WELLPILOT TROUBLESHOOTING & MAINTENANCE.pdf

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WellPilot Rod Pump Pump Opt Optimiz imizat atio ion n Cont ontroll roller er User ser Manua anuall

Troub rouble les shoot hootin ing g and and Maint ainten ena ance nce

Troubleshooting & Maintenance Table of Contents List of Paragraphs

TROUBLESHOOTING & MAINTENANCE................................. MAINTENANCE.......................................................... ..................................... ............ I Introduction .................................. ...................................................................... ........................................................... ....................... 1 Traveling Traveling Valve and Standing Standing Valve Checks............ Checks.................... ............... .............. .............. ............ ..... 1 Comments:................................................................................................4 Step-by-Step TV/SV Checks and CBE Value Determination...............................6 Valve Check Screen Commands: ........... ........................ .......................... .......................... .......................... ..........................7 .............7 TV check process ........... ........................ .......................... .......................... .......................... .......................... ......................... .....................8 .........8 SV check process ........... ........................ .......................... .......................... .......................... .......................... ......................... .....................9 .........9 CBE process ............ ......................... .......................... .......................... ......................... ......................... .......................... ..........................10 .............10

Controller Diagnostics ............................... .................................................................... ............................................. ........ 10 1 - Firmware Versions .............. ...................... ............... .............. .............. .............. ............... ............... .............. ..............11 .......11 2 - Load Input diagnostics .........................................................................11 3 - Position Input diagnostics .....................................................................13 4 - Communications Diagnostics ............... ...................... .............. .............. .............. ............... ............... ..............14 .......14 5 – FCU Comm Statistics .............. ..................... .............. ............... ............... .............. .............. .............. .............. ........... ....15 15 6 – System Restore............... Restore...................... .............. .............. ............... ............... .............. .............. .............. .............. ........... ....15 15 7 – Explorer .............. ..................... ............... ............... .............. .............. .............. .............. ............... ............... .............. ..............16 .......16 Raw Card Data Retrieval .............. ..................... .............. .............. ............... ............... .............. .............. .............. ............ .....16 16 RLC Diagnostic Information....... Information ............... ............... .............. .............. .............. .............. ............... ............... ..............17 .......17 STA Segment Detection on Serial Console Output .............. ...................... ............... .............. ............ .....17 17 STA Segment detection output in Raw Card Data ............ ........................ ......................... .......................... ............... 17 STA Segment Boundary Detect Position Profile Diagnostics......................................18

RPOC Error Messages ............................................................................. 20 Catastrophic Program Errors .............. ..................... .............. .............. ............... ............... .............. .............. .............20 ......20 RPOC Messages .............. ..................... .............. .............. ............... ............... .............. .............. .............. ............... ............... ......... .. 20 Field Troubleshooting Error Messages..........................................................28 Field Help Tips........ Tips ............... .............. .............. .............. .............. ............... ............... .............. .............. .............. ............... ........... ...29 29 RPOC Alarm / Error Messages and Host Alarm Messages Messages .............. ..................... ......... .. 32 Host Generated Soft Alarms ................................................................... 45 Host Intelligent Alarms .......................................................................... 46 MS-WPRPOCFIX-00 / Rev. C January 2014

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Troubleshooting and Maintenance

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WellPilot Rod Pump Optimization Controller User Manual

Load Cell Testing.......................................... Testing.............................................................................. ........................................... ....... 56 Resistance Testing ....................................................................................56 Voltage Testing.........................................................................................56 CPU Communications Diagnostics:.......... Diagnostics:.............................................. ................................................ ............ 57 CAN Messages Message s ................................. ...................................................................... .........................................................58 ....................58 Diagnostic Details .....................................................................................58 Diagnostic Parameters (P2890 – 2896) ............... ...................... .............. .............. ............... ............... ............59 .....59 Parameter Attribute Details ............ ........................ ......................... .......................... .......................... .......................... .................. .....61 61

Upgrading Upgrading Firmware Firmware .............. ..................... .............. .............. ............... ............... .............. .............. .............. .............. ......... 62 System Backup Backup and Restore........ Restore............... .............. .............. .............. .............. ............... ............... .............. .......... ... 65 Customizable Backup or Setup File .............. ..................... .............. .............. .............. ............... ............... ............65 .....65 Setup File.............................. File........................................... .......................... .......................... .......................... .......................... ........................66 ...........66 Creating Backup and Restore Files.............................. Files........................................... .......................... .......................... ................ ... 67

System Backup.........................................................................................68 System Restore ........................................................................................69 Analog Output Calibration............................ Calibration................................................................. ........................................... ...... 73 Recommende Recommended d Maintenance Maintenance Equipment Equipment Listing Listing .............. ...................... ............... .............. ......... .. 77 Tools .................................. ...................................................................... ..................................................................... .................................77 77 Materials..................................................................................................78 Preventative Maintenance .................................. ...................................................................... .................................... 78 Every Three Months ............... ...................... .............. .............. .............. ............... ............... .............. .............. .............. ..........78 ...78 Every Year ...............................................................................................78 Connections: ............. ......................... ......................... .......................... .......................... .......................... .......................... ........................78 ...........78

Every Three Years .............. ..................... .............. ............... ............... .............. .............. .............. ............... ............... .............79 ......79 List of Tables Table 1: Boundary Detection Parameters ............... ...................... .............. .............. .............. .............. ..............18 .......18 Table 2: RPOC Message Types.................. Types......................... .............. .............. .............. ............... ............... .............. ...........20 ....20 Table 3: RTU Error Messages .............. ..................... .............. .............. ............... ............... .............. .............. .............. .........21 ..21 Table 4: Field Troubleshooting Error Messages .................................................28 Table 5: Field Help Tips ............... ...................... .............. .............. ............... ............... .............. .............. .............. .............. .........29 ..29 Table 6: Host/RPOC Alarm Messages and Resolutions .......................................32 Table 7: Host Generated Soft Alarms ..............................................................45 Table 8: Host Intelligent Alarms ............... ...................... .............. .............. .............. ............... ............... .............. ...........46 ....46 Table 9: D5 LED Signals .............. ..................... .............. .............. ............... ............... .............. .............. .............. .............. .........57 ..57 Table 10: CAN Messages .............. ..................... .............. ............... ............... .............. .............. .............. .............. ...............58 ........58 Table 11: Source of Position Sensor Failure......................................................59 Table 12: Diagnostic Parameter Attributes .............. ..................... .............. .............. .............. ............... .............61 .....61 Table 13: RPOC Installation / Maintenance Equipment.......................................77

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MS-WPRPOCFIX-00 / Rev. C January 2014

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List of Figures Figure 1: Traveling Valve Check .............. ..................... .............. .............. ............... ............... .............. .............. ..............2 .......2 Figure 2: Standing Valve Check.................... Check........................... .............. .............. .............. ............... ............... .............. .........3 ..3 Figure 3: Valve Check Examples................... Examples.......................... .............. .............. .............. ............... ............... .............. .........5 ..5 Figure 4: Residual Friction and Fluid Loads from Valve Checks .............................6 Figure 5: Pumping Pu mping System diagnostics Menu Flow .............. ..................... .............. .............. .............. ...........8 ....8 Figure 6: Controller Diagnostics Flow .............. ..................... .............. .............. ............... ............... .............. ............ .....12 12 Figure 7: Typical Load Cell Resistance Res istance Diagram .............. ..................... ............... ............... .............. ............ .....56 56 Figure 8: D5 LED Location ............... ...................... .............. .............. .............. ............... ............... .............. .............. ............ .....57 57 Figure 9: Flow Chart of Diagnostics.................................................................60 Figure 10: System Backup Flowchart ..............................................................71 Figure 11: System Restore Flowchart..............................................................72 Figure 12: Battery Cover Being Released.........................................................79


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Introduction This Section is to be used as a guide to help solve problems with the well and optimization equipment. The following paragraphs guide you in troubleshooting and performing routine maintenance on your unit.

Traveling Valve and Standing Valve Checks TV (Traveling Valve - actually upstroke pump slippage) and SV (Standing Valve) checks are used to help determine the mechanical condition of the downhole pump. These checks should be used only in conjunction with the calculated downhole pump card and analysis data generated by the host analysis software before finally judging pump condition. It is essential understand/practice this process to improve the accuracy of the TV/SV data. CBE data, when properly collected and saved, can be used by the host analysis software as information needed to accurately calculate pumping unit gearbox torque. A secondary benefit of the WellPilot RPOC is the ability to use measured well load to indicate the possibility of downhole pump/pump valve leakage. To check for “traveling valve” or “upstroke slippage”, turn the power to the pumping unit “off” (HOA switch) and use the unit brake to slowly stop the pumping unit near the top of the upstroke (See graphic below). Because the RPOC load cell is measuring dynamic load, any leakage caused by traveling valve ball and seat problems or barrel/plunger fit will result in a loss of load (See “Valve Check Example” graphic).


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Figure 1: Traveling Valve Check

To check for “standing valve” leakage, turn the power to the pumping unit “off” (HOA switch) and use the unit brake to slowly stop the pumping unit near the bottom of the downstroke (See graphic below). Because the RPOC load cell is measuring dynamic load, any leakage caused by standing valve ball and seat problems will result in the load value showing an increase (See “Valve Check Example” graphic).

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Figure 2: Standing Valve Check


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Comments: The accuracy of traveling valve checks is especially related to stopping the unit smoothly. “Rod string bounce” is a common occurrence and can easily result in an erroneous indication of fluid slippage if the unit is not stopped smoothly. Remember that the degree of “traveling valve leakage” measured can related to the “pump fit” or “barrel/plunger clearance” of the pump used in each well as well as the traveling valve assembly. Confirm suspicious traveling valve checks through the downhole pump card shape, pump efficiency, and appropriate well site observations. Always investigate any gradual traveling valve leakage thoroughly. If the traveling valve check shows an immediate load loss, lower than as compared to the load value of the standing valve check, then severe upstroke fluid slippage is likely. Refer to the “Valve Check Example” graphic below, part “b”, for examples of “moderate” and “severe” traveling valve problems. If there is any indication of load gain associated with a standing valve check, standing valve leakage is assured. If using a downhole analysis program that calculates pump slippage based on measured data taken from valve checks, use the results for decision making with care. The procedures associated with taking traveling and standing valve checks are crucial to good results. Schools are available to train analysts in methodology and interpretation. The standing valve check load value can be used as an indicator of load cell accuracy when compared to the calculated value of the buoyant weight of the rod string.

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Figure 3: Valve Check Examples


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TV

12205

TV Load = 11365 lbs.

TV - SV = 3205 lbs.

Pol. Rod Load

Risidual Friction (R) = 605 lbs. 7850 Fluid Load = TV-SV-R Fluid Load = 11365-7850-605 Fluid Load = 2910 lbs.

0

0

Figure 4: Residual Friction and Fluid Loads from Valve Checks

Step-by-Step TV/SV Checks and CBE Value Determination 1. Select option 5, Pumping System Diagnostics, from the Main Menu to access the ability to check the traveling and standing valves for leakage and store those values for retrieval by a host analysis system and/or identify the value of CBE (Counterbalance Effect) and store this value for retrieval by a host analysis system.

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2. Press < > to access the Pumping System Diagnostics menu.

3. The cursor indicates the only active item – the selection of “Valve check / CB Effect”.

4. Press < > again to open the “traveling/standing valve check” screen.

Valve Check Screen Commands: 







Record - Records data to a temporary buffer Stop - Stops recording data Save - Saves recorded data to battery based memory Recall - Recalls this data from battery based memory



Set TV - Saves recorded data for retrieval by host system



SETCBE (90) - Saves CBE data for retrieval by host system


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Default Status Screen

Main Menu 1 - View Data 2 - Setup Menu 3 - Alarm Status 4 - Parameter Table 5 - Pumping System Diagnostics 6 - Controller Diagnostics 7 - User Defined Screen 8 - Status Screen 9 - Quick Guided Setup 10 Alarm Summary 11 Select Pumping Unit

Alarm Status Flow

Selects Travelling or Standing Valve Screen

Note: When is pressed Pointer Automatically Advances to Next Menu Item.

Records Data to Temporary Buffer Stops Recording Saves Data to Battery Backed Memory Recalls Data From Battery Backed Memory Saves Data for use by Host Saves CBE Data for use by Host

1 Record 2 Stop 3 Save 4 Recall 5 Set TV / SV 6 SetCBE

Figure 5: Pumping System diagnostics Menu Flow

TV check process Note: is the initial “active” menu item.

1. Press < > to begin the live “load vs. time” display and to “record” this data to a temporary buffer.

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Vertical “Crosshair” as positioned using the keypad “left/ritght” Arrow keys. MS-WPRPOCFIX-00 / Rev. C January 2014

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Note: The “TV” (option 5 – Set TV ) is addressed first. Note also that the menu selection is automatically advanced to the next selection each time < used to select a menu item. 





> is

Be sure the well is stable and turn off the HOA (hand–off-automatic) switch. Then, slowly apply the pumping unit brake and bring the unit to a halt near the top of the pumping unit upstroke. (This will require some practice for a “beginner”.) Press <

> to recording data and advance to the next menu item.

Now, use the < or > arrow keys to move the vertical “crosshair” to identify the proper TV value.







Press < > to Save the TV plot to battery-backed memory. Any existing data is overwritten and lost. must be executed before changing to another screen, otherwise the data is lost. Use to save the TV valve check data for use by a host analysis system.

SV check process Use the < or > key to display and save “SV” information. Note that option 6 will change to Set SV. Follow the instructions above to complete the SV check process.


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CBE process All the above instructions apply – except that the pumping unit must be stopped either near 90o or 270o before executing SetCBE to save the CBE value for use by a host analysis system. SetCBE (90) is associated with the “traveling valve” check and SetCBE (270) with the “standing valve” check. Use the < or > keys to move between “traveling” and “standing” valve screens and therefore between SetCBE (90) and SetCBE (270). Note: When the or commands on the screen are executed, a message is displayed in the lower left corner of the screen, i.e. “No Data Saved” or “Data Saved”. The value that will be saved is the current value displayed for RodLoad. Press the < the selected process.

> key to “clear” all data and re-start

Controller Diagnostics Select option 6, Controller Diagnostics, from the Main Menu to access the Controller Diagnostics menu. The figure to the right shows the Controller Diagnostics Menu Screen. Figure 6 shows the Controller Diagnostics complete programming flow diagram. The cursor, which can be moved with the arrow keys, indicates the active item. Press

- CONTROLLER DIAGNOSTICES > 1 2 3 4 5 6

-

Firmware Versions Load Input Diagnostics Position Input Diagnostics Communications Diagnostics System Restore Explorer

SELECT BY # OR ARROW KEYS THEN PRESS ENTER

< > to select the desired “diagnostic” screen.

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1 - Firmware Versions This screen shows you the firmware part numbers for the Main Processor and the I/O Processor. The installation or update time is also shown and the version number of the I/O Processor firmware is displayed.

- FIRMWARE PART NUMBERS & VERSION MAIN PROCESSOR PART NUMBER: FW00004-00 Firmware V 1:08:00 I/O PROCESSOR PART NUMBER: FF-00009-00 V01.01.00 System Backup : >0 Firmware Upgrade: (Press ENTER) System Restore : 0

2 - Load Input diagnostics The values shown here, in the figure to the right, especially the Raw Load input voltage and the Load Input in Lb. (Note that the display will show these values changing as the well is pumping) can be used to monitor and troubleshoot the RPOC loadsensing device.


- LOAD INPUT DIAGNOSTICS Input Offset (uV): 20000=+0.000MV Load Gain Factor (Lb./mV: 1500 lb/mV (30 Raw Load Input voltage: +10.815MV Load Input in Lb.: 16000 Lb. Min. Input since power on: +3.242MV Max. Input since power on: 16.056MV Clear Load Min/Max values:>(Press MODIFY)s

The cursor indicates the active item. Only one item can be accessed – “clear maximum and minimum loads”. Press <

> to edit or modify this item. When the subordinate modification screen is

displayed, make any necessary changes to the item. When complete, press < > to return to the Load Input Diagnostics screen with minimum and maximum load values reset or press <

> to abort the process.


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Figure 6: Controller Diagnostics Flow

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3 - Position Input diagnostics The values shown here, the figure shown to the right, especially the Position input voltage, (Note that the display will show this value changing as the well is pumping.) can be used to monitor and troubleshoot the RPOC position-sensing device. The cursor, which can be moved with the <

- POSITION INPUT DIAGNOSTICS -

OR

> arrow keys, indicates the active item. Then, press < > to edit or modify the selected item. When the subordinate modification screen is displayed, make any necessary changes to the item.

Continuous Position:>1=CONTIN POS Minimum Input since power up: 3.324V Maximum Input since power up: 7.832V Position Input voltage: 3.324V Minimum Input last stroke: 3.324V Maximum Input last stroke: 3.328V Input Span last stroke: 0.004V Minimum input limit: 2250=0.250V Maximum input limit: 10000=0.500V Minimum valid span: 500=0.500V

When complete, press < > to return to the Position Input Diagnostics screen with the new information displayed or press <

Position switch status: 0=OPEN

> to abort the process.

Note: Not all items on this screen can be “modified”. At this time, only those items listed below can be modified: Continuous Position - (Pick 0, 1, or 2) Minimum Input Limit - Type in Minimum Input Load value in Lb’s and the controller will convert that number to the appropriate Volts. Maximum Input Limit - Type in Maximum Input Load value in Lb’s and the controller will convert that number to the appropriate Volts. Minimum Valid Span - Type in the Minimum allowed span between the minimum load and the maximum load.


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4 - Communications Diagnostics The values shown on the Communication Diagnostics screen, figure shown below, and the Host Receive Buffer screen can be used to monitor and troubleshoot the RPOC wellsite-to-host communications.

– COMMUNICATIONS DIAGNOSTICS –

The cursor, which can be moved with the <

OR

> arrow keys, indicates the

Clear comm. statistics:>(Press MODIFY) View Receive Buffer: (Press ENTER) Character errors: 0 Characters Received: 0 Header chars received: 0 Trailer chars received: 0 Framed Msgs received: 0 Good framed Msgs received: 0 Messages processed: 0 Commands processed: 0 Responses transmitted: 0 Characters transmitted: 0

active item. Press < > to edit or modify Clear comm. statistics. When the subordinate modification screen is displayed, make any necessary changes to the item. When complete, press < > to return to the Communication Diagnostics screen with the new information displayed or press <

> to abort the process. Use the <

Receive Buffer and press <

OR

> arrow keys to select View

> to display the Host Receive Buffer screen.

Note: Not all items on the Communication Diagnostics screen can be “modified”. Only the Clear Comm. Statistics and the View Receive Buffer can be modified. Clear Communications Statistics – Invoking this command clears all of the communications buffers so that erroneous data does not get sent with the new data. View Receive Buffers: Press < listing.

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> to see page 1 of 11 pages of the receive buffers


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5 – FCU Comm Statistics This screen allows you to monitor the communication with the FCUs and clear the comm counters. Use the < > and < > keys to navigate through FCU screens. Polls are messages sent counter. Good responses are valid replies counter. No responses are invalid replies counter. ACK’s sent is the number of acknowledgments sent counter. Clear stats will clear all counters on screen, press < counters for FCU.

> and then <

> to clear all

- SYSTEM RESTORE SCREEN Quick Guided Setup :>(Press Enter)

6 – System Restore This screen allows you to backup or restore the system files to/from the RPOC internal memory or to/from a standard SD card. The cursor, which can be moved with the <

Sys Backup to Sys Restore from Sys Backup to SD Sys Restore from SD

RPOC RPOC Card Card

: : : :

(Press (Press (Press (Press

Enter) Enter) Enter) Enter)

SELECT BY # OR ARROW KEYS THEN PRESS ENTER

OR

> arrow keys, indicates the active item. Press < > to invoke the chosen command. Follow the screen prompts to finish the operation.


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7 – Explorer

- EXPLORER -

This screen shows a file and directory tree view and allows you to view, copy, paste and delete files to/from the RPOC internal memory or to/from a standard SD card. Note: The standard system files cannot be deleted. The cursor, which can be moved with the <

>/ .. eventfile_0 BkupASFile_1 CurrASFile_0 nv_parameters_0 nv_parameters_1 nv_directory FF0001200 Ff0001201 CurrentHourlyLog CurrentDailyLog Press F3=Copy Clear=Delete

OR

> arrow keys, indicates the chosen item. Press < > to change levels or invoke a command. The .. allows you to access the root tree level. Moving the cursor to one of the root directors and pressing

- EXPLORER >/ .. sys1 sys2 SD_Card

< > will show that levels list of files.

Press F3=Copy Clear=Delete Note: only one file can be copied, moved, or deleted at a time. Caution: Be sure to invoke the SD Card dismount command (P468) before removing the SD Card. If the SD Card is removed prior to being dismounted, the unit will need to be reset using the (P351) Software Reset command for the card to be acknowledged again.

Raw Card Data Retrieval This is a new diagnostic functionality added to record the raw card data (load and position). This feature can be enabled by setting P510 = 11000. The number of strokes to be recorded should be specified in P512. The maximum number of strokes that can be recorded are 255. P513 indicates the current stroke that is being recorded. When all of the specified number of raw cards are collected P513 resets to a value of 0. To re-enable (or in order to collect a new set of Raw Cards) P510 value should be toggled (reset the 4 th bit of P510 to 0 and set it again to 1000). This will delete the previously collected card data in the file and start with new strokes. 16


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The raw card data collected is stored in a file “RawCardData.txt” in the root directory (RAM Disk). This file is in volatile memory so it will be lost on power cycle.

RLC Diagnostic Information RLC Diagnostic information can be printed on the serial console by setting P510 = 20. The RLC Diagnostic information is printed for every Load sample (obtained at 50 msec) that violates the RLC Load Limits. The RLC Diagnostic information comprises of the following fields: 

RLC Load



New % output



New SPM



Speed Change



Time from the first RLC violation until the current RLC Load violation.

STA Segment Detection on Serial Console Output STA Segment Detection Diagnostic information can be printed out on the serial console by modifying P510 as follows: P510 = 40 – This will print the STA Segment detection values continuously on the serial console. P510 = 200 – This prints the STA Segment Detection information on serial console only when a new segment is detected. The above STA Segment Detection message comprises of following fields: 

Current Segment



Po sition Value



New % output



Next Segment Voltage



Time since the beginning of current segment.

STA Segment detection output in Raw Card Data This Diagnostic feature which is incorporated in the above functionality of collecting raw card data. This feature can be enabled by setting P510 = 3000. This will capture the raw position values for the 4 STA Segments detected by the controller during the stroke.


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STA Segment Boundary Detect Position Profile Diagnostics A diagnostic feature is used - Speed State:0=-to profile the STA segment Base: 4.50 SPM boundary detection process. The purpose of this feature is 150 DEG to aid in troubleshooting (S)-2.000V variations in the position (D)-2.000V where the boundary is UP detected. This feature is NN.NN SPM described in the next section. 0.00% This diagnostic is available on a new View Data menu 30 DEG screen under the VSD (S)-2.000V AuxApp Data screen. The (D)-2.000V screen title is STA Segment PRESS Diags. Its operation will be described in a following two paragraphs.

Trim Adj Op Data Dir:DN TrimSpd:2. 0 DeltaFill: 70% TOP NN.NN SPM 0.00%

210 DEG (S)-2.000 (D)-2.000

DOWN NN.NN SPM 0.00% BOTTOM NN.NN. SPM 0.00%

330 DEG (S)-2.000 (D)-2.000

EXIT TO QUIT

Profile of the Four Position Readings Preceding a Boundary Detection The purpose of this diagnostic is to provide a profile of the last four positions provided to the STA application before a segment boundary is detected. The segment to be profiled is selected in parameter 2882. Parameters 2883 – 2886 contain the four position values that precede the position at which the boundary is detected and that is stored in parameter 2887. The order is always P2886 is the position immediately preceding the segment detection position and P2883 is the position that is four back from the segment detection position. The segment boundary values are stored in parameters 1154=BOTTOM, 1155=UP, 1156=TOP and 1157=DOWN. Parameter 2882 can be set to 0=NONE, 1=UP, 2=TOP, 3=DOWN, 4=BOTTOM. If the selection is NONE then the diagnostic is disabled. The parameters are summarized in the table below. Table 1: Boundary Detection Parameters Parm # 2882 2883 2884 2885 2886 2887

The The The The The The

Description segment starting point to profile, 0=disable position preceding the one in P303 position preceding the one in P304 position preceding the one in P305 last position before the segment is detected first position detected inside the segment

All the fields on this display are updated at the end of a stroke. 18


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The delta position values and segment detect profile values are only valid when a segment is selected in parameter 301. The delta position values are updated with the minimum and maximum differences between successive position values over the last stroke. They are updated at the end of a stroke. The segment detect profile values show the five successive position values supplied to STA where the last one causes a segment boundary detection for the segment specified in the segment field (P301). The boundary delta position is the difference between the position where the boundary was detected and the position voltage that is associated with the boundary. The segment boundaries located on the lower left portion of the screen are placed there for reference and are always enabled. These are also recalculated at the bottom of each stroke.

Pump Direction STA Application utilizes Pump Direction to detect the segment boundaries. Detection can be switched from determining the Pump Direction from the POC, based on time, or from Position Voltages. The POC determination is good for fixed speed but the variable speed will throw off this mechanism. This operation can be switched by using a value of 1 in P2881 (P2881 = 1).

STA Debug Output This feature can be enabled by setting P2881 = 2. This feature will print the debug information on the serial console. This information shows the mismatch in the pump direction obtained by POC and from VSD.

STA Fetch Dyno Data This code can cause problems in the STA Application so if this bit is enabled in P2881 using value P2881 = 4, then this code is executed. There is a chance that the valid flag check for load span skips the STA processing there by creating a lag in STA segment boundary detection.

STA Trigger Event Flags are currently used to trigger STA Processing. If this feature is enabled, it uses a hardcoded 50 msec delay to trigger STA (which means STA processing occurs every 50 msec). This can be enabled by setting P2881 = 10.

STA Position Values Raw Card Data can be obtained by setting P510 = 3000. This also provides the position raw and corresponding expected and detected voltage values for STA segment boundaries. A new feature has been added to this functionality. A new MS-WPRPOCFIX-00 / Rev. C January 2014

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column has been added to the right side which indicates the previous Raw Position value that was grabbed by STA. This value should match with the previous raw position value in the first column. This diagnostic feature has been added in order to verify if there are any position values that are missed by STA Application.

RPOC Error Messages A message can be the result of an RPOC or system problem (or error), a significant RPOC status change, or just information to notify the operator of events occurring.

Catastrophic Program Errors The following messages indicate catastrophic program errors and should never occur in normal RPOC operation. Report any of these messages to Customer Service. COMM INIT FAIL MEMORY FAILURE MSG POOL FAILURE SIGNAL FAILURE

EXCHANGE FAILURE MEM FREE FAILED MSG RETURN FAIL TASK FAILURE.

RPOC Messages Messages are classified according to type. Table 2 lists the types in the order of significance or severity. Two of the message types, alarm and status, utilize the fault lamp and “Fault” message in the display. Table 2: RPOC Message Types Type

Description

A

Alarm

E

Error

I

Information

S

Status

O

Other

Table 3 contains a listing of messages, as they appear on the local RPOC Display, when the error or situation occurs or the RPOC status generates a message. When a message displays on the local 2-line display, it appears on the top line of the twoline display. Following the message is a brief description. If appropriate, corrective action is provided.

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Table 3: RTU Error Messages Message

Type

Description

1 to 799, PLEASE

EI

Invalid parameter entered after key.

AB AMPS TOO LOW

A

The motor current input signal level is too low for the air balance control to function properly.

AI1 DIG 0 ALARM

A

Auxiliary Analog Input 1 as a digital is in a closed (low voltage) condition.

AI1 DIG 1 ALARM

A

Auxiliary Analog Input 1 as a digital is in an open (high voltage) condition.

AI2 DIG 0 ALARM

A


AI2 DIG 1 ALARM

A


AI3 DIG 0 ALARM

A


AI3 DIG 1 ALARM

A


AI1 LOW LIMIT

A

No message.

AI1 HIGH LIMIT

A

No message.

AI2 LOW LIMIT

A

No message.

AI2 HIGH LIMIT

A

No message.

AI3 LOW LIMIT

A

No message.

AI3 HIGH LIMIT

A

No message.

AI4 LOW LIMIT

A

No message.

AI4 HIGH LIMIT

A

No message.

AI5 LOW LIMIT

A

No message.

AI5 HIGH LIMIT

A

No message.

AI6 LOW LIMIT

A

No message.

AI6 HIGH LIMIT

A

No message.

AI7 LOW LIMIT

A

No message.

AI7 HIGH LIMIT

A

No message.

AI8 LOW LIMIT

A

No message.

AI8 HIGH LIMIT

A

No message.

BAD DATA VALUE

EI

The value entered is not valid for the parameter modified. Check units and range.

BAD POS SENS INT

EI

An attempt was made to set Top of Stroke (TOS) with P7 when the interval of the last continuous position sensor cycle was out of range.

BAD PREV POS INT

EI

An attempt was made to set Top of Stroke (TOS) with P7 when the interval of the previous continuous position sensor cycle was out of range.


21

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Type

Description

BAD PREV SW INT

EI

An attempt was made to set Top of Stroke (TOS) with P6 or P7 when the interval between the previous two position switch closures was out of range.

BAD SHUT DOWN

A

The controller has been powered up after failing to perform a proper shutdown on power failure or fatal error.

BAD SWITCH INT

EI

An attempt was made to set the Top of Stroke (TOS) with P6 or P7 when the interval between the last two position switch closures was out of range.

BAD TIME & DATE IC

A

The real time clock chip has failed internal update and/or check. Record P668, check P669 and verify increment from 00 to 09. If the increment is not occurring, replace CPU Card. If increment is functioning, press . If this error re-occurs, replace CPU Card.

WEATHERFORD xxxx ROD PUMP

O

This appears after the RTU initializes and all internal self-checks are done satisfactorily. This message should only occur within a few seconds after power is applied or restored to the RTU, or P556 executed.

CAN’T SET 0 LB

EI

The signal from the load cell is out of range for a reasonable zero load signal.

CAN’T SET 0 KG

EI

The signal from the load cell is out of range for a reasonable zero load signal.

CLRD MULP POS SW

A

Multiple position switches have occurred and the problem has corrected itself.

CLRD POS SW FAIL

A

The position switch has failed and later returned to normal operation.

COMM OUTPUT TEST

A

The modem is in a "Constant Key" Test until P648 times out to "0" or manually set to "0".

CONTROL FAILURE

A

This occurs after the controller has been in a TEMP CONTROL LOSS situation for a period longer than the time set in P261. Possible causes include an operator took the Hand-Off-Auto (HOA) switch out of the Auto position, MCI relay failure, analog card failure, motor control panel starter relay failure, or belt failure.

CONTROL TRANSFER

S

The RPOC has transferred control of the pumping unit back to the existing controls as a result of a controller fault or the RPOC was programmed to transfer in the event of a specific limit violation.

CPU FELL BEHIND

A

The CPU has been overloaded and the RTU may re-start in order to recover. If this problem persists, report this situation to ePS Customer Service.

DI1 CLOSED ALARM

A

Digital Input 1 is in the closed condition.

DI1 OPEN ALARM

A

Digital Input 1 is in the open condition.

22


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Type

Description

DI2 CLOSED ALARM

A


DI2 OPEN ALARM

A


DI3 CLOSED ALARM

A


DI3 OPEN ALARM

A


DI4 CLOSED ALARM

A


DI4 OPEN ALARM

A


DI5 CLOSED ALARM

A


DI5 OPEN ALARM

A


DI6 CLOSED ALARM

A


DI6 OPEN ALARM

A


DI7 CLOSED ALARM

A


DI7 OPEN ALARM

A


DI8 CLOSED ALARM

A


DI8 OPEN ALARM

A


DAC Fail

Analog Output card has failed, P532, bit 13

DIVIDE ERROR

A

Attempt to divide by zero in internal calculation. Contact ePS Customer Service.

ENERGY LOCKOUT

I

The controller is holding the well idle while the current time is within the peak energy inhibit time period as set in P51 and P52.

ERROR(S) CLEARED

I

Errors have been cleared by pressing .

ESP ONLY

S

P26 is set to 4, 5, 6, or 7. RPOC functions are disabled.

FAULT

O

Flashes in the top right-hand corner of the LCD display when an error occurs.

FLUID CALC ERROR

A

Controller was unable to determine correct fluid stroke in gross fluid calculation.

GAIN TOO LARGE!

EI

When entering a load in P73, the calculated gain factor, P74 (Shown in P75) is too large. The old value is retained.

HIGH LOAD LIMIT

A

The controller has seen the pumping unit consecutively exceed the load value set in P211 on the number of strokes defined in P218.

IMMED LOAD LIMIT

A

The system load has been detected to be exceeding the limit set in P218.

AEI

The RPOC detected pump-off as soon as the pump-up delay timed out the number of consecutive times set in P230.

IMMED PUMPOFF

INVALID KEY!

EI

Unexpected key was pressed.

INITIALIZING

O

Displays while the RTU is initializing hardware and internal variables.


23

®




Type

Description

LOAD INPUT FAULT

A

The controller has detected that the load sensor, load sensor cable, or load signal amplifier has failed.

LOAD UNITS CHANGED

I

Load unit was changed from Lb. to Kg. or vice-versa by changing P14.

LOW LOAD AVERAGE

A

The load average has been found to be below the value set in P212 for the number of consecutive times as defined in P213.

LOW LOAD LIMIT

A

The RPOC has detected the polished rod load consecutively fell below the load value set in P210 for the number of strokes set in P213.

LOW LOAD SPAN

A

The RPOC has detected the pumping unit load span consecutively fallen below the load span set in P223 for the number of strokes defined in P222.

MANUAL OFF (31)

A

The controller was commanded to keep the pumping unit off by using P31.

MANUAL CTRL XFER

A

The RPOC was told to transfer control of the pumping unit to the percentage timer or to continuous “on” or “off” by using P32.

MANUAL SOFT TIME

A

The controller has been commanded with P33 to run in the software timer mode.

MAX CYCLE ONTIME

A

The RPOC is not in a power recovery mode and has run the pumping unit over the maximum cycle time value

MAX DAILY ONTIME

A

The RPOC is not in a power recover mode and has run the pumping unit beyond the value in P237.

MIN CYCLE ONTIME

A

The controller ran less than the prescribed mini-mum cycle run time as defined in P232 for the number of consecutive times defined in P233.

MISSING 619

EI

An attempt was made to set Top of Stroke (TOS) with P7 when P619 was set to zero (0) indicating that no continuous position sensor was available.

MTR OFF TOO LONG

A

The controller has been put into off until reset as result of the motor being off continuously for a time longer than the value set in P38.

MULTIPLE POS SW

A

More than one position switch closures occurred within the time limits defined by P136 and P137.

NEED ERROR RESET

EI

Clear error(s) before any action can occur. Press .

NEED PASSWORD

EI

Password must be entered in P1 or P573 before any action can be taken.

NO ERRORS NO CYCLES YET

24

I Pressing with no errors. EI

The RPOC has not seen sufficient position switch closures and load changes to declare the pumping unit running. MS-WPRPOCFIX-00 / Rev. C January 2014

®




Type

Description

NO POS CYCLES

EI

An attempt was made to set Top of Stroke (TOS) using P7 when no continuous position sensor input has been detected.

NO POS SWITCHES

EI

An attempt was made to set Top of Stroke (TOS) using P7 when no position switch closures have been detected.

NO TIMER VALUE

A

A detected failure was programmed to transfer to the software timer, but the value in P205 was 00:00:00 or the value in P204 was zero (0) and P206 was 00:00:00. If P205 was zero, it was likely the result of too few undisturbed cycles. The controller will automatically transfer control.

NON DATA PARAM

EI

An attempt was made to modify “Display Only” parameter.

NVS INITIALIZED

I

Indicates that non-volatile memory (NVM) was reset to factory values in all parameter locations as a result of modifying P472.

OFF UNTIL RESET

S

The controller has experienced a failure that resulted in “Off Until Reset by Operator”.

ON FOR 15 SECS

A

The fault lamp is being tested for 15 seconds per P350.

PARAM 20 MISSING

A

P20 is set to zero (0). RPOC needs appropriate value for parameter.

PARAM 21 MISSING

A


PARAM 23 MISSING

A


PARAM 24 MISSING

A


PARAMS EXPANDED

A

A new version of RTU firmware has been installed with additional parameters. This is an "information only" message. Press to clear the message.

PARAMS INIT'ED

A

All parameters are set to ePS factory default values.

PEAK HOURS IDLE

S

The RPOC is holding the well idle because the current time is within the peak energy inhibit time period set by P51 and P52.

POC OVERRIDE (27)

A

The RPOC was commanded with a value entered in P27 to continue pumping and to ignore fluid pound conditions until the value in P27 counts down to zero.

POS SWITCH FAIL

A

The position switch is not responding and the RPOC will take action as defined in P200.

POS SWITCH SET

I

The position switch has been calibrated in relationship to the stroke by the controller.


25

®




Type

Description

POS SWITCH SETUP

I

The position switch has not been set using P6 or P7 or by forcing a position location using P130.

POWER FAIL

O

The RTU has received a signal from the Power Supply Module indicating that Input Power is low or "off".

PROGRAM ERROR

A

The RTU has experienced an internal error. Report this to ePS Customer Service.

PUMP ALREADY OFF

I

was pressed while the RPOC has the pump turned “off” in idle time.

PUMP ALREADY ON

I

was pressed while the RPOC has the pump turned “on”.

reserved

---

Reserved for future use.

RESET

---

The hardware reset button was pressed.

RESTARTING

I

Displays after “NVS INITIALIZED”.

REVERSED

I

The position switch fraction in P130 has been reversed as a result of executing CA131.

REVERSE PUMPOFF

A

The controller has detected that the well is not pumped off and the control method chosen in P26 is set to a reverse pump-off option (P26 = 2, 3, 10, or 11).

RUN UNDER 50%

A

Run time was below 50% in idle time stabilization mode.

SAME AS 0 LB

EI

An attempt was made to set the load gain (P74) using P73 when the measured load value was zero.

SAME AS 0 KG

EI

An attempt was made to set the load gain (P74) using P73 when the measured load value was zero.

SOFTWARE TIMER

S

The RPOC had a failure that was programmed to go to the software time mode of operation.

SORRY, READ ONLY

EI

Cannot modify "Read Only" parameters.

TEMP CONTROL LOSS

A

The controller detected load and position signals when the pumping unit should have been “off” or the RPOC did not detect load and position signals when the pumping unit should be running. Refer to Control Failure and Control Transfer.

?TIME?DATE?

A

The RTU record of the last power failure occurred at an unrealistic time, as compared to the time and date from the internal battery clock. Check P3, P4, and P5 and take corrective action as indicated.

TOO FEW POS SENS

EI

An attempt was made with P7 to set Top of Stroke (TOS) when less than four continuous position sensor cycles have been detected.

TOO FEW SWITCHES

EI

An attempt was made to set Top of Stroke (TOS) with P7 when less than four switch closures have been detected.

26


®




Type

Description

UNKNOWN ERROR

A

Displayed if an error bit is set in P527 – P530, for which no error message has been defined.

UPDATE

I

Transfer of non-volatile parameter data to EPPROM in progress.

UPDATE CANCELLED

I

Transfer of non-volatile parameter data to EPPROM storage stopped because of active alarm.

UPDATE COMPLETE

EI

Non-volatile parameter data successfully copied to EEPROM storage.

VALUE TOO LARGE

EI

An attempt was made to enter a number that is too large for the selected parameter.

ZEROED


I

The load cell offset (mV with no load) has been computed and stored using P70.

27


®


Field Troubleshooting Error Messages Table 4 contains the error messages as they appear on the RPOC display. Following the message is a brief description and corrective action. The keypad and display are the most important tools available for field troubleshooting. Table 4: Field Troubleshooting Error Messages Error Message

Description

IMMED PUMPOFF

The RPOC detected pump-off as soon as the pump-up delay timed out. Reset pump off points in P21 and P23.

LOAD INPUT FAULT

A bad load cell and/or bad load cell cable is detected. Determine which piece of equipment is defective.

LOW LOAD AVERAGE

The low load average is below the value set in P212. Check P89 containing the load average over the last stroke. Reset P212 if this value is too close.

LOW LOAD LIMIT

The actual load has gone below value set in P210. Check for parted rod or stuck pump. Also, P210 may be set too high.

LOW LOAD SPAN

Actual load span fell below value set in P223. Verify if unit is pumping fluid. Check for bad or stuck pump valve or deep rod part. P223 could be incorrect.

NO TIMER VALUE

Controller tried to transfer to software timer, but a value was not found. This probably caused by another error with consequential rod pump control action. Watch display for error causing software timer problem.

SOFTWARE TIMER

RPOC has transferred to software value in P204. Watch display for the problem that caused the transfer action.

A/D FAILURE

Analog to digital converter has failed. The RPOC has gone to the software timer. The CPU or Analog Card is defective. The controller may need to be re-initialized.

BAD TIME & DATE IC

The real-time clock (RTC) has failed. Press . If error reoccurs, replace CPU Card.

CONTROL FAILURE

RPOC cannot control pumping unit. Check HOA switch. It should be in “Auto” mode. If not, put in auto mode and press . Press and to start and stop pumping unit.

CONTROL TRANSFER

RPOC has transferred control to time clock. Watch the display to see what caused transfer and correct any problem(s) displayed.

HIGH LOAD LIMIT

Rod load has exceeded value in P211. Check P86 for actual load value that caused the fault. Check for stuck pump and determine whether the load value in P211 should be changed.

TEMP CONTROL LOSS

RPOC control and pumping unit condition not the same. Watch the display to see what caused control loss and correct any problem(s) displayed.

BLANK DISPLAY

Nothing appears on the display. Turn RPOC “off” and “on”. This should clear and activate display.

28


®



Field Help Tips The following table lists some helpful field tips: Table 5: Field Help Tips Display

Possible Cause

Resolution

Fault lamp flashes. Display shows CONTROL FAILURE. Pumping unit not running under control of RPOC.

The RPOC has been in a TEMP (Temporary) CONTROL LOSS situation for a period longer than the time set in P261.

Check to see if HOA is in Auto. Check MCI relay, analog card, motor control panel starter relay and belt condition.

Fault lamp flashes. Display shows TEMP CONTROL FAILURE. Pumping unit not running under control of RPOC.

RPOC detected load and position signals when the pumping unit should have been off - OR - RPOC did not detect load and position signals when the pumping unit should have been running. If RPOC remains in this condition for the time defined in P261, then the RPOC will go into CONTROL FAILURE.

Check to see if HOA is in Auto. Check MCI relay, analog card, motor control panel starter relay and belt condition.

FLUID CALC ERROR

Fault lamp flashes. Display shows FLUID CALC ERROR. Calculated production numbers not available (P811-P830)

RPOC unable to determine correct fluid stroke in gross fluid calculation.

Confirm fluid parameter settings (P800 - P810) for accurate values.

HIGH-HIGH LOAD LIMIT

Fault lamp flashes. Display shows HIGH LOAD LIMIT. Pumping unit off until reset (if P214 is set to 3)

RPOC detected the polish rod load exceeded the load value in P211 for the number of consecutive times defined in P213

Check for stuck pump. Check for paraffin. Check for high flowline pressure. P211 may be set too low. Monitor maximum load values for last stroke in P80 while pumping.

CONTROL FAILURE

TEMP CONTROL LOSS

Symptom


29

®



Table 5: Field Help Tips Display

LOW-LOW LOAD LIMIT

LOW LOAD SPAN

TIMMED PUMPOFF

LOAD INPUT FAULT

30

Symptom Fault lamp flashes. Display shows LOW LOAD LIMIT. Pumping unit off until reset (if P216 is set to 3) Fault lamp flashes. Display shows LOW LOAD SPAN. Pumping unit off until reset (if P225 is set to 3) Fault lamp flashes. Display shows IMMED PUMPOFF in fault section.

Fault lamp flashes. Display shows LOAD INPUT FAULT.

Possible Cause

Resolution

RPOC has detected the polish rod load fell below the load value in P210 for the number of consecutive times defined in P215.

Check for parted rods or stuck pump. P210 may be set too high. Monitor minimum load values for last stroke in P79 while pumping.

RPOC has detected the polish rod load span has fallen below the load value in P223 for the number of consecutive times defined in P222.

Check for bad pump or stuck pump. Also check for possible deep rod part. Monitor P87 for span while pumping.

RPOC had detected pump off as soon as the pump up delay (P25) has been exceeded.

Reset pump off points in P21 and P23. Increase Idle time in RPOC (P20).

RPOC has detected the load cell, load cell cable or load cell protection board has failed.

Insure Load Cell cable is securely terminated in RPOC and properly attached to Load Cell. Check that entire length of cable is intact. Check that voltage from RPOC to load cell (Pin 1 & 2 on J5) is 10 volts. Check voltage from Load Cell (P77) is between 0.00 to 21.00 mv. If < 0 possible short in load cell or possible ground fault in pumping system. If > 24 cable is broken or damaged - Ohm if possible.


®



Table 5: Field Help Tips Display

Symptom

Possible Cause

Resolution

POS SENSOR FAILURE

Fault lamp flashes. Controller is in SOFTWARE TIMER (If P200 is 1, which is the default).

Position Sensor is malfunctioning. Position Sensor cable is damaged.

Insure Position Sensor cable is securely terminated in RPOC. Check that entire length of cable is intact. Check that P29 = 2. View P104, P105, P106 and compare to set points in P270, P271, P272. Check that voltage from RPOC to Position Sensor (Pin 1 & 2 on J4) has 13 volts.

SOFTWARE TIMER

Fault lamp flashes. Display shows SOFTWARE TIMER in fault section.

The RPOC has transferred control to software timer, using the value in P205 (Run time in P205 and Idle time in P20).

View status screen to determine why RPOC is in SOFTWARE TIMER mode and correct problem.

Controller tried to transfer to software timer, but a value was not found in P205 or P206.

Set value in P206, in case minimum number of cycles (P204) is not achieved before software timer is needed. Identify why controller went to SOFTWARE TIMER mode.

Fault lamp flashes. NO TIMER VALUE Display shows NO TIMER VALUE.

MANUAL SOFTWARE TIMER

PUTTING CONTROLLER INTO MANUAL TIMER MODE

Fault lamp Determine why RPOC flashes. The controller has been is in manual timer Display shows instructed (P33) to run in mode. Pressing ALARMS: the software timer mode CLEAR ALARM will MANUAL SOFT (Run time in P206 and Idle take RPOC out of TIMER in fault time in P20) manual timer mode. section. To put the RPOC into manual timer mode, enter desired “on time” into P206 (P205 shows the average run time of the last six undisturbed cycles). Change P204 to 0. Go to P33 and Modify/enter. Fault lamp will flash and display will show “ALARMS: MANUAL SOFT TIMER”. The value in P20 (idle time) will be the manual off time. Press CLEAR ERROR to take out of MANUAL TIMER. Reset desired average # of strokes (P204 to 6)


31


®


RPOC Alarm / Error Messages and Host Alarm Messages Table 6 lists the Host/RPOC Alarm Messages and the resolutions for those error messages. Table 6: Host/RPOC Alarm Messages and Resolutions Host / RPOC Alarm Message

Alarm Description

Resolution Check P86 (Load max since power up) for actual load value that caused the fault. Check for stuck pump or other DH problems to determine whether the load value in P211 should be adjusted.

The highest polished rod load High load limit reading has exceeded the “High load limit” setting in the controller (This is a SD on a single stroke (rod load has violation limit exceeded value in P211. A setting of “0” disables this alarm. The for all Weatherford default alarm action is to go “off until manually reset”. When set as RPOCs.) an “alarm”, the action should be set to “alarm only”.

32

(P211) Defines a maximum allowed polished rod load. When this value is violated for a set number of consecutive strokes (Consec Load Viol For Action – P213), the userdefined action is taken and an alarm is sent to the user. This value is generally set to 10-12% above the Normal Peak Load if this limit violation is set as an “alarm”. This value is generally set to 20-25% above the Normal Peak Load if this limit violation is set as a “shutdown”. Be sure not to exceed the maximum load rating for the currently installed rod string / pumping unit structure.


®



Table 6: Host/RPOC Alarm Messages and Resolutions Host / RPOC Alarm Message

Alarm Description

The highest polished rod load reading has exceeded the “HighHi-Hi load sd High load limit” setting in the controller on a single stroke (rod (ePIC & RPOC load has exceeded value in P218. A only) setting of “0” (default) disables this alarm. The default alarm action is “alarm only”. This alarm should be activated and the alarm action set to “manually off until reset”.

High temperature

Temperature is too high, so the well is automatically shut down as a precaution. This is typically configured through one of the auxiliary analog inputs to the RPOC. Refer to the RPOC manual for specific input parameters

Resolution Check P86 (Load Max since Power up) for actual load value that caused the fault. Check for stuck pump or other DH problems to determine whether the load value in P218 should be adjusted. (P218) Defines the absolute maximum polished rod load limit. When this value is violated for a set number of consecutive strokes (Consec Load Viol For Action – P213), the user-defined action is taken and an alarm is sent to the user. This value is generally set to 20-25% above the Normal Peak Load. Be sure not to exceed the maximum load rating for the currently installed rod string – pumping unit structure. Well should remain down until a project engineer is notified so as to make adjustments to the offset injectors. A “Temperature Survey” of the well needs to be ordered to identify the string that needs adjustment. Check P90 (Min average since power up). Reset P212 if this value is too close.

The lowest average polished rod (Address 212) Uses the average load reading has dropped below the polished rod load calculated over the “Lowest average load limit” value last pumping unit stroke as the set in the controller (P212). allowed low load limit. When this limit Typically, this alarm is used only if is violated for a set number of the minimum load drops below “0” Low avg load consecutive strokes (Consec Load and “Low load limit” cannot be sd Viol For Action – P213), the userused. The alarm action is to go “off defined action is taken and an alarm until manually reset” (default). A is sent to the user. This is an setting of “0” (default) disables this alternative to Low-Low Load SD Limit alarm. for situations such as shallow wells, where the minimum load may fall below "0" (rod float), thus shutting the well down under Low-Low Min Load SD Limit. Set this value below the actual average load.


33


®



Alarm Description

This is the difference between the highest load and lowest polished rod load readings (“load span”) on “10” consecutive cycles (P222) Low load span (default) has dropped below the “Low load span” setting (P223) (default is “1000” lbs.). A setting of “0” disables this alarm. The default alarm action is to go “off until manually reset”.

Resolution

Verify if the well is pumping fluid. Check for bad or stuck pump valve, deep rod part or for problems related to gas in the pump. P223 setting could require adjustment. Set this value at “60%” of the normal load span and then adjust if needed. Check P85 (Load minimum since Power up) for actual polished rod load value that caused the fault.

When this value is violated for a set number of consecutive strokes The lowest polished rod load (Consec Load Viol For Action – P213), reading has dropped below the the user-defined action is taken and Low load limit “Low load limit” setting in the an alarm is sent to the user. Check controller on a single stroke (P210) for parted rods, stuck pump, or other (This is a SD (default is “1000” lbs.). The default DH problems. Also, P210 may be set violation limit alarm action is to go “off until too high. Set this value “1000-1500” for all manually reset”. A setting of “0” lbs. below the “normal” minimum Weatherford disables this alarm. When set as an load for deeper wells and “10-20%” RPOCs.) “alarm”, the action should be set to of the normal minimum load for “alarm only”. shallow wells if the limit is to be used as an “alarm”. Set this value “20002500” lbs. below the “normal” minimum load for deeper wells and “20-30%” of the normal minimum load for shallow wells if the limit is to be used as a “shutdown”.

The lowest polished rod load reading has dropped below the “Low-Low load limit” setting in the Lo-Lo load sd controller on a single stroke (P208) (default is “0” lbs.). The default (ePIC & RPOC alarm action is “fault lamp”. A only) setting of “0” disables this alarm. The default alarm action is “alarm only”. This alarm should be activated and the alarm action set to “manually off until reset”.

34

Check P85 (Load minimum since power up) for the actual load value that caused the alarm. When this value is violated for a set number of consecutive strokes (Consec Load Viol For Action – P213), the user-defined action is taken and an alarm is sent to the user. Check for parted rods, a stuck pump or other DH problems. Also, P208 may be set too high. Set this value to “2000-2500” lbs. for deeper wells and “20-30%” of the normal minimum load for shallow wells.


®




Alarm Description

The calculated surface card area has dropped below the “Minimum Low card area card area (ft-lbs)” setting (P256) for the defined number of (ePIC & RPOC consecutive stroke (P222) (default only) – “10”). The default alarm action is “alarm only”. Set the violation action in P257. A setting of “0” disables this alarm (default). The calculated surface card area has risen above the “Maximum card area (ft-lbs)” setting (P258) for the High card area number of consecutive stroke (P222) (default – “10”). The default (ePIC & RPOC alarm action is “alarm only”. Set only) the violation action in P259. A setting of “0” disables this alarm (default). EEPROM bad

Fld Stroke disabled

RPOC malfunction.

The “Fluid Stroke” calculation is disabled.

The well is already pumped off for the first “2” strokes (default) (P24) – (POC strokes for pump off) following the “30” second (default) Immed pump pump-up delay period (P25) after off start up of a cycle. The default alarm action is to “go to idle time”. A value of “0” (default) disables this alarm.


Resolution Check P255 (Current card area) and compare with the current value of P256. This alarm can be used to detect deep rod parts in “deep” wells. It is also very useful in detecting any other source of “decreased” work being done by the pumping system.

Check P255 (Current card area) and compare with the current value of P258. This alarm can be used to detect paraffin formation, emulsified fluid or any other source of “extra” work being done by the pumping system. Replace the EEPROM chip. There is no action from this alarm, it is for information only and will be displayed by the host software. Users may want to turn this function “on” and, with proper configuration; the RPOC will estimate total fluid production each day. This is done in P800-807. See RPOC manual for details.

Reset pump off setpoints in P21 (Pump-off Position %) and P23 (Pump-off Load %) or increase P20 (Idle Time). It is also possible that P25 (Pump-up delay) may need adjustment.

35


®



Alarm Description

Resolution

Check P76 (Load raw input and volts – Counts / VoltA) and P77 (Current The signal from the load cell is Load input in mV). Also, check P92absent or outside normal operating 93 to see what the “minimum / limits. The default action is to go maximum mV since power-up” are to to “Software Timer” operation Load sensor determine the condition that created which uses the average length of fault the alarm. A bad load cell and/or bad the “on” cycle times from the last load cell cable could be the problem if “6” cycles on the “run” time period the maximum mV is greater than (P204). “23”. Determine which (if any) piece of equipment is defective and repair it as necessary. As a result of a load / position sensor failure or other system condition, a user may command a well to cycle (P33) using a preset Manual S%TMR cycle run time (P206) which overrides the calculated average cycle time (P204). The default setting of “0” disables this action.

Check parameter settings. Set P204 to “0” and P206 to the desired runtime if the RPOC is to operate in this mode.

Manual ctrl xfer

The RPOC was told to transfer control of the pumping unit to a Return to normal operation when external timer or to continuous “on” possible. or “off” by using P32.

Manual sd

The well has been stopped by Wait for the well to be switched back someone at the wellsite controller to RPOC operation or contact the or from the host software package. operator for current well status.

The controller was commanded to Manual off (31) keep the pumping unit down by using P31.

Return to normal operation when possible.

The maximum allowed cycle run time (P235) for a single cycle has been exceeded for a set number of cycles (P233) – default is “2”. The Max cycle time default result is an error message with no action taken. A setting of “00:00:00” (default) disables this alarm.

Check parameters settings. Set P235 to the desired maximum cycle run time, P236 (Maximum cycle violation action) to the action to be taken, and P233 (Minimum cycles for action).

The minimum allowed cycle run time (P232 ) for a single cycle has been exceeded for a set number of cycles Min cycle time (P233) – default is “2”. The default result is an error message with no action taken. A setting of “00:00:00” (default) disables this alarm.

Check parameters settings. Set P232 to the desired minimum cycle run time, P234 (Minimum cycle violation action) to the action to be taken, and P233 (Minimum cycles for action).

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POC override (27) Oper override

Alarm Description

The controller has been set to run continuous using P27 (POC Override timer).

The RPOC senses that it is no longer in control of the pumping unit. It has issued a “’stop” or POC control fail “start” command that has been ignored – meaning that the well is idle when it should be running or vice versa.

The position switch is not Pos switch fail responding or the signal from the position switch is absent.

Resolution Contact the operator for the well status. P27 can be set to run a

well for a maximum of “99:99:99” hours. P27 will count down to “0” and the RPOC will then revert to “normal run” operation. Check the HOA switch. It should be in “Auto” mode. If not, put in auto mode and press . Press and using the RPOC keypad to start and stop pumping unit.

(P261) (Required time (min.) Refers to the time period allowed following a control failure before an "action" is taken. (This value must be set to at lea st "30" seconds less than P20 ( PU Idle Time). Controller will switch to “Software Timer” (default) operation. Check P144 (Debounced closed flag –

“Open/Closed”) to see if the position switch is operating. The default action is to go to “Software Timer” operation.

Check P102-P106 for position related The signal from the continuous Position fault position sensor is absent or outside data. One possible solution, if the RPOC is an ePIC, is to set P34 (Position input normal operating parameters. source) to “1” (Continuous position sensor). Execute P351 (Software reset) if P34 is changed in this manner.

RPOC control status and pumping unit operation are not the same. The controller has sensed that it is Temp ctrl loss no longer in control of the well. After “4” (default) minutes (P261), this error will switch to “POC control fail”.

Watch the display to see what caused control loss and correct any problem(s) displayed. P261- Refers to the time period allowed following a control failure before "action" is taken. This value must be set to at least "30" seconds less than P20 (PU Idle Time).

The controller’s record of the last power failure occurred at an Bad time/date unrealistic time as compared to time and date from the controller internal battery clock.

Check P3 (Time of day), P4 (Today’s Date), and P5 (Current Day of the week), and take corrective action as indicated.


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A/D failure

AB amps too low

Alarm Description The controller analog to digital converter section has malfunctioned three times. The controller will automatically switch to “Software Timer” operation.

Resolution The controller CPU or Analog Card is defective. The controller may need to be re-initialized.

The “Motor Current Input Signal Level” is too low for the Air Balance Check P40-46. Control feature to function properly.

AI1 DIG 0 Alarm

Auxiliary “Analog Input 1” as a digital is in a “Closed” (Low Voltage) condition.

There is no action from this alarm, it is for information only.

AI1 DIG 1 Alarm

Auxiliary “Analog Input 1” as a digital is in an “Open” (High Voltage) condition.


Auxiliary “Analog Input 2” as a digital is in a “Closed” (Low Voltage) condition.


Auxiliary “Analog Input 2” as a digital is in an “Open” (High Voltage) condition.


AI2 DIG 0 Alarm AI2 DIG 1 Alarm

The “value” selected is not Bad data value acceptable for the respective “Parameter” being modified.

Check parameter units and range, and try again.

An attempt has been made to set TOS (Top of Stroke) with P7 Bad POS sens (Automatic top of stroke) when the Check parameter settings. int interval of the previous “Continuous Position Sensor Cycle” was out of range. An attempt has been made to set TOS (Top of Stroke) with P7 Bad prev POS (Automatic top of stroke) when the Check parameter settings. int interval of the previous “Continuous Position Sensor Cycle” was out of range. When the intervals of the previous two “Position Switch Closures” were Bad prev SW out of range, an attempt was made Check parameter settings. int to set TOS (Top of Stroke) with P6 (Manual top of stroke) and P7 (Automatic top of stroke). Controller has been powered up after failing to perform a proper Bad shutdown shutdown on power failure or fatal error.

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Alarm Description

Resolution

An attempt has been made to set TOS (TOP-OF_STROKE) with P6 (Manual top of stroke) and P7 Bad switch int (Automatic top of stroke) when the Check parameter settings. interval between the last two position switch closures was out of range. Bad Time & Date IC

The real-time clock (RTC) has failed.

Press . If error reoccurs, replace controller CPU card.

Baker 8800 Rod Pump

Message after controller initializes and all internal self checks are performed satisfactory.

This message should only occur within a few seconds after power is turned on or restored.

Nothing appears on the display.

Turn RPOC “off” and “on”. This should clear and activate display.

Blank LCD display

The signal coming from the load Check P76 (Load raw input and volts Can’t Set 0 Lbs cell is out of range for a reasonable – Counts / Volt) and P77 (Load input “Zero Load” signal. in mV). Clrd Mulp POS Multiple position switch closures Sw have occurred – then cleared.

Allow the well to run several strokes. The problem will likely correct itself.

Clrd POS SW The position switch has failed – Fail then cleared.

Allow the well to run several strokes. The problem will likely correct itself.

The radio modem is in a “Constant Comm Output Key” test until P648 (Tx test time in There is no action from this alarm, it Test seconds) “times Out” to “0” or is is for information only. modified to “0”. Control Watch the display to see what caused The RPOC has transferred control to transfer (CNTL transfer and correct any problem(s) a time clock. XFER) displayed. CPU Fell Behind DI1 Closed Alarm DI1 Open Alarm DI2 Closed Alarm DI2 Open Alarm DI3 Closed Alarm DI3 Open Alarm DI4 Closed Alarm

This indicates that the CPU has If this error persists, report this to been overloaded and therefore, the the Customer Service Department. controller may restart to recover. Digital Input 1 is in the “Closed” condition.

There is no action from this alarm.

Digital Input 1 is in the “Open” condition.


Digital Input 2 is in the “Closed” condition.











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Table 6: Host/RPOC Alarm Messages and Resolutions Host / RPOC Alarm Message DI4 Open Alarm DI5 Closed Alarm DI5 Open Alarm DI6 Closed Alarm DI6 Open Alarm DI7 Closed Alarm DI7 Open Alarm DI8 Closed Alarm DI8 Open Alarm

Alarm Description

Resolution



















The controller is holding the well idle while the current time is within the peak energy inhibit time period There is no action from this alarm, it Energy lockout as set in P51 (Begin run inhibit is for information only. time) and P52 (End run inhibit time). Error(s) cleared

Controller errors have been cleared by pressing the “CLEAR ERROR” Information only. key on the local keypad.

Error(s) remain

An RPOC error has not been cleared after pressing the “CLEAR ERROR” Correct the error. key on the local keypad.

Fault

This message flashes in the top right-hand corner of the RPOC LCD Correct the error. display whenever an error exists.

Gain too large

The load gain factor, P74 (displayed Check parameter units and range. in P75), is too large.

Immed load limit

The system polished rod load value has been detected to be exceeding Check parameter units and range. the limit set in P218 (Maximum allowed polished rod load).

Initializing Invalid Key!

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Displayed while the controller is initializing hardware and internal variables.

Information only.

Keyboard entry has not been correctly executed.

Refer to the Operator Manual for instructions. MS-WPRPOCFIX-00 / Rev. C January 2014

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Manual Ctrl Xfer

Alarm Description

Resolution

The controller has been commanded to transfer control of the pumping unit to an external Information only. timer or to continuous “On” or “Off” by using command P32 (Manual control transfer).

Max Daily Ontime

The controller is not in a power recovery mode and has run the pumping unit over the value set in P237 (Maximum daily run time).

Information only.

Missing 619

An attempt has been made to set TOS (Top of Stroke) with P7 (Automatic top of stroke) when P619 (Position data available) was set to “0”, indicating that no position sensor was available.

Check P619.

Motor Moisture Restart Protection The controller has been put into “Control Transfer” as the result of Motor Off Too the motor being off continuously for Information only. Long a time longer than the value set in P38 (Off time limit – Maximum allowed off time and restart automatically). More than one position switch Multiple POS closure occurred within the time SW limits defined by P136 and P137. Need error reset

Must first “CLEAR ERROR” before any action can take place.

Reset SPM with command P149 (Well Speed Change – Clear and reset all SPM Information) - press “Modify”, and then “ENTER”. Press “CLEAR ERROR” key.

Password must be entered in P1 (User-entered password) or P473 (Maintenance password) before Need password Set password. action can be taken. Password needed in P1 is the same as what is stored in P500 (Keypad password). The controller has not seen sufficient number of position switch No cycles yet closures and load changes to Information only. declare the pumping unit to be in a “running” state. No errors

This message appears when pressing the “CLEAR ERROR” key when no errors exist.


Information only.

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Alarm Description

An attempt has been made to set TOS (Top of Stroke) using P7 No POS cycles (Automatic top of stroke) when continuous position sensor input signal has been detected.

No POS Switches

An attempt has been made to set TOS (Top of Stroke) with P6 (Manual top of stroke) or P7 (Automatic top of stroke) when no position switch closures have been detected.

Resolution

Information only.

Information only. Check P144 (Debounced closed flag – Open/Closed) to see if the position switch is operating.

If the well is to continue to run when this same alarm occurs again, got to “Menu”, option 4 - Parameter Table, press “204” - then “Enter” and observe the parameter name at the bottom of the screen (Selected: Manual Set Timer On Time). Press Controller tried to transfer to “Modify” and “240000” and “Enter”. software timer, but a value was not This will set the manual timer value found. The “No timer value” to 24:00:00 (twenty four hours). message means the RPOC does not Move the cursor up to P204 and have any cycle time history. Go to observe the parameter name at the No timer value the “Alarm Status” in the RPOC bottom of the screen (Selected: No. “Menu” option 3 to see what caused of run times to average), press the unit to try and go into “Modify”, “0”, “Enter”. By doing this, “Software Timer Mode” and the unit will now use the manual therefore address the root cause of timer value set in P206 (“24:00:00”) the alarm. if this type of alarm occurs again. If it does, there should be an Alarm Message that reads, for example, “Load Input Fault” and a Status Message of “On Timer”. The well will not shut down unless there is a load limit violation. Non data param

An attempt has been made to Information only. modify a “Display Only” parameter.

Indicates Non-Volatile Memory (NVM) is reset to all factory values NVM Initialized in all parameter locations as a result of modifying P472. The controller has a failure that Off until reset resulted in “Off Until Reset” condition.

Information only. P472 (Reset to factory default) Caution: All field set parameters are lost if this action taken. Enter “Maintenance password” in P473 first. Information only.

The fault lamp is being tested for On for 15 sec “15” seconds per P350 (15 sec fault Information only. lamp test). 42


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Alarm Description

Resolution

Param 20 missing

P20 (Idle time) is set to “0”.

Controller needs appropriate “Idle time” value. value.

Param 21 missing

P21 (Pump-off Position %) is set to Controller needs appropriate “Pump “0”. off position %” value.

Param 22 missing

P22 (Pump (Pump off off action) action) is set to “0”.

Controller needs appropriate “Pump off action” value.

Param 23 missing

P23 (Pump-off Load %) is set to “0”.

Controller needs appropriate “Pump off load %” value.

Param 24 missing

P24 (POC strokes for Pumpoff) is set to “0”.

Controller needs appropriate “POC strokes for pump off” value.

Params expanded

A new version of controller firmware has been installed with additional parameters available.

This is an “Information Only” message. message. Pressing Pressing the “CLEAR “CLEAR ERROR” key clears the message.

Indicates all parameters are set at Controller will be in a “control Params Init’ed factory default values, and transfer” mode when in this situation. controller has no control capability. The controller is holding the well in “idle” because the current time is within the peak energy inhibit time Peak hours idle Information only. period set by P51 (Begin run inhibit time) and P52 (End run inhibit time). The position switch has been successfully calibrated in POS switch set relationship to the polished rod motion by the controller.

POS switch setup

Power fail

Program error

Information only.

The position switch has not been set using using P6 (Manual (Manual top of stroke stroke)) or P7 (Automatic top of stroke) or Information only. by forcing a position location using P130 (TOS to Position Switch fraction). Controller has received a signal from the power supply module indicating that the input power is low or missing.

Check power source.

The controller controller program program has experienced an internal error.

Report problem to Customer Service Department.

“Idle Time” key was pressed when Pump already the controller already has the well off in “idle” time.

Information only.

“Pump On” key was pressed when Pump already the controller already has the well on running.

Information only.


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Table 6: Host/RPOC Alarm Messages and Resolutions Host / RPOC Alarm Message Reserved Reset

Alarm Description

Resolution

Reserved for controller internal use. Information Information only. The hardware hardware reset reset button on the CPU board has been pressed.

Information only.

The controller has detected that the well is NOT pumped-off and the Reverse Pump control method selected in P26 Information only. Off (POC method) is set to a reverse pump-off option (P26 = 2, 3, 10, or 11).

Reversed

The position switch fraction in P130 (TOS to Position Switch fraction) has been reversed as a result of Information only. executing command P131 (Reverse Position Switch setting).

An attempt has been made to set the load gain (P74) using P73 when Same as 0 Lbs Information only. the measured load value was zero (“0”). RPOC has transferred to software Software timer value in P204 (No. run cycles to average). Sorry, read only

Cannot modify “READ ONLY” parameters.

Watch display for the problem that caused the transfer action. Information only.

An attempt has been made to set TOS (Top of Stroke) with P7 Too few POS Allow the well to run four or more (Automatic top of stroke) when less sens strokes and try again. than four (4) continuous position sensor cycles have been detected.

Too few switches

An attempt has been made to set TOS (Top of Stroke) with P6 Allow pumping unit to run four or (Manual top of stroke) and P7 more strokes before trying to set (Automatic top of stroke) when less TOS. than four (4) switch closures have been detected.

Displayed if an error bit is set in Unknown error P527-530 for which no error message has been defined.

Check parameter units and range.

An attempt has been made to enter Value too large a number which is too large for the Check parameter units and range. parameter type selected. Zeroed

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The load cell offset value (mV with no load), has been computed and stored using P70 (Set zero load).

Information only.


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Host Generated Soft Alarms Host generated “Soft “Soft Alarms” Alarms” are the result of the downhole analysis of cards gathered from each well every day. The alarms can be setup under: csBEAM - The “Parameter “Parameter System Parameters” Parameters” panel, except the “Runtime deviation” alarm – which is configured using the “Parameter “ Parameter Control Parameters” Parameters” panel. LOWIS – Analysis  Configuration  System Configuration and Configuration and the RTU the RTU Read-Write child tab under the AWB Control Params for the “Runtime deviation” alarm for the “Runtime deviation” alarm.

Table 7 lists the Soft Alarms and Host Message along with the Alarm description and Alarm specific information that may be needed by the repair technician.

Table 7: Host Generated Soft Alarms “Soft alarms” Host Message

Alarm Description

If the average run time column is set to other than “0”, and the parameters for the variance Runtime are set, this alarm signifies that the well has Deviation either exceeded or dropped below the daily run time settings settings.. There is no action action from from this alarm, it is for information only.

Alarm Information Increase the Run Time Deviation (%) value to decrease the number of warning messages related to Run Time Deviation violations in csBEAM and LOWIS.

Increase this value to decrease All wells with a measured structure load the number of warning Beam (polished rod load) greater than this value will messages related to Beam Load Load High display this alarm. High violations in csBEAM and LOWIS. G Box Torque High

Increase this value to decrease the number of warning All wells with a calculated gearbox torque messages related to Gear Box greater than this value will display this alarm. Torque High violations in csBEAM and LOWIS.

Pumping All wells with a calculated pump efficiency of Eff Low less than this value will display this alarm.

All wells with a calculated rod stress greater Rod Stress than this value (% of allowable) will display High this alarm.


Increase this value to decrease the number of warning messages related to Pumping Efficiency Low violations in csBEAM and LOWIS. Increase this value to decrease the number of warning messages related to Rod Stress High violations in csBEAM and LOWIS.

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Host Intelligent Alarms Intelligent Alarms, Alarms, also called “Soft “Soft Alarms”, Alarms”, are the result of the downhole analysis portion of the diagnostic process and the values set under Parameter under Parameter  Diagnostic (csBEAM) csBEAM) or the under the LOWIS LOWIS “Analysis” tab  Configuration  System Parameters  Beam Diagnostic Parameters. Parameters. Intelligent Alarms are either “enabled “enabled”” or “disabled “disabled”” by using the “Intell “Intelligent igent Alarms Grid” Grid” in csBeam (Configuration  Intelligent Alarm) Alarm) or under the LOWIS “Analysis” LOWIS “Analysis” tab  Configuration  System Parameters  Intelligent Alarms Configuration.

Note: Note: All Intelligent Intelligent Alarms are Alarms are set to “disable” or “0” by default. To activate a a csBeam Intelligent Alarm, Alarm , enter a “1 “1” in the “Activated? “Activated?”” column, or type a “0” “0” to disabl disable e it. To activat activate e a LOWIS Intelligent Alarm, Alarm, enter a “1 “1” in the “Active “Active / Inactive Flag” Flag ” column, or type a “0” to “0” to disable it. You can also assign a a “Alarm Priority” value for the order in which an alarm will display under the “Current the “Current Status” and and “Group Status” grids. Table 8: Host Intelligent Alarms Host Message Intelligent Alarms

FAP/PIP% 1 day -Dg

Description Any well with a one-day change in calculated “FAP/PIP” greater than the value set under (Beam) Diagnostic Parameters. FAP/PIP trend deadband (%) and the diagnostic process value will display this alarm.

All wells with a measured structure load Beam Load High value greater than the value set using -Dg System Parameters Beam Load High Structure Load Limit (%) / Structure Load High and the High -Dg analysis process will display this alarm. All wells with a calculated card area that exceeds the entered “std dev” value set Card area SPC - under (Beam) Diagnostic Parameters. Card area trend deadband (std dev) Dg as a result of the diagnostic process will display this alarm.

Card area% 1 day -Dg

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Any well with a one-day change in calculated card area greater than the value set under (Beam) Diagnostic Parameters. Card area trend deadband (%) as a result of the diagnostic process will display this alarm.

Alarm Information

Increase this value to decrease the number of warning messages related to FAP/PIP% 1 Day violations. Increase this value to decrease the number of warning messages related to Beam Load High violations.

Increase this value to decrease the number of warning messages related to Card area SPC violations.

Increase this value to decrease the number of warning messages related to Card area% 1 Day violations.


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Table 8: Host Intelligent Alarms Host Message Intelligent Alarms

Description

Any well with a change in the sevenday trend of calculated card area greater than the value set under Card area% 7 (Beam) Diagnostic Parameters  Card day -Dg area trend deadband (%) as a result of the diagnostic process will display this alarm.

Card Pattrn Mtch -Dg

Any well with a change in the sevenday trend of calculated “FAP/PIP” greater than the value set under (Beam) Diagnostic Parameters. FAP/PIP trend deadband (%) as a result of the diagnostic process will display this alarm.

All wells with a measured flow line pressure that exceeds the entered “std Flow Prs SPC dev” value set under (Beam) Diagnostic Dg Parameters. Flow line pressure trend deadband will display this alarm.

Flow Prs% 1 day -Dg

Increase this value to decrease the number of warning messages related to Card area% 7 Day violations.

All wells where the collected card, when compared to all cards in the pattern Increase this value to decrease library, matches or exceeds the value the number of card matches set under (Beam) Diagnostic Parameters  Card pattern matching related to Card Pattern Matching. limit (%) as a result of the diagnostic process will display this alarm.

All wells with a calculated “FAP/PIP” value that exceeds the entered “std FAP/PIP SPC - dev” value set under (Beam) Diagnostic Parameters  FAP/PIP trend deadband Dg (std dev) as a result of the diagnostic process will display this alarm.

FAP/PIP% 7 day -Dg

Alarm Information

Any well with a one-day change in measured flow line pressure greater than the value set under (Beam) Diagnostic Parameters. Flow line pressure trend deadband (%) as a result of the diagnostic process will display this alarm.


Increase this value to decrease the number of warning messages related to FAP/PIP SPC violations.

Increase this value to decrease the number of warning messages related to FAP/PIP% 7 Day violations.

Increase the entered “std dev” value to decrease the number of warning messages related to Flow Line Pressure SPC violations.

Increase this value to decrease the number of warning messages related to Flow Line Pressure % 1 Day violations.

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Flow Prs% 7 day -Dg

Description

Any well with a change in the sevenday trend of measured flow line pressure greater than the value set under (Beam) Diagnostic Parameters. Flow line pressure trend deadband (%) as a result of the diagnostic process will display this alarm.

Alarm Information Increase this value to decrease the number of warning messages related to Flow Line Pressure % 7 Day violations. Note: The “flow line pressure” alarms require that a flow line pressure analog be defined for each well and that each analog “Description” contain the word “flowline”. Otherwise, this diagnostic analysis will be ignored.

All wells with a calculated gearbox torque greater than the value set under G Box overload System Parameters. GB Torque High Dg Limit (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to G Box overload violations.

Any well with a calculated difference between peak upstroke and peak downstroke gearbox torque greater than value set under (Beam) Diagnostic Parameters. Gearbox torque difference deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Gearbox Box peak imbalance violations.

G Box peak imbal -Dg

G Box Torque High -Dg

All wells with a calculated gearbox torque greater than value set under System Parameters. GB Torque High Limit (%) as a result of the analysis process will display this alarm.

Any wells with an average run time over the past twenty eight days of less than the value set under (Beam) Diagnostic Parameters. Run time Hi displacement displacement reduction limit (hrs/day) -Dg as a result of the diagnostic process will display this alarm, indicating that the well is over displaced when compared to the well’s inflow.

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Increase this value to decrease the number of warning messages related to Gear Box Torque High violations.

Increase this value to decrease the number of warning messages related to High displacement violations.


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Description

Alarm Information

Any well with a calculated stress range in a rod taper above the entered percent value of the calculated Hi stress range - maximum stress for that taper set Dg under (Beam) Diagnostic Parameters. Rod stress range limit (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to High stress range violations.

All wells with a calculated load span difference between the measured values and the “calibrated” values that is greater than the entered value set Load span calib under (Beam) Diagnostic Parameters. -Dg Measured/Calibrated load span difference deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Load span calibration violations.

All wells with a calculated difference between the measured load span and the calculated load span that exceeds Load span SPC - the entered value set under (Beam) Diagnostic Parameters. Load span Dg trend deadband (std dev) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Load Span SPC violations.

Any well with a change in the sevenday trend of measured load span greater than the value generated from Load span% 7 the value set under (Beam) Diagnostic Parameters. Load span trend day -Dg deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Load span% 7 Day violations.

Any well with a one-day change in the measured load span greater than the value generated from the value set Load span% I under (Beam) Diagnostic Parameters. day -Dg Load span trend deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Load span% 1 Day violations.


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Description

Alarm Information

Generated from the diagnostic process if the average run time calculated over the past thirty days is “24”. Any wells Low found that meet these criteria will displacement - display this alarm, indicating that the Dg well is under-displacement when compared to the well’s inflow or possibly has a downhole mechanical problem.

May be a mechanical problemcheck physical well.

All wells with a measured maximum load that exceeds the entered “std dev” value generated from the value set Max load SPC under (Beam) Diagnostic Parameters. Dg Max load trend deadband (std dev) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Maximum load SPC violations.

Max load% 7 day -Dg

Any well with a change in the sevenday trend of measured maximum load greater than the value generated from the value set under (Beam) Diagnostic Parameters. Max load trend deadband (%) as a result the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Maximum load% 7 Day violations.

Max load% I day -Dg

Any well with a one-day change in the measured maximum load greater than the value generated from the value set under (Beam) Diagnostic Parameters. Max load trend deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Maximum load% 1 Day violations.

Min load SPC Dg

Min load% 7 day -Dg

50

All wells with a measured minimum load that exceeds the entered “std dev” value generated from the value set under (Beam) Diagnostic Parameters. Min load trend deadband (std dev) as a result of the diagnostic process will display this alarm. Any well with a change in the sevenday trend of measured minimum load greater than the value generated from the value set under (Beam) Diagnostic Parameters. Min load trend deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Minimum load SPC violations.

Increase this value to decrease the number of warning messages related to Minimum load% 7 Day violations.


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Description

Any well with a one-day change in the measured minimum load greater than the value generated from the value set Min load% I day under (Beam) Diagnostic Parameters. -Dg Min load trend deadband (%) as a result of the diagnostic process will display this alarm.

Alarm Information

Increase this value to decrease the number of warning messages related to Minimum load% 1 Day violations.

All wells with a calculated difference between the measured minimum load value and the “calibrated” minimum load value that is greater than the Mn load calib - entered “%” generated under the value Dg set under (Beam) Diagnostic Parameters. Measured / Calibrated load span difference deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Minimum load calibration violations.

All wells with a calculated difference between the measured maximum load value and the “calibrated” maximum load value that is greater than the Mx load calib - entered “%” generated from the value set under (Beam) Diagnostic Dg Parameters. Measured/ Calibrated load span difference deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Maximum load calibration violations.

All wells with calculated pump efficiency less than the value generated from the Net pump effy value set under System Parameters. Dg Efficiency Low (%) as a result of the analysis process will display this alarm.

Decrease this value decrease the number of warning messages related to Net pump efficiency violations.

All wells with a calculated polished rod horsepower difference between the measured value and the “calibrated” value that is greater than the entered PRHP calib -Dg “%” generated from the value set under (Beam) Diagnostic Parameters. Prime mover / PRHP size difference deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to PRHP calibration violations.


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Description

Alarm Information

All wells with a calculated “prime mover size” difference between the calculated size and the currently installed prime mover that is greater than the entered Prime movr size “%”generated from the value set under (Beam) Diagnostic Parameters. -Dg Prime mover/PRHP size difference deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Prime mover size violations.

All wells with a calculated pump efficiency value that exceeds the entered “std dev” value generated from Pump effy SPC - the value set under (Beam) Diagnostic Parameters. Pump efficiency trend Dg deadband (std dev) as a result the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Pump efficiency SPC violations.

Any well with a one-day change in calculated pump efficiency greater than the value generated from the value set Pump effy% 1 under (Beam) Diagnostic Parameters. day -Dg Pump efficiency trend deadband (%) as a result of the diagnostic process will display this alarm. Any well with a change in the sevenday trend of calculated pump efficiency greater than the value generated from Pump effy% 7 the value set under (Beam) Diagnostic Parameters. Pump efficiency trend day -Dg deadband (%) as a result of the diagnostic process will display this alarm. Pumping Eff Low -Dg

All wells with calculated pump efficiency less than the value generated from the value set under System Parameters. Efficiency Low (%) as a result of the analysis process will display this alarm.

All wells with a calculated rod stress greater than the value (% of allowable) Rod overstress - generated from the value set under System Parameters. Rod Stress High Dg Limit (%) as a result of the diagnostic process will display this alarm.

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Increase this value to decrease the number of warning messages related to Pump efficiency% 1 Day violations.

Increase this value to decrease the number of warning messages related to Pump efficiency% 7 Day violations.

Increase this value to decrease the number of warning messages related to Pumping Efficiency Low violations. Decrease this value to decrease the number of warning messages related to Rod overstress violations.


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Description

Alarm Information

All wells with a calculated rod stress greater than this value (% of allowable) Rod Stress High generated from the value set under -Dg System Parameters. Rod Stress High Limit (%) as a result of the analysis process will display this alarm.

Increase this value to decrease the number of warning messages related to Rod Stress High violations.

All wells with a run time value that exceeds the entered “std dev” value generated from the value set under Run time SPC (Beam) Diagnostic Parameters. Run Dg time trend deadband (std dev) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Run time SPC violations.

Run Time Up Dg

Generated from the diagnostic process if the average run time calculated over the past seven days is “24”. Any wells found that meet these criteria will display this alarm, indicating that the well is under-displacement when compared to the well’s inflow or possibly has a downhole mechanical problem.

Run time% 1 day -Dg

Any well with a one-day change in run time greater than the value generated from the value set under (Beam) Diagnostic Parameters. Run time trend deadband (%) as a result of the diagnostic process will display this alarm.


May be a mechanical problemcheck physical well.

Decrease this value to decrease the number of warning messages related to Run time% 1 Day violations.

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Description

Alarm Information Decrease this value to decrease the number of warning messages related to Run time% 7 Day violations.

Run time% 7 day –Dg

Any well with a change in the sevenday trend of run time greater than the value generated from the value set under (Beam) Diagnostic Parameters. Run time trend deadband (%) as a result of the diagnostic process will display this alarm.

Note: The Run time% 1 day and Run time% 7 day alarms use a “reverse sliding scale”. The deviation is not calculated as a straight percentage and the adjustment parameter has a “reverse” effect. Experience has shown that a well that has a “4” H/D run time might easily fluctuate in run time by “30” minutes or so per day (12.5%). But if a well is pumping 24 H/D and runtime Decreases to 23.5 H/D (only a 3% Decrease), this change should be brought to the attention of the user. Wells that pump 24 H/D should continue to pump 24 H/D unless something in the pumping system changes. The “reverse sliding scale” is intended to facilitate the use of a single "tuning" parameter to apply to all wells - regardless of their average run time.

All wells with a well test (total liquid volume) that exceeds the entered “std dev” value generated from the value set Test fld SPC -Dg under (Beam) Diagnostic Parameters. Test fluid trend deadband (std dev) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Test fluid SPC violations.

Any well with a one-day change in a well test (total liquid volume) greater than the value generated from the Test fld% 1 day value set under (Beam) Diagnostic -Dg Parameters. Test fluid trend deadband (%) as a result of the diagnostic process will display this alarm.

Increase this value to decrease the number of warning messages related to Test fluid% 1 Day violations.

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Description

Any well with a change in the sevenday trend of well test volume (total liquid) greater than the value generated Test fld% 7 day from the value set under (Beam) Diagnostic Parameters. Test fluid -Dg trend deadband (%) as a result of the diagnostic process will display this alarm.

Verify Parm Failed -Dg

This alarm is generated for any well where any Load, Control, or Fluid Parameter Panel value difference between the “Host” and the “RPOC” is found by the diagnostic process.


Alarm Information

Increase this value to decrease the number of warning messages related to Test fluid% 7 Day violations.

When differences are found, try to understand why new values were entered in the wellsite RPOC. “Upload” the new values to the “Host” to clear the alarm.

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Load Cell Testing Resistance Testing A load cell typical resistance circuit is shown below:

1 Ve

Plug on Load Cell

541-549

541-549

3

2 1

5

3

4 5

4

526-528

526-528 Vc 2 Figure 7: Typical Load Cell Resistance Diagram





A resistance check between pins 1 and 5 or pins 1 and 4 will yield a measured reading of 541 to 549 . A resistance check between pins 2 and 5 or pins 2 and 4 will yield a measured reading of 526 to 528 .

Voltage Testing 1. Apply +10.0 Volts DC to pins 1 and 2 of the Load Cell. 2. With a voltage of +10.0 Volts DC applied and depending upon the weight applied to it, the output from the Load Cell will be -1.0 mV to +28 mV.

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CPU Communications Diagnostics: Communications between the two processors, the ColdFire and the Cygnal 8051, is very important and an LED has been provided to assist in determining how well the processors are communicating. D5 is used to visually determine some possible correct functions and some loss of function. Table 9: D5 LED Signals Function Startup Normal Operation No Comm between processors

D5 Response One second ON and one second OFF for a total of 25 seconds. 95% ON and 5% OFF in each second. 50% On and 50% OFF in each second.

U P C

J22

d r a o B

J23

D5

J24

D5 Diagnostic LED Figure 8: D5 LED Location MS-WPRPOCFIX-00 / Rev. C January 2014

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CAN Messages Table 10: CAN Messages Message ID

Class

Node Type = Main CPU

Address

00

000000

00000

Data

Node Specific Target Node Target Type Address 001000

00000

Message Type

(0-8 bytes)

00100

0 Bytes

00

000000

00000

001000

00000

00101

01

001000

00000

000000

00000

01001

CAN Message Type

CAN Message

CMD = RESET 0x00002004 8051

0x00002005 CMD = 0 Bytes Auto_Recover 8051 0x09000009 8051 Diagnostic Info for MCF just 0 Bytes when 8051 relinquishes communication

*Note: When 8051 stops Communication, MCF commands 8051 to retry 3 (Configurable) times. If three Auto-Recovery attempts fail then MCF forces 8051 to reset. If 8051 Reset fails then MCF issues an A2D Failure.

Diagnostic Details When the MCF receives a 8051_Diagnostic CAN Message (0x09000009) it increments the Diagnostic P2892 (Default value for P2892 = 0). So P2892 indicates the number of times 8051 tried to recover or was reset. This indicates that 8051 timed out on MCF Heartbeat. The 8051 Timeout for MCF Heartbeat is = 4 seconds. When the Pump is running and 8051 goes into Fail Mode (due to missing Heartbeat messages from MCF) then a TEMP_CONTROL_LOSS message is displayed on the Screen. If 8051 recovers the system should return to Normal operation but TEMP_CONTROL_LOSS continues to show up and MCF assumes that the Pump is still in RUN Time (WS_SENSED_ON mismatches WS_OFFICIALLY_ON). P2895 when configured to PUMP_IDLE (1) MCF forces Pump to IDLE on successful recovery thus avoiding Temp_Control_Loss->Control Transfer. When Pump is IDLE WS_SENSED_ON = WS_OFFICIALLY_ON = 0. This is logged as MANUAL_PUMPOFF event. If P2895 = 0 (Control_Transfer) then the MCF gets into TEMP CONTROL LOSS -> Control Transfer. This happens only when Inter-Processor communication fails during Pump_ON. This is because WS_SENSED_ON mismatches withWS_OFFICIALLY_ON resulting into Temporary Control Loss. If the Message Counts from 8051 are less than 95 for 2 consecutive times then it is considered as a failure in which case the Auto-Recovery/Reset mechanism is kicked-in if Enabled. 58


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Diagnostic Parameters (P2890 – 2896) P2890: This Parameter displays the maximum time difference between MCF Heartbeats. This Parameter latches the Maximum Heartbeat interval. This will help us understand if MCF ever failed to send Heartbeats once per second. This will indicate if any task hogged CPU preventing Tx of Heartbeats. Priority wise RTC Task is being suspected for now. Priorities are not changed as of now. P2891: This Parameter displays hex value indicating the source for Position Sensor Failure. This will help us understand what triggers this Fault. The table below indicates various sources for this Fault corresponding to the value in P2891. Table 11: Source of Position Sensor Failure Bit# 1 2 3 4 5

Source of Position Sensor Failure PP_PROBLEM_CP_FAIL_MIN_P271 PP_PROBLEM_CP_FAIL_MAX_P272 PP_PROBLEM_CP_FAIL_SPAN_P270 PP_PROBLEM_PEND_MISSING PP_PROBLEM_PEND_MULTIPLE

P2892: Number of times 8051 tried to Recover/Reset. This Parameter is stored in Battery Backed RAM. P2893: This Parameter Enables/Disables Auto-Recovery mechanism. This Parameter can be used to disable auto-recovery/8051-Reset if only diagnostic information is needed. P2894: This is the number of times 8051 will be forced to Auto-Recover. This is defaulted to 3. P2895: This is the action that will be taken on successful Auto-Recovery. As of now only 2 actions are provided – ControlTransfer(0)/PumpIdle(1). P2896: This Parameter holds the value of the position being compared when a Position Sensor Fault occurred. Currently it holds a value when Position value exceeds either P271 or P272.


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Figure 9: Flow Chart of Diagnostics

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Parameter Attribute Details Table 12: Diagnostic Parameter Attributes Parameter #

Read/Write Attributes

Data Type

Parameter Description

2890

RW (Password Protected)

Long

2891

RO

Display Parameter

2892

RW

Long

2893

RW

Byte

2894

RW

Byte

AutoRecovery Retries

3

2895

RW

Byte

AutoRecovery Actions

1 = PUMP IDLE

2896

RW

Word

Pos Value for PosSensFault

0

MCF Sample Max Time

Pos Sensor Fault Src C8051 Diagnostic Info C8051 Auto Recovery

Default Values

Comments

0 0x0 0

Please verify the defaults for P2891 – P2896 when P472 = Reset to Defaults is executed.

1= ENABLED

*Note: P2890 is Password Protected.


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Upgrading Firmware The following steps outline upgrading your firmware in the WellPilot RPOC unit using the SD Card. CAUTION: Shut down the well prior to upgrading firmware. Firmware upgrades require priority CPU time and the controller must be restarted before the new firmware is operational. 1. Shut down the wellsite. 2. Insert the SD card, containing the new upgrade files, into J18 SD Card Reader. The SD Card LED will glow Red.

Note: The SD card will only fit into J18 one way. The disk must be so that the gold colored lands are facing inward and to the bottom of the card reader. See the picture on the right. 3. The Main Menu can be accessed from any EGD screen location in the screen display sequence by pressing < 4. Use the <

/

> on the Display Control Keypad.

> arrow keys or type in the number “6” to move the cursor

to the “Controller Diagnostics” menu Item and press < 5. Use the <

/

> arrow keys to move the cursor to the “Firmware

Versions” menu Item and press < 6. Use the <

/

>.


Upgrade” menu Item and press <

62

>.

> to open the Firmware Upgrade screen.


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7. Use the < / > arrow keys to move the cursor to the “Supervisor Password” menu Item and press < >. The Modifying P0473 Supervisor Password screen will appear.


- FIRMWARE UPGRADE Current FW Version : Firmware V 1.08.00 Supervisor Password: >0 Perform Upgrade : (Press MODIFY) Remove SD Card : (Press MODIFY) SD Card Status Ethernet Status

: :

0=No Card down

8. Enter the Supervisor Password and press < >. The screen will return to the “Firmware Upgrade” display.

9. Use the < / > arrow keys to move the cursor to the “Perform Upgrade” menu Item and press < >. The Modifying P0475 Perform Upgrade screen will appear


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10. Press <

®


> and the system will be upgraded to the new firmware. Press

< > to abort the upgrade process and leave the upgrade screen. The display will return to the Firmware Upgrade screen and “Firmware Upgraded” will flash at the bottom of the screen.

Note: If there is not an upgrade file on the card, the status message shown to the right will display. Replace the card with a card containing the proper upgrade file. 11. When the upgrade process is complete, a message will display to notify the operator that a re-start is needed to invoke the new firmware.

Note: Some SD Cards from the factory may contain an auto re-start feature that will cause the controller to automatically re-start when the file transfer is done.

12. Use the < / > arrow keys to move the cursor to the “Remove SD Card” menu Item and press < > to open the Remove SD Card screen P0468. 13. Press < > and the SD card may be removed.

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14. The SD Card LED will turn green as shown to the right. You can then remove the card by pulling it straight up out of the card holder. 15. Firmware upgrade is now complete. SD Card Status - The SD Card Status displays when an SD card is installed in the reader and/or the status of the card. Ethernet Status - The Ethernet Status shows when the unit is connected to the Ethernet or not connected. The Controller will automatically detect an Ethernet presence and connect to it. If there is a password required for Ethernet connection, a screen will appear asking for a password.

System Backup and Restore This functionality allows the user to take a backup of Parameter values and restore the values on demand. Parameter P0467 is used which can take values from 1 to 255. A value of 255 is reserved for Entire System Configuration. Values from 1 to 254 are used for Customizable back up.

Customizable Backup or Setup File The user can provide a specific set of Parameters which need to be backed up or used to create a setup file for multiple installations. These Parameters are provided in a text file with Filename “RestoreFilexxx.txt”, where “xxx” is a number in between 1 and 255 (inclusive). This means there can be 255 Restore Files (255 sets of Parameters). The value 255 is reserved for the Entire System Backup (details provided in next section). The backup and restore file can be created on any text editor such as Notepad or in Word. The file must then be named (RestoreFilexxx.txt ) and transferred to the unit. MS-WPRPOCFIX-00 / Rev. C January 2014

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Setup File The Setup script file is a text file provided for configuring WellPilot RPOC Parameters. These files can be used from FFS (/sys1) or from the RAM Disk (/). The Setup File can be created using following rules. The setup script file must be named SetupFile where is a number in between 0 - 255. Reading the script is activated by entering in parameter P470. The first line of the setup script must be exactly: #parameter setup file Each of the script lines contains a statement of one of the following forms: # comment Pnnn=vvv (this is/are the parameter number and value lines) Cnnn (command line) Wxxx (wait or delay line) Any line except the first that starts with a # in the left column is ignored (blank lines were supposed to be ignored, but they produce a warning). No spaces are allowed in the beginning of a line. Pnnn=vvv sets Pnnn to the value vvv (if it is a legal value). P470 cannot be modified in a script (no recursion). Cnnn executes command parameter nnn Wxxx waits xxx seconds. An example of this Setup File text named “SetupFile6.txt” is as follows: #restore file parameters #setup file for several units P21=70 P23=30 P20=000500 P34=1 W003

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After transferring this file to the controller, invoke this file by going to Parameter 470 and typing in the Setup File number of 6 in this example. Press < invoke the command.

> to

Creating Backup and Restore Files The first line in this file should contain the signature “#restore file parameters”. If this signature is missing then it fails to backup the Parameters. The following lines contain Parameter numbers as shown in the example below. The user can introduced a wait command with “W” followed by a number which indicates seconds. Any line beginning with “#” is a comment and is ignored by the firmware (except the first line which is a signature). Example: The following RestoreFile lists Parameters 21, 23, 20 and 34 which need to be backed up. A Wait Statement is added at the end with 3 seconds delay time. The first line in the example is the signature and lines 2 and 3 are comments. #restore file parameters #This is a comment. #The First Line should not change in this File. 21 23 20 34 W003 When the RestoreFile Number “xxx” is provided in P467 it runs the corresponding Restore File which results in creation of a Setup File which has the same Setup file number as the Restore File. The Setup File created snap shots the values of Parameters provided in the Restore File.


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System Backup This option allows you to perform a full system backup or to set a custom backup to the controller memory if the custom restore file has been provided to the controller. A value of 255 is reserved for Entire System Configuration Parameter Backup. When a value of 255 is provided in P467 it snapshots the values of all System configuration Parameters and saves it in SetupFile255.txt. Configuration Parameters are the Parameters which are stored in Flash or Battery Backed Memory. The user can RestoreFile255.txt file. On executing this file (P467 = 255) results in creation of DelayedSetupFile.txt which is similar to Setup File. If the user does not provide RestoreFile255.txt then a predefined (hardcoded) RestoreFile255.txt is generated. 1. The Main Menu can be accessed from any EGD screen location in the screen display sequence by pressing < 2. Use the <

/




/


Versions” menu Item and press < 4. Use the <

/

>.

>.

> arrow keys to move the cursor to the “System Backup”

menu Item and press <

>.

5. At the System Backup option, press < > and the Create System Backup Screen will appear.

- FIRMWARE PART NUMBERS & VERSION MAIN PROCESSOR PART NUMBER: FW00004-00 Firmware V 1:08:00 I/O PROCESSOR PART NUMBER: FF-00009-00 V01.01.00 System Backup : >0 Firmware Upgrade: (Press ENTER) System Restore : 0

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6. Use the keypad to type in the System Restore file number of 255 for a full system backup or any other number from 1 to 254 for customized System Restore files. Press < > and the system parameters file will be created in memory. When the file is done being created a “Backup Complete” message will appear.

System Restore 1. The Main Menu can be accessed from any EGD screen location in the screen display sequence by pressing < 2. Use the <

/




/


Versions” menu Item and press < 4. Use the < / > arrow keys to move the cursor to the “System Restore” menu Item and press <

>.

>.

- FIRMWARE PART NUMBERS & VERSION MAIN PROCESSOR PART NUMBER: FW00004-00 Firmware V 1:08:00

>.

I/O PROCESSOR PART NUMBER: FF-00009-00 V01.01.00 System Backup : 0 Firmware Upgrade: (Press ENTER) System Restore : >0


69


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5. At the System Restore option, press < > and the (P0470) System Restore Screen will appear. 6. Use the keypad to type in the System Restore file number of 255 for a full system restore or any other number from 1 to 254 for customized System Restore files. Press < > and the system parameters file will be restored from memory. When the file is done being restored a “File Restore Complete” message will appear. The System Backup and System Restore features are detailed in the flow charts on the next page.

70


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Figure 10: System Backup Flowchart


71


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Figure 11: System Restore Flowchart

72


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Analog Output Calibration This screen allows you to calibrate the AO channel to allow for a more accurate output from that channel. Note: A calibrated Voltmeter or Ammeter must be connected to the Analog Output terminals on the CPU Card, TB1 bottom row, when this calibration is taking place.

-

ANALOG OUTPUT CALIBRATION —

Calibrate Voltage 0-10V (Press ENTER) >Calibrate Current 4-20mA (Press ENTER) Select AO Calibration Type

Calibration can be performed as a function of Voltage or Amperage. To select the Analog Output Calibration Type, use the <

or

> arrow keys to move the cursor

(>) in front of the type of calibration needed and press <

>.

Calibrate Voltage 0-10V. The following steps guide you in calibrating the Analog Output for Voltage. 1. Connect a precision Voltmeter to the Analog Output terminals on TB1, bottom row, AO+ and AO- on your units CPU board. The AO- terminal and the COM terminals should be shorted or connected together. 2. On the Analog Output Calibration screen, position your cursor (>) in front of the Calibrate Voltage 0-10V line and press < >. The controller will apply 0 Volts to the AO terminals and that is what should be read on the meter.


-


>Calibrate Voltage 0-10V (Press ENTER) Calibrate Current 4-20mA (Press ENTER) Adjust AO Output to 0V Calibrate Voltage Lower Limit :

0

Use PgUp/PgDn/Up/Down to adjust AO Outp Press ENTER to accept AO Calibration

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Caution: The screen will show a representation of the ADC Counts and not the actual output voltage. The voltage is read from the meter connected to the output terminals.

3. If 0 Volts is not read on the meter, use the <

> and <

> keys to course

tune the output or the < or > arrow keys to fine tune the output until the correct reading is shown on your Voltmeter. Do Not Confuse the representative ADC Counts shown on the screen with the AO Output Voltage!

Note: The <

> and <

> keys move the count number in large 8 count

increments. The < count increments.

or

> arrow keys move the count number in 1

4. Once the correct reading is achieved, press < calibration screen.

> again to go to the 10 Volt

5. If 10 Volts is not read on the meter, use the < > and < > keys to course tune the output or the < or > arrow keys to fine tune the output until the correct reading is shown on your Voltmeter. Do Not Confuse the representative ADC Counts shown on the screen with the AO Output Voltage!

-


>Calibrate Voltage 0-10V (Press ENTER) Calibrate Current 4-20mA (Press ENTER) Adjust AO Output to 10V Calibrate Voltage Lower Limit :


Once the correct reading is achieved, press <

> again and the display will

return to the Analog Output Calibration screen. Press < calibration screen to the level desired.

74

4095

> to back out of the


®



Calibrate Current 4-20mA. The following steps guide you in calibrating the Analog Output for Current. 1. Connect a precision Ammeter to the Analog Output terminals on TB1, bottom row, AO+ and +24V on your units CPU board. The AO- terminal and the COM terminals should be shorted or connected together.

-


Calibrate Voltage 0-10V (Press ENTER) >Calibrate Current 4-20mA (Press ENTER) Adjust AO Output to 4mA Calibrate Current Lower Limit :

2. On the Analog Output Calibration screen, position your cursor (>) in front of the Calibrate Current 4-20mA line and

655


press < >. The controller will apply 4mA to the AO terminals and that is what should be read on the meter. Caution: The screen will show a representation of the ADC Counts and not the actual output current. The current is read from the meter connected to the output terminals.

3. If 4mA is not read on the meter, use the <

> and <

> keys to course

tune the output or the < or > arrow keys to fine tune the output until the correct reading is shown on your Ammeter. Do Not Confuse the representative ADC Counts shown on the screen with the AO Output Current!

Note: The <

> and <

increments. The < count increments.


> keys move the count number in large 8 count or

> arrow keys move the count number in 1

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4. Once the correct reading is achieved, press < calibration screen. 5. If 20 mA is not read on the meter, use the < > and < > keys to course tune the output

-

> again to go to the 20 mA


Calibrate Voltage 0-10V (Press ENTER) >Calibrate Current 4-20mA (Press ENTER)

Adjust AO Output to 20mA or the < or > arrow keys to fine tune Calibrate Current Lower Limit : 3276 the output until the correct reading is shown Use PgUp/PgDn/Up/Down to adjust AO Outp on your Voltmeter. Do Press ENTER to accept AO Calibration Not Confuse the representative ADC Counts shown on the screen with the AO Output Current! 6. Once the correct reading is achieved, press <

> again and the display will

return to the Analog Output Calibration screen. Press < calibration screen to the level desired.

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> to back out of the


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Recommended Maintenance Equipment Listing Maintenance of the RTU requires either specific parts or tools to perform the task. Weatherford offers suggestions, shown in Table 13, for equipment, tools, and materials for installing and maintaining the optimization unit and the wellsite. Table 13: RPOC Installation / Maintenance Equipment Equipment

Description

Load Cell Assembly

Part number PC8500-571, PC8500-572, PC8500-581-00, PC8500-58200

Position Switch

Required for pump-off control. The position switch is part number PC8500-600-00 – PC8500-603-01 depending on cable type (standard or rodent resistant) and cable length (25ft. to 120ft).

Continuous Position Sensor

Optional sensor for analysis programs or sensor for air balance control.

Position Potentiometer

Part number PC8500-605-00 – PC8500-605-04 depending on cable type (standard or rodent resistant).

Position Inclinometer

Part number PC8500-610-00 (standard cable).

Tools Following are the recommended tools for working on the RPOC unit 

Electric drill with drill bits and 110V inverter for car battery or Cordless DC Drill and drill bits



Extension cord if using AC powered Electric Drill



Needle-nose pliers, channel lock pliers, and standard pliers



Small, medium, and large Phillips and standard straight slot screwdrivers



1/4" hex nut driver (card installation and removal)



Electrical tape



Digital volt meter (DVM)



Electrical fish tape (100 feet)



Crimp/Lug tool.


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Materials Following are the recommended materials for maintenance on the RPOC unit. 

Wire and conduit (if used) between controller and external MCI



Wire and conduit between external MCI and electrical motor panel



Mounting hardware – post(s), panels, bolts, nuts, screws, etc.



Electrical connectors – conduit couplings, CGB type coupling for position switch, and load cell cables into controller (and MCI if external)



Tube of silicone seal



Sta-kon connectors



Tie wraps.

Preventative Maintenance The following is a minimal set of recommended preventative maintenance procedures that should prolong the service life of the controller and other equipment.

Every Three Months Clean the Solar Panel (If supplied). The cleaning interval should be every 3 months depending on the local weather and module tilt angle (more rain and higher tilt angle means less cleaning). Regular cleaning is imperative if the location is dusty or near the ocean where salt crystals can form. Keeping the surface of the panel clean enhances light transmission and allows the panel to perform at its designed capacity. The array surface may be cleaned with water, a commercial glass cleaning compound, or if necessary, a mild detergent. Solvents, abrasives, and strong detergents should not be used. DO NOT use cleaning solvents on the circuit box or the solar panel.

Every Year Connections: Check all exterior and interior connections for tightness and integrity. Ensure that power is removed from the unit before checking tightness of connections.

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Every Three Years Replace the size ½ AA Lithium battery on the CPU board with a new Lithium battery (P/N: PC00-23067-00). CAUTION: Replacing the battery will remove keepalive voltage from all battery backed memory and delete any stored data in that memory. The clock will also be reset to factory zero and will need to be restored to the correct time and date. The following instructions apply for replacing the CPU board battery: 1. Ensure that power is removed from the unit before changing the battery. 2. Using a small straight slot screwdriver, insert the screw driver in one of the slots on the end of the battery cover and pry gently inward toward the battery. The cover should disconnect from the base on that end.

Figure 12: Battery Cover Being Released MS-WPRPOCFIX-00 / Rev. C January 2014

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WELLPILOT TROUBLESHOOTING & MAINTENANCE.pdf

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