Sure Stroke Intelligent LiftTM Systems

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Operations Manual

SSi –WI-019. Rev 0

 TABLE OF CONTENTS

1. Components of the SSi Lift

2. Control Panel
3. Touch Screen
4. Log in Screen
5. Set speed and Cycle
6. Alarm history, Warnings and Counters
7. Set pump off control parameters
8. Balancing the Unit
9. Tracking the pumping unit back
10. Tracking the pumping unit forward to operation position
11. Orientation

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1. Components of the SSi Lift
 The pumping unit stands over the wellhead and attaches to the polished rod.
 The power unit provides the logic and controls for the pumping unit.

Image 1: Pumping Unit and Power Unit

Components of the pumping unit

 Counterweight chamber (CWT). Only one chamber is found on model 250 and two on the
larger units.
 CWT actuator valve with nitrogen fill/bleed port for balancing
 Sight glass on the CWT
 Three chambered hydraulic cylinder

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  Up and down cylinder bleed ports
 Automatic lubricators
 Pulley assembly
 Celesco chain (position sensor)
 Wire rope cables and carrier bar
 Cable break sensor
Components of the Power Unit
 Hydraulic cabinet
 Electrical and communication cabinet
 Control panel
 Touch screen
 Main circuit breaker

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2. CONTROL PANEL

JOG/RUN JOG UP/DOWN

This switch changes the unit With the Run/Jog switch in Jog Mode, move
from Run mode to Jog mode for the lever in direction you want to jog. (This
manual operations. switch is spring loaded to the off position)

WARNING RESET
START/STOP/RESET
(PULL OUT TO RUN, PUSH IN TO STOP) Reset warnings and to reset
hydraulic max pressures and
This red mushroom button is for manually starting rod load
and stopping the unit. It also reset any warnings
when pushed in.

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3. TOUCH SCREEN
 The touch screen is located on the power unit above the control panel
 With a 460 volt power supply to the power unit and the main breaker on, simply touch the
screen to activate it
 On the bottom left corner of the screen, one will see the directory button (Fast Sel)
 There are fifteen different screens available to be displayed

Image 3: Directory page on the HMI (human machine interface)

 The operations screen will be the main screen one will use on a regular basis. Use this screen
for:
o Balancing the pumping unit
o Checking stroke length and strokes per minute (SPM)
o Monitoring rod load

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 o Hydraulic oil temperature

Image 4: Operations page on the HMI

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4. LOG IN SCREEN

Image 5: Log in screen on the HMI; entering password

 Push LOG IN.

o Enter 121 for the ability to change speeds or stroke length
o Enter 131 for full data entry capability

*Time out will occur within 20 minutes.

Image 6: Log in screen on the HMI

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5. SET SPEED AND CYCLE
For normal day to day operation unit should always be in the Auto Command (Auto Active). With unit in
Auto and the Max Auto Height and the Min Auto Height values inputted the Top and Bottom Decel
Points will automatically adjust to constantly stop at the Max and Min values.

Note: To run the unit in manual please contact your local SSi Service Technician for further assistance.

To adjust the speed touch the up or down speed number and then once the new value is entered press
Enter New Speed while unit is in that part of the stroke i.e. to change the up speed enter the new speed
during the up stroke.

Image 7: Set speed and cycle on the HMI

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6. ALARM HISTORY, WARNINGS, COUNTERS AND SET POINTS
Functionality of other screens

 Jog Control - This screen performs the same function as the control panel, just on a touch screen
 Set Time and Date - Should only have to be set at start-up, time changes or after a long period
of a power outage
 General Set Points, Set psi Alarms, Set Load Alarms - These settings should only be altered with
the help & recommendation of an authorized Sure Stoke Intelligent Lift™ Systems technician
 Alarm and Warning History – Helps diagnostic why the unit is shut off for troubleshooting
purposes

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7. SET PUMP OFF CONTROL PARAMETERS

Image 8: Pump of Control (POC) on the HMI

Built into the program of the SSi power unit is the pump off configuration. One will find access to the
POC on the directory of the touch screen. To properly use the POC, one must log in and have a good
understanding of the pumping unit, downhole equipment and the well formation.

The downhole pump is equipped with two valves; a standing valve which is designed to hold pressure
from above while allowing fluid to flow from below. A travelling valve which closes the barrel chamber
allowing the trapped fluid to be lifted on the upstroke.

When the plunger begins to travel downward, the travelling valve contacts the trapped fluid in the
pump. When the force inside the pump exceeds the force of the fluid column above, the travelling valve
opens. Therefore the SSi POC is set by monitoring the rod load on the down stroke and the use of the
load graph located on the touch screen.

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 Image 9: Pump card

On the dynacard, the highlighted area in yellow is the upstroke and the remaining portion is the down
stroke. One can see on the fill pump card the load drops off at the end of the upstroke and on the pump
off card, the pumping unit is carrying the load on the down stroke. The value that needs to be entered
on the SET PUMP OFF ROD LOAD, is the amount of rod load being carried down; this value can be
obtained by the load graph or by looking at the operations page monitoring the rod load on the down
stroke. The value needed to be entered in SET POC CHECK POSITON is where the stroke length one
would like the rotary encoder to checked.

Example: If one selects 220 inches while the unit is travelling downwards, it will check the entered rod
load valve at 220 inches. This position is also displayed on the operator’s page of the touchscreen.

When this value is found at the position at 220 inches, the pumping unit will slow down to its lowest
speed in the VFD on the down stroke allowing more time for pump fill. Depending on production, one
has the option to count the number of consecutive POC stroke before stopping. The number of stop
minutes is also programmable through the touch screen.

If one wishes to not monitor the POC, enter 9999 on both of the values on the SET PUMP OFF ROD LOAD
and SET POC CHECK POSITON of the POC touchscreen.

Helpful Hint:

When well is in a pump off condition, watch the rod load and position values on the operations page
and watch the actual rod load being carried down until the travelling valve opens. (Rod load well will
decrease by several thousand pounds. At that moment check the position reading and it will help
determine exactly how much fluid is actually in the pump.

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8. BALANCING THE UNIT
 Check the balance by accessing operations screen located on the power unit’s touch screen

 Watch the up hydraulic psi and the down hydraulic PSI. Take note of the peak up psi and peak down
PSI
 If the peak up hydraulic psi is greater than peak down hydraulic PSI, you will need to add nitrogen to
the CWT Vessel
 To add nitrogen:
 Connect the balancing hose located in hydraulic cabinet of power unit
 Connect hose to nitrogen bottle before connecting to the CWT Actuator valve
 Carefully discharge some nitrogen through the hose to ensure hose is clear of debris
 (Note: aim hose away from yourself to avoid possible injury)
 Connect the hose to the CWT vessel
 Add nitrogen until the down hydraulic psi is approx. 200 PSI greater than the up hydraulic
PSI
 Over balance situation occurs when the hydraulic down psi reaches 2400 PSI and alarms the
pumping unit
 To correct this situation, simply bleed nitrogen from the CWT chamber through the
fill/Bleed port

* In the northern climate, due to temperature variations, a slightly higher value on the down hydraulic
psi helps maintain a proper balance.

**On start-up higher casing levels will require less force to lift the fluid, as the level decreases the load
will increase.

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9. TRACKING THE PUMPING UNIT AWAY FROM WELLHEAD
When service work is required to be performed on the well:

 Stop the pumping unit approximately midway by switching from run to jog on the control panel

 Jog down until the hydraulic cylinder is retracted as much as possible

 Push in the red stop button. It is normal for the cylinder to spring back up, due to counterweight
pressure to well load ratio.

 To ensure that stored energy or electrical energy will not cause the hydraulic cylinder to move in
either direction the following steps must be taken:

 Follow all your companies lock out/tag out procedures

 Disconnect the counterweight actuator solenoid
 Shut off main circuit breaker
 Check or install lower polished rod clamp, so that it is capable of holding the load of the
polished rod and prepare the stuffing box to receive the load
 Slowly open the Fill/bleeder valve located on the counterweight actuator valve to bleed off
nitrogen pressure, lowering the hydraulic cylinder and the carrier bar
 Slowly bleed the nitrogen off, the carrier bar should come in contact with the lower rod
clamp and stuffing box. Continue until all nitrogen pressure has been released
 Close the nitrogen fill/bleed valve
 Reminder: Follow all companies lock out/tag out procedures. Remove the pin on the
carrier bar to allow you to detach the carrier from the polished rod. Exercise caution when
removing the carrier bar from the polished rod, ensure that the rod rotator does not slide
down the polished rod with the potential of injuring yourself or a fellow workers
 Swing the carrier bar away from the polished rod and attach it to the base of the pumping
unit
 Clean the tracks of the skid rails and lubricate; Recommended a silicone spray or dish soap as
it does not attract a lot of dirt
 Remove the safety chains that attach the base legs to the front of each skid rail
 Connect a winch cable/chain come along to the lug at the bottom rear of the CWT chamber
 Connect the opposite end to the anchor point provided at the rear of the center pier or I
beam

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  Slowly pull the pumping unit back in short increments until the pumping unit is within one
foot of the end of the skid rail

GUIDE RAILS

WINCH

Image 10: SSi model 400; top view

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 Image 11: Accessibility to a service rig with our unit tracked back

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10. TRACKING THE PUMPING UNIT FORWARD TO OPERATING POSITION
 Choose a suitable anchor point in front of the well head

 Attach the winch cable/chain come along to the connection points on the front of the pumping
unit v-base

 Attach opposite end to approved anchor point – i.e. Service rig

 Slowly pull the pumping unit forward until the adjustable legs rests against the V block. Stop.

 Re-attach the safety chains at the front of each base leg

 Re-check alignment of pumping unit; confirm hydraulic cylinder’s level. Note: Settings in PLC
may have to be changed if down hole pump size or rod configuration has been changed

 Slide the rod rotator up the polished rod creating room for the carrier bar. Re-attach the carrier
bar to the polished rod and secure it with the pin

 Check that upper rod clamp to be torqued correctly

 Ensure both ball valves on the hydraulic cylinder are opened

Never add nitrogen to the system with the up and down hydraulic valves in the closed position.(
Located on the pumping unit, equipment failure will occur)

 Connect the nitrogen balancing hose to a nitrogen cylinder

 Before connecting balancing hose to counterweight fill/bleed valve, discharge some nitrogen
through the hose to ensure there are no containments in the hose

 Connect balancing hose to fill/bleed valve. Slowly add nitrogen, the hydraulic cylinder will start
moving upward. Stop when carrier bar comes in contact with the polish rod clamp

 Check rod rotator alignment to rod rotator actuator

 Check carrier bar cable tension; ensure that the tension feels equal to the right and left side of
the polish rod

 Confirm carrier bar is levelled

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  Continue to add nitrogen until the carrier bar is approximately midway through the up stroke

 Re-install the counterweight actuator solenoid electrical connector

 Check to make sure the red stop button is in

 Switch the main circuit breaker to the on position

 Set the control panel to the jog position

 Pull out the red stop button

 Jog the cylinder up and down to the capacity of the pumping unit to assure that the polished rod
length, rod spacing and pumping unit is performing normally

 Jog the unit several times before switching to run mode

 Confirm the unit is in auto mode

 Check the unit for balance in run mode and balance if necessary

For more information on operating, troubleshooting, and maintenance of the unit please
read the Sure Stoke Intelligent Lift™ Systems operators manual located in the door of the
electrical cabinet, or contact your local service representative.

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11. LEARNING CHECKLIST
Can the trainee operator locate or identify the following:

 The pumping unit

 The power unit
 The counterweight chamber
 CWT Actuator valve and nitrogen fill/Bleed valve
 Hydraulic oil sight glass in CWT chamber
 CWT oil return line
 Hydraulic up down cylinder
 Hydraulic up down ball valves
 Celesco position counter
 Automatic lubricators
 Reel Assembly
 Carrier bar
 Hydraulic Cabinet
 CWT actuator solenoid
 Hydraulic filter
 Electrical cabinet
 Main Electrical circuit breaker
 Control panel
 Stop button
 Touch screen
 Hydraulic cabinet

Is the operator capable of performing the following tasks:

 Starting and stopping the pumping unit

 Jogging the pumping unit up and down
 Changing the up or down speeds of the unit
 Altering stroke length with the top and bottom deceleration points
 Operate unit in manual and auto mode
 Performing data entries
 Balancing of the pumping unit
 Releasing the load and tracking back of the pumping unit
 Tracking forward the pumping unit and acquiring the load
 Setting POC mode

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