to side deflection is less than one inch, the chain MUST be loosened. 7. If the chain will deflect more than two or three inches when the tension is the greatest (deflection is least), the chain tension needs to be adjusted.
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8.2 ADJUSTING THE TOWER LOAD CHAIN To adjust the Rotaflex Pumping Unit load chain, follow these procedures: CAUTION: Do not over tighten the chain! Over tightening the Rotaflex pumping unit chain can put damaging stress on the top idler sprocket. Under tightening the chain will cause some excessive noises and will allow the transversing mechanism to come in contact with the transversing mechanism frame. 1. Turn the unit off with the bottom of the counterweight box approximately 2 feet above the top of the front opening, set the manual brake and emergency stop. 2. Turn off and lock out the main power. 3. Climb the service ladder to the mid-tower platform and open the mid-tower door. This will expose the top sprocket, the telescoping mounting for the top sprocket and a portion of the chain. 4. Loosen three (3) 3/4 -inch locking nuts (two on the front and one on the left side of the telescope mounting bracket) and loosen the three (3) 3/4-inch set screws. This will allow the telescoping member to move up and down. 5. There are four (4) jack-bolts with locking nuts, one on each corner of the telescoping member of the mounting bracket. Loosen the locking nuts. 6. Turn the four (4) jack-bolts clockwise to increase tension on the chain. Turn each jackbolt an equal amount to keep the mounting bracket as level as possible. Do not make more than one complete turn of the four (4) jack-bolts at this time. 7. Check the chain tension again. 8. When the chain tension is correct, tighten the four (4) locking nuts on the jack-bolts. 9. Tighten the three (3) set screws on the telescoping member of the mounting bracket and tighten the three (3) locking nuts. 10. Close and fasten the mid-tower door. 11. If the chain tension is still right, close and secure the front doors. 12. Return electric power to main panel. Release brake and restart the Rotaflex pumping unit.
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8.3 ADJUSTING WEIGHT BOX GUIDE WHEELS There are three guide wheels on each corner of the weight box to keep the weight box positioned properly inside the tower. One wheel on each corner is to align the weight box from side to side. The other two wheels on each corner are to align the weight box from front to back. Each guide wheel has an adjusting bolt and lock nut. Based on the position of the transversing mechanism, the weight box is seldom perfectly aligned with the tower. One of the bottom sideto-side guide wheels and the opposite top side-to-side wheel will be experiencing all the load. The other two side-to-side guide wheels will not be touching the I-Beam. When the direction of movement of the weight box reverses, the opposite wheels will be carrying the load. The back guide wheels are factory set. All adjustment to the guide wheels should be done with the front wheels ONLY. When the unit is standing, the Front and Back guide wheels should be just touching the respective tower beam flange. When necessary, adjust the front guide wheels so that the condition is achieved. To adjust the wheels, loosen the locknut on the adjusting bolt and turn the bolt clockwise to reduce the clearance between the guide wheel tread and the IBeam. When the adjustment is completed, re-tighten the locking nuts. There has to be a 1/8” gap for any side of the Side Guide Wheels to the respective tower beam. When necessary, adjust the corresponding guide wheels when the unit is standing up. The remaining eight (8) guide wheels keep the weight box centered between the front and back of the tower. These guide wheels also align the chain with the sprockets. If these guide wheels need adjusting, consult your ROTAFLEX representative for proper chain alignment. All 12 guide wheels can be adjusted from the front of the unit, but the four guide wheels near the back of the tower can only be replaced when personnel climbs inside the tower. WARNING: The weight box must be blocked and/or chained before personnel climbs inside the tower!
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8.4 TOP IDLER DRUM INSPECTION The crown hood is located at the top of the unit and is for access to the idler drum, load belt and the two pillow block bearings that support the idler drum. The hood is equipped with a safety support. When opening the hood, check the safety support to make sure it is in the locked position. With the safety support properly latched, you will have to manually unlatch it to close the hood as shown in Figure 28. WARNING: The hood is approximately 45 feet above ground level. At this elevation, the wind currents could make handling the hood very dangerous. Be aware the safety support could be accidentally unlatched if the wind causes the hood to move. Do not place head, hands or feet in a position where the lid could accidentally close and cause injury! The top idler drum holds all the combined weight of the weight box and the well load. Due to the significant load, a visual inspection of the drum, the end plates of the drum, and the condition of the welds is required. Model 800DX and 900 units with serial number 499 or higher These units are equipped with poly-pak sealed for life bearings in the pillow blocks of the top drum. This also applies to units with earlier serial numbers which had pillow blocks replaced in the field after June 1996. These bearings should NOT be lubricated otherwise it may cause damage. If it is unclear which bearing existed on the unit, please contact the customer service department for clarification. Model 800DX and 900 units with serial number 498 or lower and all model 1100 units The pillow block bearings in these units should have additional grease (AAR M-942 or equivalent, for all temperature ranges) added after 6 months of operation and every 6 months thereafter. The bearings may require as much as 20-25 pumps from a hand-held grease gun or until excess grease appears through the grease relief opening.
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Figure 28. Accessing Top Drum
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9.0 REPLACING THE LOAD BELT Equipment requirement: Crane with minimum 75-foot hook height Wireline cables and shackles Special clamp for load belt (obtain from Weatherford, CPS) Wrenches Safety belt with lanyard for two employees Procedure: 1. Remove the windguard from the load belt, if so equipped. 2. Remove the carrier bar from the polished rod. 3. Remove the bridle from the belt bar. 4. Tie 1/2-inch rope 35 foot long to the belt bar. WARNING: Do not let rope get wrapped around hands or feet! 5. Carefully lower the counterweight box to the bottom of the tower, keeping tension on the rope to prevent the belt from hitting the top of the tower. 6. Set hand brake and emergency stop. 7. Lock out power at main service pole. 8. Open and secure front doors. 9. Open crown hood and center the special load belt clamp on the top of the tower, parallel to the load belt. The tapered clamps bolted to the special load belt clamp are positioned behind the load belt so the load belt is between the longer angle-iron and the short, tapered angle-iron clamps. Tighten two bolts on both ends, clamping the load belt securely. 10. Attach wireline cables to the clamp. Crane operator should get sight tension on the cables and hold. 11. Personnel climbs through the front doors to the inside of the tower on top of the weight box. Remove the bolt and large washer from the pin holding the belt bar to the weight box. Install a 1/2 inch eye-bolt in this hole and attach a 5 foot length of small rope in the eye-bolt. CAUTION: If the large pin is accidentally dropped behind the weight box, it cannot be retrieved without possible damage to the Rotaflex Pumping Unit. Rev -F
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12. Carefully remove the large diameter pin from the belt bar. The belt bar may have to be adjusted to allow the pin to be removed. 13. The personnel climbs out of the tower through the front doors, removing all tools, pin, washer and bolt. 14. Personnel at top of tower removes the belt retainer bar fastened to the tower in front of the idler drum. Note the location of the belt retainer bar in relation to the load belt. Store the belt retainer bar on the work platform at the top of the tower. 15. The crane operator carefully lifts the belt through the top of the tower. Personnel at the top of the tower guides the belt to keep it from getting caught inside the tower. 16. After the belt has cleared the top of the tower, lay the belt flat on the ground with the special load belt clamp on top. 17. Measure the distance from the end of the bridle bar to the clamp and remove the clamp. 18. Place the new belt on top of the old belt, paying attention to the orientation of the belt for proper attachment of the bridle, and measure the same distance from the bridle bar. Place the special clamp on the new belt 12 inches closer to the bridle bar. This measurement should be about 60 inches from the belt clips. 19. Untie the rope from the old belt and tie it to the new belt. CAUTION: If the wind is blowing, use two ropes! 20. Attach the wirelines to the special load belt clamp and lift the new belt until the lower end of the belt clears the tower. 21. Lower the belt into the tower, paying attention to the orientation of the belt for proper attachment of the bridle. 22. When the bottom of the belt reaches the top of the weight box, align the hole in the belt bar with the eye on top of the box. 23. Personnel climbs back into the tower through the front doors and on top of the weight box and carefully replaces the 3-inch diameter pin through the belt bar and the weight box. Replace the washer and bolt on the pin. 24. Personnel climbs out of the tower. 25. Personnel on top of the tower removes the special load belt clamp. The crane operator lowers the clamp to the ground.
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26. Personnel at the top of the tower replaces the belt retainer bar, paying special attention to the location and alignment. (The belt must not rub on the retainer bar. Check this again after the well load is attached to the load belt.) Tighten all bolts and remove all tools. Close the crown hood. 27. Turn on power to the unit. 28. Disengage the emergency stop. 29. Apply tension to the rope and raise the weight box to the top. Set manual brake and emergency stop. 30. Remove rope and install bridle. Attach bridle to polished rod. Install wind guard. 31. Release emergency stop, then release manual brake. The unit is now ready to run.
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Occasionally, the Rotaflex Pumping Unit will be pumping a well when the sucker rod string has a failure in the upper part of the string, polished rod, polished rod clamp, bridle, etc., and there is not enough weight on the load belt to pull the load belt over the idler drum as the weight box is lifted. Usually the unit is served with a prime mover of sufficient size to raise the fully loaded weight box without help from the well load. When the prime mover is operated and begins lifting the weight box, sometimes the load belt will try to fold or “double up” inside the tower. If this happens, it is recommended to attach a rope or cable to the bridle or belt bar that can be pulled by personnel on the ground to start the load belt over the idler drum. To accomplish this, it may be necessary to get a bucket truck to raise the personnel high enough to attach a rope to the load belt.
WARNING: THIS PROCEDURE CAN BE DANGEROUS! The personnel must be aware that the rope can get caught on the valves or fittings around the well head or even get caught around the hands, arms, feet, legs or other parts of the anatomy. If the weight box should fall, the personnel should immediately turn loose of the rope and get away from the unit. IMPORTANT: The hand brake operates a set of calipers with brake pads on a disk brake attached to the input shaft of the gear reducer. If the operator needs to raise the weight box without the well load attached to the load belt, the adjusting bolt on the brake calipers should be adjusted fairly tight against the disk, so it will have sufficient gripping power to hold the weight box when it is raised. The EMERGENCY STOP button should also be depressed after the hand brake is set. The Rotaflex Pumping Unit has a positive lock-out system built into the disk brake. Insert the keeper pin through the brake housing and into the holes drilled through the disk to activate this positive lock-out system. This locks the gear reducer and will keep it from turning, but will not prevent the weight box from moving if the load-belt or chain inside the tower should fail.
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10.0 MOVING THE UNIT It is important that the mechanical brake system be in good operating order and adjusted properly before working on the unit. 1. Before disconnecting electrical service from the unit: a. b. c. d. e.
Drain or vacuum the oil from chain reservoir. Lower the weight box to the bottom of the tower. Remove all the auxiliary counterweight from the weight box. Set the manual brake. Set the emergency stop on the automatic brake. Remove vent plug from gear reducer and replace with solid oil plug.
2. Make sure there are no sub-poles, electrical lines or guy wires that will interfere with the lowering of the tower. When the unit is lying down, the top of the tower is approximately 20 feet longer than the skid. 3. Remove belt guard, belts and prime mover. Remove the sheave and hub from the input shaft of the gear reducer. 4. Make sure both tie-down bolts are properly tightened. 5. Position 50-ton (or larger) crane with 50-foot (or greater) boom height on one side of the unit, near the middle of the 24-foot concrete pad. Position the load hook rigged with the spreader bar above the tower. Attach wireline cables to the spreader bar and to the pad eyes located near the top of the tower (one on each side of the crown hood.) Wireline cables should be only long enough to clear the top of the crown hood. 6. Remove six (6) bolts (three on each side of the tower) that hold the tower beams and skid together. 7. Remove the pins from the lower end of the standing struts and guide shoe. The struts will move towards the rear of the unit as the tower is lowered. 8. NOTICE: The following is the procedure used at the manufacturing facility to lower the units before shipping. The crane operator may recommend a different method or may desire to set his crane in a different location. a. b. c.
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Place the boom of the crane towards the back of the unit 2 or 3 feet behind the pivot point. Lock the swing brake while holding tension against the load. Lift the load. This should begin the breakover movement of the tower. If the motion is not enough to begin the breakover, ease the unit to the upright position and begin at step A and use more swing. (Swing the boom towards the back of the unit 3 to 4 feet behind the pivot point and lock the swing brake while holding tension against the load.) The motion of the tower is to tilt towards the back of the unit, NOT raise up.
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9. The pivoting point is approximately 7 feet from the front of the unit. The crane should continue tilting the tower towards the rear of the unit, keeping the line above the top of the crown, not allowing it to swing to either side. (This will allow the unit to lie down parallel to, and on top of, the skid.) Breakover point of the Rotaflex Pumping Unit occurs when the lower ends of the struts are about even with the rear of the skid. The crane operator should be aware of this change of load. 10. After the breakover point is reached, continue lowering the tower until the pins can be removed from the top of the struts. 11. Attach the shipping supports in place of the struts. Continue lowering the tower until the shipping supports meet the skid. Attach the shipping supports to the skid with two bolts for each support. 12. Attach four 20-foot wireline cables to the four pad eyes. Two are located near the bottom of the tower and two are located two-thirds of the way up the tower on the front. 13. Attach the load line of the crane to the four wire line cables and hold the line snug while removing the tie-down bolts. Make sure all tie-down bolts are removed as shown in Figure 29.
Figure 29. Lifting The Rotaflex Unit
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14. The unit will be heavier at the base end when unit is picked up from the concrete pad. The crane operator should lift the unit straight up until it clears the concrete pad, then set it on the truck. 15. Support the tower near the top end with temporary shipping posts between the truck bed and the tower. Chain the unit to the truck with good quality load chains and load binders, using a “cross tie-down” method as shown in Figure 30.
Figure. 30. Positioning Rotaflex Unit on Truck
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11.0 PRODUCT IMPROVEMENT The manufacturer of Rotaflex pumping unit is constantly improving the design quality of the unit. In many instances, the feedback of the end users provide tremendously benefit to the continuous product refinement effort. The Product Performance Report (PPR) is aimed to gather product performance information from the end users for product improvement. Although it is the policy that all warranty claim must have a PPR number assigned by the manufacturer, all end users are encouraged to submit PPRs to the manufacturer via the customer service. Customer Service - USA Tel: (432) 334-4575 Fax: (432) 334-4555 A copy of the Product Performance Report is included at the end of this manual. End users is free to make copies for submission via the customer service. When a significant change in design which will affect the maintenance of the Rotaflex units, Field Service Bulletins are issued to all field service personnel so that proper procedures can be followed. Weatherford Artificial Lift Systems is committed to provide the highest quality of oil field equipment to our customers. Provide us feedback to us serve you better.
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