Sercel GRC ESP Series Field Installation Manual
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Sercel GRC ESP Series Field Installation Manual

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  • Page 1 !"#$#%&& ESP Monitoring System !.%12-.(&$'11'$."(- /'(3'1 , - ' , - % ( ) * + % # % ( ) $ . / % 0 % # ) $ . / % ,...
  • Page 2 Sercel-GRC Corp, and with the further understanding that this manual is for informational purposes only and that suggestions and recommendations contained herein shall not be understood or construed as a guarantee or warranty of any method, product or device.

  • Page 3: Table Of Contents

    Table of Contents INTRODUCTION ......................5 Customer Service/Support ................... 5 BENCH TESTING AND VERIFICIATION PROCEDURES ..........6 Tools Required ......................6 Process Steps for Bench Test and Verification ............6 INSTALLATION PROCEDURES FOR DOWNHOLE GAUGE ........8 Installing the ESP Sensor to the Motor ................ 9 Installing the Sensor Discharge Pressure Base Adapter (For ESP&...
  • Page 4 Table of Contents, cont. APPENDIX ........................57 Surface Readout Status Message Summary ............. 57 Fortress ESP Monitoring System Field Checklist............58 ESP Gauge and Surface Control Interface Diagram..........59 Surface Readout Devices - Gauge Interface Specifications ........60 SPS-3000 ......................... SPS-1500 .........................

  • Page 5: Introduction

    INTRODUCTION This field installation manual will detail and explain the operation and installation of the Sercel-GRC FORTRESS ESP Monitoring System, including gauges:   ESP-1000 ESP-3500   ESP-1500 QESP-2500   ESP-1800 QESP-3500  ESP-2500 and surface readout equipment: ...

  • Page 6: Bench Testing And Verificiation Procedures

    Note: Bench test and verification procedures are applicable to all Fortress ESP gauges. Tools Required  110V Power Source  Either a Sercel-GRC SCOUT-3000 (Surface Readout) o Portable Scouts will include a twisted wire pair with alligator clips Or a SERCEL-GRC SCOUT-2200 ...
  • Page 7 HOCKEY PUCK Figure 1: Fortress ESP Wiring Configuration Figure 1A Fortress ESP Wiring Configuration Doc No. 006-0211-00 Rev AD Page 7 of 62...
  • Page 8 Figure 1B: Fortress ESP Wiring Configuration The end of the 3-phase cable will come out somewhere in the center of the ESP cable spool as shown in Figure 1 above. Follow the steps below to test the gauge through the ESP cable spool once the cable has been connected to the motor. ...

  • Page 9: Installation Procedures For Downhole Gauge

    INSTALLATION PROCEDURES FOR DOWNHOLE GAUGE Installing the ESP Sensor to the Motor This procedure outlines the best practices that should be taken in the field. The sensor can be mounted to the motor before the motor is shipped to the field. In that case, the procedure will be the same, but probably not done on the back of a flat bed trailer as shown in these pictures.
  • Page 10 Figure 3. Gauge stabbed into motor base. 3. Once the sensor has been stabbed as far as shown in Figure 3, place one of the motor base bolts through the bolt hole and into the sensor motor head to make sure that the bolt holes are lined up. DO THIS BEFORE PROCEEDING TO STAB THE SENSOR FULLY ONTO THE MOTOR BASE.

  • Page 11: Installing The Sensor Discharge Pressure Base Adapter (For Esp& Qesp-3500 Gauge Models Only)

    Testing the ESP Sensor While Installing Tubing Figure 4. Spooling Unit. Installing the Sensor Discharge Pressure Base Adapter (For ESP& QESP-3500 Gauge Models Only) Discharge Port Connection All Dual Pressure gauges are equipped with a Discharge Pressure Port. The Discharge Pressure Port must be purged with motor oil, vent plugged, and connected to the hydraulic tubing connecting to the pump discharge sub before being deployed.
  • Page 12 THIS OPERATION NEEDS TO BE COMPLETED IN ITS ENTIRETY BEFORE THE MLE IS CONNECTED TO THE MOTOR. 1. Remove the fitting and ensure that the NPT threads have been Teflon taped. 2. Install the n fitting back into the base. 3.

  • Page 13: Installing The Resistance Temperature Detector "Rtd" (For Non-Factory Installed Rtds, Probe Style)

    The first step is to determine where the RTD is going to be placed. It can be either inside the ESP motor oil passage or inside the Sercel-GRC gauge. Inside the gauge is the safest and is the least likely to come in contact with rotating motor components, but it will be slower in responding to temperature variations of the ESP motor.
  • Page 14 Figure 6. Three pieces of shrink tubing on gauge wires. f. Twist one RTD wire and one RTD gauge wire together creating a splice so that it appears as a straight wire and not two wires side by side. At this time solder the two wires together using high temp solder.

  • Page 15: Wye Point Replacement

    Figure 8. Long piece of heat shrink tubing over both wires. Finally, replace the wye point if you have removed it. Attach the Scout-3000 or portable Scout to any of the motor terminals of the wye point or to the gauge wire if not using our wye point.
  • Page 16 Procedure Cut P/N 037-0050-04 off from the communication wire, refer to Appendix Fig. A1. Thread the communication wire through the hole on the terminal. Be sure not to use the RTD wires as all wiring from the choke is white. Fold the excess wire back towards itself making a loop.
  • Page 17 Now solder the wire to the terminal with the aid of flux making sure not to leave any sharp edges. Refer to Fig. 11. After soldering, clean the solder with alcohol and slide the clear plastic wire insulator to the solder joint. Refer to Fig. 11. Figure 11.
  • Page 18 Now slide the second piece of heat shrink tubing down to the base of the threaded pin. This will go over the first heat shrink tubing. Refer to Fig. 13a. Figure 13. WYE Connector Shown with the Second Heat Shrink Tubing. Apply heat to the heat shrink to complete the assembly.

  • Page 19: Installing The Surface Interface Equipment

    INSTALLING THE SURFACE INTERFACE EQUIPMENT SCOUT-3000 Installation Figure 14 shows a typical wiring and installation schematic for the ESP surface equipment. Figure 15 describes the specific connections of a Scout-3000 to a gauge. Connections are also detailed for the 4-20mA Current Loop and Modbus. Figure 14.
  • Page 20 Signal Name Recommended Wire Colors AC Power-In Black-Live, White-Neutral, Green-Earth Gnd Gauge Red-Signal (+), Green-Return (-) Orange/Gray 4-20mA #1 (Connections for Scout-3000 w/ Optional 4-20mA Current Loop) Blue/Violet 4-20mA #2 (Connections for Scout-3000 w/ Optional 4-20mA Current Loop) Blue/Violet Modbus (Connect to Pins 1 and 4) Figure 15.

  • Page 21: Sps-1500 Installation

    SPS-1500 Installation Illustrations on how to install the SPS-1500 is shown in Figure 17 below. USB Connection Gauge Fuse: 5x20mm 100mA Fast Acting Blue LED: Power Power/Gauge Red LED: Modbus Traffic 1: Gauge Signal RS-485/422 2: Well Ground Orange LED: Gauge Data Byte 1: TR - 3: Vdc Ground Green LED: Gauge Data BIt...

  • Page 22: Scout-2200 Installation

    SCOUT-2200 Installation For installations using a SCOUT-2200 ESP Surface Monitoring System, the installation and operations manual can be found on the Sercel-GRC website at www.sercel- grc.com. Doc No. 006-0211-00 Rev AD Page 22 of 62...

  • Page 23: Installing The Surge Suppressor And Surface Choke

    INSTALLING THE SURGE SUPPRESSOR (PROTECTOR) AND SURFACE CHOKE The ESP gauge surface readout equipment such as the Scout-3000 connects to the downhole tool via the motor power cable through the Surge Suppressor and Surface Choke. Communication and power are provided via a “Comms-On” technique; meaning the communication and power are both transmitted through the motor cable.
  • Page 24 Figure 18b. Three Phase Surface Choke Connections Surge Panel Protector/Suppressor The Surge Panel provides protection for the ESP Surface Interface equipment from several failures including; overvoltage from imbalance, transient voltage pulses, and switching spikes. User Replaceable 1/2A HV Fuse User Replaceable MOV –...

  • Page 25: Surface Choke And Surge Protector Panel Assembly #90B2175

    Late model Surge Panel Protectors have a bleed resistor installed across the MOV (pin7 to pin 8) to dissipate static line Figure 19b. Surge Protector Schematic and Connections charges. Surge Protector/Fuse Block Connections 1 - 8 1. No Connection 2. Gauge signal wire to SPS-1500 or Scout-3000 3.

  • Page 26: Surface Choke

    Surface Choke and Surge Protector Panel Assembly #90B2175 Surge Protector Surface Choke Interface to motor power cable Assembly 3 Phase Fuse Assembly Figure 20. Combined Surge Protector and Surface Choke Panel Doc No. 006-0211-00 Rev AD Page 26 of 62...
  • Page 27 Surface Interface Motor Wire Connection Connection to Scout or Green – WHG (Wellhead Ground) SPS-1500 Phase A, B, C Red – Gauge Signal Black – Gauge Ground Figure 21. Surface Choke and Surge Protector Wiring Diagram Doc No. 006-0211-00 Rev AD Page 27 of 62...

  • Page 28: Scout-3000 Relay Alarms Setup

    Relay board, you may still use the relay alarms to log events to the USB drive and showing alarms on the Scout-3000 display. (Firmware must be updated to RCM 2.2A and LCD 1.2A for multiple alarm delays. Contact Sercel GRC Customer Service for more information.
  • Page 29 To set a delay timer for any alarm parameter, press the time option next to the trigger value. Select the desired trip time from the Time Delay menu shown in Figure 61. Figure 25. Edit Trigger Value Figure 61. Time Delay Menu The alarm timers will begin counting down when any of the trigger values reach the trip point.

  • Page 30: Software And Firmware Installation And Updates

    SOFTWARE AND FIRMWARE INSTALLATION AND UPDATES Scout-3000 (for Rev. A Only) Updating SPS Firmware Using Tera Term - TTermpro Parts Required: 1. USB A-B CABLE 2. TTL CONVERTER 3. TTERMPRO UTILITY Procedure: 1. Use USB A-B cable between computer and TTL converter. 2.
  • Page 31 Figure 27. Serial Port Settings. 8. Select OK 9. SHIFT-U and power up the Scout-3000 10. FILE TRANSFER XMODEM SEND 11. Screen shows BEGIN TRANSFER and “C” 12. Select file MODBUS 32.BIN from whatever location you have it stored in and DOUBLECLICK.

  • Page 32: Updating Lcd Firmware

    Figure 29. File transfer completed. 15. Close TTERMPRO 16. Power down Scout-3000 17. Remove TTL Convertor and re-attach ribbon cable to last two pins on the right side of J3. 18. Reinstall Scout-3000 faceplate. Updating LCD Firmware Parts Required: 1. USB Cable Type A to Type B Mini 2.
  • Page 33 Select Comm port Change Baud Rate Connect Figure 30. BMPLoad Software. 5. Select the Comm Port associated with the USB connection. 6. Change the Baud Rate to 460800. 7. Click “Connect”. Doc No. 006-0211-00 Rev AD Page 33 of 62...
  • Page 34 Load File Button SLCD Status Message Figure 31. BMPLoad software checking the SLCD status. 8. Verify SLCD Status shows ‘Connected’. 9. Click “Load from File” and the Open screen will appear, change the file type to Combined Upgrade .FWU. See Figure 32a. Doc No.
  • Page 35 Change File Type to Combined Upgrade [*.FWU] Figure 32a. Changing the file type. 10. Select Firmware file “Scout-3000 SLCD_Firmwarexx.FWU” and click “Open”. See Figure 32b. Select Firmware file “Scout-3000 SLCD_Firmwarexx.FWU” Figure 32b. Selecting the right firmware for the Scout-3000. Doc No. 006-0211-00 Rev AD Page 35 of 62...
  • Page 36 11. A message will appear that indicates the binary file is ready to be transferred. Click “OK” 12. Click “Store into SLCD” to begin transferring the file to the LCD. See Figure 33. The SLCD status screen will indicate the file transfer as shown in Figure 34. Click “Store into SLCD”...
  • Page 37 The SLCD Status screen will indicate the file transfer. Figure 34. SLCD status screen indicating the LCD file transfer. Doc No. 006-0211-00 Rev AD Page 37 of 62...
  • Page 38 13. After the file is prepared for transfer the software will ask to calibrate the screen, Click “No” as shown in Figure 35. Calibrate Touch Screen - NO Figure 35. Do not calibrate the touch screen. Doc No. 006-0211-00 Rev AD Page 38 of 62...
  • Page 39 14. After Clicking “No” the software will show the LCD is programmed. Click “Quit” to exit the program. See Figure 36. SLCD Status screen will show the program was successfully transferred. Click “Quit”. Figure 36. Final screen showing that the program was transferred successfully. 15.

  • Page 40: Scout-3000 (For Rev. B And Later Versions)

    Scout-3000 (for Rev. B and Later) Updating RCM Firmware with Memory Tools & USB Cable NOTE: THIS PROCEDURE ONLY WORKS WITH REV. B SCOUT-3000 AND LATER VERSIONS, NOT WITH REV. A VERSIONS OF THE SCOUT. 1. Open Memory Tools and select drop down box located on second toolbar from the top.

  • Page 41: Sps-1500

    Figure 37. RFU in the Communications Options 4. Select USE SERIAL CONNECTION button. 5. Select 115200 from BAUD RATE DROPDOWN BOX. 6. Select correct com port from the COMM PORT DROPDOWN BOX. 7. Clear ENABLE PROCESSOR DETECTION CHECKBOX. 8. Check USE USB TO SERIAL CONVERTER CHECKBOX. 9.
  • Page 42 4. If this is the first time to plug in the SPS-1500, you may need to install drivers (SEE SCOUT-3000 USB SERIAL DRIVER SECTION BELOW in Figure 38). Windows should try to automatically install drivers. If this fails, please contact Sercel-GRC Customer Service at (918) 834-9600 for assistance. SCOUT 3000 USB SERIAL DRIVER Go to: http://www.ftdichip.com/FTDrivers.htm...
  • Page 43 10. Press and hold the "Shift" and "U" keys on the computer keyboard while simultaneously turning the SPS-1500 power on. You should soon see "BEGIN TRANSFER" displayed in HyperTerminal. If you do not, power down the SPS- 1500 and repeat this step. 11.

  • Page 44: Updating Sps-1500 Using Tera Term - Ttermpro

    Updating SPS-1500 Using Tera Term - TTermpro 1. Open TTERMPRO 2. Select SERIAL BUTTON 3. Drop down box and select USB SERIAL PORT and COM PORT NUMBER found under CONTROL PANEL/DEVICE MANAGER/PORTS. 4. OK 5. SETUP MENU then SERIAL PORT. See Figure 39. a.
  • Page 45 Figure 40. 8. On the Tera Term toolbar select FILE-TRANSFER –XMODEM-SEND 9. Go to file location and choose 90A3141-MODBUS (SPS 1500) to open location. 10. Select SPS-1500_20g.BIN and then click OPEN which will begin transfer as shown in Figure 41. Figure 41.

  • Page 46: Procedure For Viewing Usb Memory With Memory Tools Software

    Procedure for Viewing USB Memory with Memory Tools Software Viewing Data On A Computer 1. Open Memory Tools program. 2. Click on READ Button at top of page, choose the file on the USB memory you would like to see. 3.

  • Page 47: 4-20 Ma Card Installation And Configuration

    4-20 mA CARD INSTALLATION AND CONFIGURATION Installing 4-20mA optional cards into the Scout-3000 Figure 42 labels the main components of the Scout-3000. The procedure follows. SPS Module (Gauge Power Gauge Signal Supply) and Signal Return Connections Modbus 4-20mA Current module Loop Module Connecti Connection...
  • Page 48 Install standoff here Figure 44. Standoff placement. 2. Check switch position on 4-20 mA card to verify it is configured properly as shown in Figure 45. 4-20mA If a second 4-20 mA card is Switch installed, the upper card will position have this switch in the opposite position.
  • Page 49 5. Check switch position on relay card to verify its position is correct as shown in Figure 48. Relay Switch position Figure 48. Check switch position on relay card. 6. Connect the signal wires to the relay card as shown below. Normally Closed contact...

  • Page 50: Scout-3000 4-20Ma Port Setup

    Scout-3000 4-20mA Port Setup The 4-20mA Port Setup menu allows you to configure the optional 4-20mA current output loops. The term Channel reflects which gauge sensor is connected to the current loop. The single 4-20 mA card is channel 1. The 4 mA allows you to set the value that the 4 mA of current will reflect.

  • Page 51: Troubleshooting

    TROUBLESHOOTING Sensor To Surface Communication Troubleshooting The definitive method for troubleshooting installation problems is to separate the downhole equipment from the surface equipment, including the junction box and surface cable. Once this is done the ability is gained to truly see where the problem lies with the installation.

  • Page 52: Scout-3000 Troubleshooting

    Scout-3000 Troubleshooting Before attempting to troubleshoot there are a few general items you should double check:  Check that all connections to the fuse block and three phase choke are correct.  Check the fuse on the fuse block.  Check the fuses in the Scout-3000 (line circuit breaker and gauge signal fuse). ...
  • Page 53 Figure 51. Scout-3000 Main Display Select “SPS Menu”. Figure 52. Scout-3000 System Menu Select “Operation Settings”. Select Operation Settings Figure 53. Scout-3000 SPS Setup Menu Select “Set Voltage” to change the SPS voltage. Doc No. 006-0211-00 Rev AD Page 53 of 62...
  • Page 54 Select Set Voltage Figure 54. SPS Operating Settings Menu After changing the voltage, the voltage will be set on the SPS. (Set Voltage cannot be saved with Auto Volt turned on) Now turn off the Scout-3000 and turn it back on again. If you still are receiving errors then repeat the above process incrementing the voltage by 4 volts.

  • Page 55: Sps-1500 Troubleshooting

    SPS-1500 Troubleshooting The SPS-1500 may experience communication problems due to noisy environments, grounding problems, or installation issues. The LCD on the SPS-1500 will display certain error codes depending on the failure the controller is detecting. Below is a list of common error codes and possible solutions to assist with troubleshooting the SPS- 1500.

  • Page 56: Scout And Sps Error Codes And Corrective Actions

    Replace SPS board inside the Scout or change out REFERENCE SPS board inside the Scout- the Scout-3000. 3000 may be damaged. Call Sercel-GRC customer service. ESP FRAMING Communication problem as ESP OVERRUN the Scout looks for the In manual mode, increase the voltage; in auto-volt...

  • Page 57: Appendix

    APPENDIX Surface Readout Status Message Summary Status Messages Message Description SPS Idle Run Mode Disabled SPS SncPhs 1 Applying Voltage SPS SncPhs 2 Initial Current Check SPS SncPhs 3 Detecting 1 Signal Transition SPS SncPhs 4 Measuring Tool Signal SPS SncPhs 5 Wait for End of Sync Phase SPS Power Off Gauge Power Off...

  • Page 58: Fortress Esp Monitoring System Field Checklist

    FORTRESS ESP Monitoring System Field Checklist Initals PRE LOADOUT CHECK CUSTOMER ESP SENSOR READING FUSE Ω SURGE SUPPRESSOR CONTIN PIN 2-4 WELL OPERATOR PWR ON SCOUT FUSE INTEGRITY GAUGE LINE WELL NAME CONTINUITY BETWEEN 3 PHASES AND Y-POINT 3 PHASE SURFACE CHOKE LINE 1-Y LINE 2 -Y LINE 3 - Y...

  • Page 59: Esp Gauge And Surface Control Interface Diagram

    ESP Gauge and Surface Control Interface Diagram The following components are used to provide downhole pressure and temperature data in an ESP installation as shown in Figure 56. 1. ESP Gauge Surface Readout Interface (SPS-1500/SPS-3000/Scout- 3000/Datalogger-2000) 2. Surge Panel Equipment (Surge Suppressor and Fuse Protection #90D2215 or #90B2175) 3.

  • Page 60: Surface Readout Devices - Gauge Interface Specifications

    Surface Readout Devices – Gauge Interface Specifications SPS-3000 The Scout-3000 is our simplest gauge interface that provides Modbus slave polling via RS-485, RS-422, and RS-232. SPS-3000 Specifications:  Low cost dust proof enclosure  Single ESP gauge interface  Modbus communication via RS485, RS- 232, RS422 ...

  • Page 61: Scout-3000

    Scout-3000 The SPS-3000 provides increased user interface with a graphical backlit color touch screen interface. All data may be viewed in addition to viewing graphical pressure and temperature trending data. Real-time graphical trending data may be viewed in for periods of hours to 42 days. Figure 59.

  • Page 62: Datalogger-2000

    Datalogger-2000 The Datalogger-2000 ESP Gauge interface includes a powerful RTU for local data storage as well as a robust set of I/O for control and monitoring of other sensors. Push- button control and a 2-line Character LCD is also onboard for local control and monitoring of any parameters.
  • Page 63 Anywhere. Anytime. Everytime. Sercel-GRC Corp. is a worldwide leader in downhole data acquisition and the leader in proprietary technology for measuring, recording and delivering reliable and accurate well data with extremely high resolutions. Sercel-GRC provides gauges and surface readout tools for permanent, memory, mechanical and artificial lift applications and is the manufacturer of the Amerada®...

This manual is also suitable for:

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