Linear Rod Pump (LRP) Startup

This presentation follows a typical startup of a Linear Rod Pump (LRP) articulating system.

Unclassified. Property of Unico, Inc. Authorized for external use .

Linear Rod Pump (LRP)

The linear rod pump is a rackand-pinion actuator system that strokes up and down via the forward and reverse action of a positioning servo motor. The two major pieces are the pump actuator, and the Variable Speed Drive.

Linear Rod Pump installation

Install the hardware on the well-head, according to the Linear Rod Pump installation document.

Preinstall check list

Proper size rod clamp. Polish rod spacer. Proximity sensor. Proximity cable. 4 LRP bolts. 1 Grease fitting. 1 Lube drain pipe.

Linear Rod Pump installation

1. Prepare equipment and site. 1.1 Ensure well completion Is prepared for LRP. The base of the LRP stand is designed to attach to the API casing flange, BOP, or tubing mount. The picture on the right is of the API flange. The base should be as per ordered before installation.

Linear Rod Pump installation

Clean casing flange of all dirt, oil and debris. Using a level check casing stand for horizontal alignment. (look at the level and determine where horizontal is for the top of the flange.)

Spacing of the polish rod

1.2 Polish rod spacing. Your polished rod needs to be 1.25 for all 239 gearboxes. If using the 381 gearbox then the polish rod can be either 1.25 inches or 1.5 inches. This should be confirmed when ordering of the LRP unit. To space the polished rod the most common method used is the singe rod method. To determine the correct spacing you will need the following information: - Height of casing stand. - LRP height. (This is found on the LRP label. see next slide) - Spacer and coupling. - plus 6 to 12 inches (20 to 30 CM)

LRP unit height.

Detail work
1.3 Remove any piping and fittings obstructing installation. Some of the piping or fittings may need to be temporarily removed to fit the LRP stand. Remove cap, and as necessary, any fitting obstructing mounting of the stand. 1.4 Determine stand mounting direction and flange bolts. The LRP stand is opened on one side to allow mounting without removing all of the piping. Determine the mounting orientation required for your installation. Identify the four bolts that will be used for the stand.

Final preparations
1.5 Remove flange bolts. Remove the four flange bolts previously identified to be used for the stand mounting. Replace the bolts or studs if they do not have at least extra thread to allow threading through the stand base.

2. Setting of the stand

2.1 Lift stand over flange. Using a crane or rig, lift the LRP stand over the flange. Orient it to align the bolt holes in the flange and the stand. 2.2 Install bolts. Install the four bolts and hand tighten.

Checking the polished rod for proper alignment

2.3 Check for proper alignment . The polish rod should be at a 90 angle to the casing stand. Caution should be taken as the rod clamp can pull the polish rod to one side, giving a false reading.

Install lube drain pipe and fittings

2.4 Place thread compound on the end of the supplied nipple. Install nipple into the lower tube fitting. The drain should extend beyond the stand flange pointing down. Ensure the valve is closed.

Fill with oil

2.5 Fill the lower tube with gear oil. Ensure the oil level indicator is completely covered, warning!, do not overfill! You can fill the LRP unit with oil, either while on the ground or after the LRP unit is mounted on the stand. Check Installation manual for correct oil type and viscosity. Check gear box oil level and insure gearbox is filled before starting. Gearbox may have been emptied due to requirements of some shipping companies.

3. Mounting of the LRP unit

3.1 Lifting the LRP. Using a crane or rig, lift the LRP over the polished rod. When lowering, orient the LRP unit to align with the bolt holes in the stand. 3.2 Install the four bolts supplied and hand tighten.

Mounting of the LRP unit

3.3 Tighten all bolts previously installed. Tighten bolts that connect the stand to the flange. Tighten bolts that connect the LRP unit to the stand.

Mounting of the LRP unit

3.4 Verify stand. Verify LRP stand is still at a 90 degree angle to the polished rod +/- 1 degree after the bolts are tightened. (The stand, LRP unit, and polished rod should be perpendicular to the casing.) If angle is not correct repeat steps so you can shim the stand until a 90 degree angle +/- 1 degree can be achieved. This prevents damage to the pump, stuffing box, and also premature failure of equipment due to improper installation.

S1100/S1200 Basic start-up

The balance of this presentation discusses the basic connection, and software startup of the series 1100, and series 1200 drives.

4. Connect motor leads

Connect the motor to the drive using appropriate cabling, in accordance with the electrical schematics.

Initial drive set-up

Verify the correct power, and compare to specifications on the drive label. Three phase power input is wired to terminal blocks R,S, and T. Three phase motor output is wired to U,V, and W. Ground in accordance with local regulations.

DB wiring
The DB circuit is wired into DB, with a return to B-. In an LRP application, it is important that the DB be properly installed, and wired. Failure to do so may result in many Bus Overvoltage faults.

Control connections
Ensure all switch inputs (motor on, run enable, external fault, etc.) are wired into TB-1. Ensure all analog inputs (speed pots, inclinometers, load cells, TB-1 etc.) are wired into TB-2. Check that any required communications devices are connected to the appropriate ports.

TB-2

Initial power application

Ensure that the power applied is correct for the drive. This includes voltage, as well as phase, and balance, with respect to each phase, and ground. This can be verified on the drives label

Initial screens
After the drive is powered up, the screens will display, as shown, after the software completes its internal checks. The displayed information is a result of set-up data, entered during the start-up process.

Verify software version

Check for latest software version. From the Unico logo page enter 3 times to Setup Menu then scroll down to Help Display and enter. Software number and revision are listed at the top of the display.

Clearing initial faults

Faults that are associated with a new installation may be identified at this time. If a DSP has been replaced, and/or new software downloaded, an Identification Error, or NV Memory, fault may be detected. The NV Memory fault may be cleared by pressing the Function, key, and 0 key at the same time. Changing any fault reset bit (in I/O) will have the same effect. Identification error can be reset as preformed on the next slide.

Resetting the drive Identification error

By navigating to the Archive menu, the Reset ID function may be used. This resets the Identification bits, that are used to determine drive horsepower and/or voltage. This is most often needed when exchanging DSPs, but may be needed to resolve any Identification faults.

Resetting factory defaults

It may be required to reset the original factory defaults. This can be done by navigating to the Archive menu, and selecting the Default submenu

Defining the motor

The first step in setting up the drive, is to define the motor, to the drive software. This is done through a test called the AC test. By pressing the ENT button several times, the setup menu may be selected.

Defining the motor

AC Test can be found on setup menu #4. When ENT is pressed, AC Test is selected. The drive begins asking the operator about the motor.

Defining the motor

The questions that are asked, can be found on the nameplate of the motor. Make sure that the taps of the motor are noted. Motor voltage will be requested in another screen.

Defining the motor

On these screens, enter the correct information from the name-plate, by pressing the digits on the key-pad. Ensure you select induction and NON MOVING test parameters for the LRP Unit. Ensure that the voltage entered reflects the taps on the motor. When the value is correct, just press ENT.

Defining the motor

Continue entering information as the screens prompt. Enter the nameplate frequency. Enter the nameplate amperage. Ensure the correct current is selected for the motor taps.

Defining the motor

Enter the nameplate RPM. If the drive is a model 1130, or a model 1230, answer the Regen/DB question yes. If there is a DB resistor connected to the drive, answer this question yes. For an LRP unit this will always be a yes.

AC Test with DB connected

In LRP unit installations, a resistor is connected to the DB output to absorb regenerated energy, and prevent DC Bus overvoltage. If this is connected, DB should be chosen for this test by entering 1 for yes.

Running the test

By selecting the first choice (startup), all of the tests are performed one after another. The drive will ask for the operator to turn the motor on. Ensure that a motor on switch is made, along with the run enable switch.

Other options
If a single test needs to be performed, these may be chosen individually. Most testing can be done with the startup option.

Non-moving completion
This completes the motor startup for the LRP installations. Control options may now be set up. (Speed pots, transducers, communications, etc.)

Navigating the drive

The two methods of navigating the drive are; directly off the keypad/display, and via UEdit . Refer to the UEdit PowerPoint, and/or quick reference guide for information on setting up, or using UEdit. Refer to the keypad guides (one may be found in the software document), for information on navigating directly from the keypad/display.

Quick start
Follow Quick Start Guide. Using this guide enter all values listed for well parameters. Enter Gear Ratio. Enter Pumping Unit information. Enter DB. The Quick Start menu has most of the values that can be used for basic startup.

UEdit Quick Start

At the right, is an example of how the Quick Start menu appears in a UEdit view. Completion of the Quick Start items will allow enough information to allow basic well operation.

Stroke ID
See Quick Start Menu: Set Stroke ID Enable parameter to ENABLE. Briefly turn motor on. Verify that the unit direction matches the LRP Sub State message. Turn motor off quickly. If direction is wrong, change Torque Invert setting. Set Stroke ID Enable to OVERRIDE. Set Stroke ID Length to the value printed on the LRP Label (Total Stroke).

5. Clamping polished rod

5.1 Place the polished rod spacer over the polished rod, then firmly attach the rod clamp against the rod spacer. Caution: Be sure the polished rod clamp is tightened to the correct torque for the rod string weight.

6. Install Proximity Switch

6.1 The proximity switch is installed into the hole on the side of the LRP pinion box. The switch should be threaded in until it stops (touches the rack). The switch must then be backed out 3 to 3.5 full turns. If using ATEX switches then 5 to 6 turns may be necessary. Lock in place with the second locking nut.

7. Install LRP top cover

7.1 Place the top cover over the polished rod and tighten with a strap wrench. 7.1a If the top cover is the new style then it is a twist lock system. In this case grasp the handles on each side and twist until it is locked in place.

Open gearbox vent

8. Connect proximity cable

Connect the proximity switch to the drive using the supplied cable according to the electrical schematics. It is suggested that the proximity cable and the motor phase leads be run in separate conduits, to reduce electrical crosstalk.

9.

Finish installation

9.1 Remove rod clamp from stuffing box. The rod weight is now supported by the rod clamp above the LRP rack.

Well ID test
The Well ID test is done to calculate the whole system load, and the drives response to it. Parameters identified are Ref Position Up, Ref Position Down, Rod Friction, Rotary Inertia, Snug Auto Position Error, and Snug Auto Vel Error. The Well ID function may be selected from the Quick Start, or Well ID menus.

Well ID
Select Well ID enable, from either the DSP keypad, or Uedit, then turn on the motor. An early failure of this test is often caused by a mis-wire of the proximity switch.

Well ID Status
The Well ID takes approximately ten strokes. During this test Well ID Status will be In Progress, which indicates that the well Id is running properly. A No Ref Input, or No Ref Verify will indicate a problem with the Proximity switch wiring, or in more rare cases, a defective switch. An ID Abort message will be shown of the motor is shut off in the middle of the test. ID Complete will be displayed when the test is successfully completed.

Snug Torque Limit

During the Well ID test, the drive will command the motor to move the rack in a direction. When the rack hits a stop, the motor current will rise, until the Snug Torque Limit is detected. Failure of the unit to stop at a stop is either caused by a bad value in Snug Torque Limit, or a problem in the current feedback circuit.

Errors
If the unit does not operate as expected, look at the LRP Status on the Quick Start, or Pumping Unit menu. It may be necessary to re-run the Well ID. Motor On Normal Operation Ref Input Loss, indicates either a mis-wire of the proximity switch, or an appropriate value in Ref Window Tol. The Stroke ID Length could also be bad.

Errors
Position Error usually indicates a torque limit or mechanical bind. Snug Auto Pos Error, on the Pumping Unit menu could affect this. Velocity Error, is very similar to position error. This may also indicate operation over base speed. Max Gearbox Torq, either indicates an over torque condition, or a bad value in Snug Auto Max Gearbox Torq, in the Pumping Unit menu.

Errors
Min Gearbox Torq, indicates a torque value below the Snug Auto Min Gearbox Torq parameter in the Pumping Unit menu. This could also indicate a mechanical issue. Snug Fault, indicates that the motor did not stop during the snug-up reference process. Check for possible rack disengagement from the pinion. Power Loss, indicates that the power dropped below the Power Loss Bus Level. This could indicate either a bad setup value, or a power issue.

Specifics
Enter a value that makes sense for the installation in Up/Down Maximum spm, and Up/Down Minimum spm, in the Quick Start, or Pump Speed menus. Choose weather the speed select is to be from the keypad, or a control pot. This can be selected from Up Speed Select, and Down Speed Select on the Signal In menu. Set the Speed Mode Select to Single Speed in the Quick Start, or Pump Speed menu.

Specifics
Verify Power Loss Bus Level , and Power Loss Bus Tol, on this menu. If the voltage drops below setup tolerance, the system will assume a power-loss, and return to the parked position.

Linear Rod Pump

8.2 Complete drive startup procedure See 806434.xxx for the complete startup procedure of the LRP unit and drive.

Setting up the drive to a well

This completes the basic mechanical, and electrical setup of the LRP system. The next steps involve defining the well mechanics, and well formation details to the drive. This is done, to allow the drive software to build a model of the well, for optimizing, and other site needs.

Basic vs. Enhanced setup

In any basic setup, enough drive parameters are defined to allow for the well to operate. In an enhanced setup, more parameters are selected to allow for more automated operation. It is normal practice to begin with basic setup, then add in functions as the need is determined.

Low Speed Testing

Plot and verify dynacards. Ensure the gearbox efficiencies make sense, and the gearbox torque loads, are not exceeded. See the Exhaustive startup guide for dynacard, and charting details.

Adjusting frictions
If the stuffing box friction is excessive, this screen will allow you to compensate. Make sure auto friction is enable The rod/pump makeup geometries may be adjusted here as well.

Pump Fill Monitor

Verify that the pump fill values make sense. If they do not, the cause is probably incorrect settings in the down hole information. Correct as needed.

Optimizer
If the previous information looks good, then choices may be made to the final set-up of the well. Many final set-ups are set to optimize. The set-up screens for the optimizer is shown on the right.

Bridle control
Bridle Control detects rod float in the event the rod does not descend as fast as the rack. This option may be set up in the Control menu, shown at the right. This helps to reduce the mechanical slamming caused by heavy fluids, or deviated wells.

Set up Desired Fault Checks

Maximum Rod Load? Maximum Pump Load? Etc. The Fault/Event menu allows setup of all the faults that are detectable by software.

Setting the calendar

Setting the calendar to the correct date in time, helps identify faults and event order with respect to outside influences. This is set-up from the Help menu, sub-choice Calendar.

Calendar
The calendar can be monitored from UEdit, but not set. Other time based functions can be set from this screen.

Run Well report

If not already set-up, install the WPR files on your computer. When running the WPR, set Excel to Medium security, and allow Macros. The well report generator collects data on the operation of the well, and has a Predicted dynacard screen. This Predicted dynacard screen can be used to verify the proper set-up of well parameters, by comparing to actual cards collected.

Archiving/Store to flash
Use the Data/Archive function of UEdit to collect a final archive of the installation. Store parameters to flash, from the keypad, by selecting Archive, then Store. The drive will ask two questions. Default data items on recall. Select No Recall if NVmem error. Select Yes. The drive will now reset. In the event of a loss of data, you now can select Recall, to restore your work.

Further information
Additional details can be found in the following documents. Software documentation (805661.xxx or 806434.xxx for LRP) LRP Quick start guide. LRP Exhaustive start guide. These guides can be found on the CD that is sent with the units. Additional copies can usually be e-mailed.