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Ace RELIANCE Operation Manual

Downhole sensor
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ACE RELIANCE SENSOR OPERATIONS MANUAL
ACE Reliance Sensor Operations Manual
V2.3
1 |
P a g e

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Summary of Contents for Ace RELIANCE

  • Page 1 ACE RELIANCE SENSOR OPERATIONS MANUAL ACE Reliance Sensor Operations Manual V2.3 P a g e...

  • Page 2: Table Of Contents

    ACE RELIANCE SENSOR OPERATIONS MANUAL Table of Contents Contents Product Description ............................ 3 Product Specifications ..........................5 Installation tools and materials ........................6 4. TEC cable preparation ..........................9 Downhole Instrument Installation: 10 kPSI Sensor Model ...............14 Sensor and cable Integrity testing ......................23 1kPSI Sensor Model Installation........................24...

  • Page 3: Product Description

    ACE RELIANCE SENSOR OPERATIONS MANUAL 1. Product Description ACE Reliance is a downhole sensor designed to be deployed in non-ESP wells (GasLift, PCP, Rod Lift, Hydraulic Lift, …). ACE Reliance sensor consists of two main components - a downhole instrument and a surface read-out unit. The downhole instrument is a completely sealed, welded device.
  • Page 4 SD memory cards. The SRU2i also includes insulation monitoring. The SRU3i adds direct Wi-Fi local connection plus direct connection to Baker Hughes VSD’s. The SRU's operates from nominal 120 VAC50/60Hzline voltage. ACE Optix is a battery powered, solar power capable version.

  • Page 5: Product Specifications

    ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 3 Surface read-out unit (SRU) Product Specifications Table 1 Downhole tool specifications Pressure Range 0-1,000 psi 0-10,000 psi Pressure Accuracy 0.2% 0.2% Pressure Resolution (0.01 to 1 PSI 0.0305 psi 0.305 psi depending on readout)

  • Page 6: Installation Tools And Materials

    ACE RELIANCE SENSOR OPERATIONS MANUAL WiFi Interface Standard worldwide, license Standard worldwide, fee 802.11 b/g/n license fee 802.11 b/g/n Analog Outputs ( 4x 0-20 Ma User isolated) configurable ( SRU2 sources power) Relay Outputs ( 2x Form C User Isolated)
  • Page 7 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 4 Crimp tool Figure 5 Crimp tool ( cont.) V2.3 P a g e...
  • Page 8 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 6 Wire cutters Figure 7 Vise grips V2.3 P a g e...

  • Page 9: Tec Cable Preparation

    ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 8 Tube cutter Figure 9 Tube cutter 4.TEC cable preparation 4.1 Use the ACE cable strip gauge to measure and mark the cut-off length (fig 10) V2.3 P a g e...
  • Page 10 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 10 Measuring and marking the tube cut-off length 4.2 Use tube cutter to make a groove in the tube (fig 11) Figure 11 V2.3 10 | P a g e...
  • Page 11 Then remove the tube (fig 12 and fig 13). Figure 12 Figure 13 4.4 Use the cable cutter to remove a length of the Teflon insulation as per dimensions of the ACE cable strip gauge (fig 14) V2.3...
  • Page 12 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 14. TEC cable stripping dimensions as per the ACE Downhole strip gauge 4.5 Insert the end of the TEC cable wire into the pin (fig 15). Figure 15 4.6 Terminate with a pin using the crimp tool (fig 16). If it is assembled but does not match the gauge then cut off V2.3...
  • Page 13 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 16 Using the crimp tool to terminate the wire with the pin V2.3 13 | P a g e...

  • Page 14: Downhole Instrument Installation: 10 Kpsi Sensor Model

    ACE RELIANCE SENSOR OPERATIONS MANUAL 5.Downhole Instrument Installation: 10 kPSI Sensor Model 5.1 Unscrew the stop block cover from the instrument housing (fig 17) Figure 17 Stop block Stop block cover Sensor housing assembly 5.2 Slide TEC cable through the stop block cover (fig 18) Figure 18 5.3 Retrieve the stop block assembly from the stop block cover and dismantle the stop block.
  • Page 15 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 19 Stop block assembly Figure 20 5.4 Screw the nuts of the stop block assembly back together (fig 21) Figure 21 Insert the TEC cable into the instrument head. Don’t apply force at this time. Just push it in slightly (fig 22) V2.3...
  • Page 16 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 22 5.6 Hold the TEC cable in place, unscrew the short nut from the instrument base and slide it further right along the TEC cable. Hold the TEC cable near the pin with your left hand and use your right hand to shake off the cone and the ferrule from the instrument head nut.
  • Page 17 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 24 Ferrule pressed into the head and a masking tape applied The cone is pushed into the The tape applied next to the cone head of the instrument to hold it in this location 5.8 Withdraw the tubing from the gauge and verify that the cone is at least 3/16”...
  • Page 18 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 26 Step 2. Apply petroleum jelly on the Step 1. Verify the connection between the circumference of the thread TEC cable and the instrument head is tight. Push it in more if needed. 5.9.1 Screw the short nut back on the instrument head and tighten it up with your fingers (fig 27).
  • Page 19 ACE RELIANCE SENSOR OPERATIONS MANUAL V2.3 19 | P a g e...
  • Page 20 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 29 Locate stop block to be positioned ½” inches (use measuring tape or the ACE strip gauge type 2 (fig 30.1) 5.9.3 from the instrument head short nut as shown in the picture. Tighten the stop block finger tight. (fig 30) V2.3...
  • Page 21 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 30 This distance is 1/2” Figure 30 .1 1/2” Figure 30.1 1 V2.3 21 | P a g e...
  • Page 22 ACE RELIANCE SENSOR OPERATIONS MANUAL 5.9.4 Hold the long nut of the stop block assembly with the 1/ 2 “wrench. Tighten up the short nut of the stop block assembly using the 9/16” wrench on the short nut. Make sure that the long nut stays in place and the gap between the instrument head nut and the stop block remains the same (1 / 2 “).

  • Page 23: Sensor And Cable Integrity Testing

    ACE RELIANCE SENSOR OPERATIONS MANUAL 5.9.6 Pull the stop block cover back and screw it on the instrument head. Tighten it up with your fingers. Insert the 5/8” wrench and the 3 / 4” wrench into the groves on the instrument head and the top of the stop block cover. Hold the sensor head with the 5/8”...

  • Page 24: Kpsi Sensor Model Installation

    Components that are not present in the 1K sensor model are crossed out Figure 35.1 1K sensor model 1. Surface Read-Out Unit Set-up 8.1. Connect a surface cable (from a junction box) and the DC power cable to the ACE Optix SRU. V2.3 24 | P a g e...
  • Page 25 8.2 The ACE Optix device contains a GPS receiver. If mounted in a metallic container it’s possible the internal GPS will not receive a signal, in this case the ACE Optix external GPS receiver may be plugged into the front of the ACE Optix case as shown in the figure 37 below.
  • Page 26 8.3 Power up the ACE Optix SRU. It will take a couple of minutes for the SRU to initialize. During initialization all LEDs will be blinking. Once initialized without errors, green light only will stay on as shown in the picture 37 below.
  • Page 27 ACE Optix SRU initialized (green light is on) 8..4 On your cell phone or a tablet go to “Settings > WiFi” and connect to the ACE OPTIX WiFi network. The last four letters in the WiFI network (2CDO shown below) are the last 4 letters of the ACE Optix device MAC address, so will be different for all ACE Optix devices, allowing them to be identified if several are running close together.
  • Page 28 8.5 Open a web browser on your device and type 1.2.3.4 in the web address tab. It will take a few seconds for the browser to display Opix SRU status screen. Once ACE Optix SRU has initialized, you will be taken to a set up menu (figure 39).
  • Page 29 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 39 SRU Optix set-up menu V2.3 29 | P a g e...
  • Page 30 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 40 Main sensor status screen on the cell phone 8.6 To download a data log file, click on “Log File Download”. As the message to confirm download shows up, select the day to download (defaults to today) then download (fig. 41) V2.3...
  • Page 31 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 41 Downloading log files 8.7. Once the log file is downloaded you can find it and access it in the top right hand side corner of the web browser fig. 42) V2.3 31 |...
  • Page 32 GPS coordinates of the well site. It will also assign date and the time stamp to each pressure and temperature reading. Please note when ACE Optix SRU is paired with the 150°C (302°C) Ace Reliance sensor the system provides a fast data rate of 1.4 seconds. While you will have such data granularity in SCADA system, for the purpose of the log file an average value of measurements will be populated in a log file every 10 seconds.

  • Page 33: Sensor And Cable Integrity Monitoring During Run In Hole

    9. Sensor and Cable Integrity Monitoring During Run in Hole 9.1 ACE Spooler overview The ACE Spooler allows continuous monitoring of an ACE Reliance downhole sensor and the connecting TEC cable in real time during installation. The unit can be mounted inside the rotating cable spool and is electrically connected to the end of the cable inside the spool.
  • Page 34 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 44 ACE Spooler V2.3 34 | P a g e...
  • Page 35 9.2 ACE Spooler set-up The ACE Spooler set-up is identical to ACE Optix SRU set-up. Data viewing is also the same as for ACE Optix RTU. (please refer to the SRU Optix instructions in this manual). V2.3...
  • Page 36 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 45 Spooler set-up screen 9.3. Spooler log file The start of a typical file will be as follows. The first line will be the GPS coordinates when the Spooler was first turned on. After that each line will have the date, time and the channel readings, in the example below the Spooler.
  • Page 37 ACE RELIANCE SENSOR OPERATIONS MANUAL Figure 46 Example Spooler log file 36° 42.73047' N 95° 56.05790' W 05/23/19,09:16:58,72.53,2.20,0.00,0.00,0.00,0.000 05/23/19,09:17:08,72.53,2.20,0.00,0.00,0.00,0.000 05/23/19,09:17:18,72.87,1.84,0.00,0.00,0.00,0.000 05/23/19,09:17:29,72.87,1.84,0.00,0.00,0.00,0.000 05/23/19,09:17:39,72.87,1.33,0.00,0.00,0.00,0.000 05/23/19,09:17:49,72.87,1.03,0.00,0.00,0.00,0.000 05/23/19,09:17:59,72.87,0.98,0.00,0.00,0.00,0.000 05/23/19,09:18:08,73.21,1.37,0.00,0.00,0.00,0.000 05/23/19,09:18:20,73.21,1.37,0.00,0.00,0.00,0.000 05/23/19 09:18:30,73.21,1.04,0.00,0.00,0.00,0.000 Error Conditions: 9.4 Error Conditions The Spooler is able to identify and display three main causes of errors. If the audible beeper is enabled these will also cause the alarm to sound Fig.
  • Page 38 ACE RELIANCE SENSOR OPERATIONS MANUAL Fig. 47 A short circuit again indicates a problem somewhere in the system which may be at the surface or downhole. Turn off the Spooler before trying to locate the problem. Fig. 48 If ‘Cannot decode sensor data’ screen is displayed it indicates that data is being received from the sensor, however the Spooler cannot decode the data.
  • Page 39 ACE RELIANCE SENSOR OPERATIONS MANUAL The Spooler is just the opposite, as it draws a very low, limited current (0.1 Amp normally, 0.25 Amp maximum) and its desirable for the Spooler to operate as long as possible without changing the batteries. So although the Spooler will operate with ‘vape’...
  • Page 40 ACE RELIANCE SENSOR OPERATIONS MANUAL shorter battery run times. Although users are able to refresh their device screens as quickly as they wish the Spooler defaults to updating each device every 10 seconds (unless prompted by a user request), since faster rates increase power consumption.

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