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375 ESP Sensor User Manual

375 ESP Sensor

User Manual
Ver 1.0
Applicable Equipment

375 ESP Sensor (150 and 175°C Versions)

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375 ESP Sensor User Manual

Document Information
Document No. 279-38-002
AL Monitoring
Document Ref. 375 ESP Sensor User Manual
Version No. 1.0
Date 18/12/2018
Created By Johnny Clark
Approved By Donald Jamieson

User Manual Version History

Version Issue Date Description By App.

1.0 18/12/2018 Initial Release JC DJ

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Safety Warnings and Information

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Brief

This manual is specifically for the RMSpumptools downhole 375 ESP sensor. While other products
are mentioned in this manual, there is separate documentation for each mentioned product, that
includes specific installation and operational information. The document numbers for these manuals
can be found below, and may be requested from RMSpumptools

Document Number Description

279-38-001 Surface Equipment User Manual
279-38-002 375 ESP Sensor User Manual
279-38-003 DataLITE User Manual
279-38-004 TransCVR User Manual

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Document Information .......................................2 Sensor Measurement Error .......................... 31

User Manual Version History ..............................2 Shorting Ring .................................................... 32
Safety Warnings and Information .......................3 Method A: Pre-Fitted Suitable Wire ............. 32
Brief ...................................................................10 Method B: Splice........................................... 33
Overview ...........................................................12 Sealing Boot Assembly...................................... 34
Dimensions....................................................13 Before Starting.............................................. 34
Functional Description ......................................14 Compatibility ................................................ 35
Callout ...........................................................14 Seal Fit .......................................................... 35
High Voltage Lead .........................................15 Re-Use of Boots ............................................ 36
Sealing Boot Connections .............................16 Step 1: Fit Boot to Wire ............................ 36
Pressure Connections ...................................17 Step 2: Insulator........................................ 37
Single Pressure Connection ..........................17 Step 3: Spring Crimp ................................. 37
Temperature Probe.......................................17 Step 4: Lock in Place ................................. 38
Discharge Pressure........................................18 Discharge Pressure ........................................... 39
Motor Oil Temperature.................................19 Pressure Take-off .......................................... 39
Motor Winding Temperature .......................20 Capillary Line Connection ............................. 40
Vibration Measurements ..............................21 Capillary Line Protection............................... 40
Diagnostic Measurements ............................21 Running in hole ................................................. 41
Additional Data .............................................22 Preparation ................................................... 41
Insulation Testing ..............................................23 Motor Ohms ................................................. 41
Test Voltage ..................................................23 Insulation Testing ......................................... 41
Test Lead .......................................................23 Bullnose and Centralisers ............................. 42
Tester Polarity ...............................................24 Motor Pick Up ............................................... 43
Testing ...........................................................25 Discharge Line Installation ............................ 44
Function Testing................................................26 Capillary Line Test ......................................... 47
Test Lead .......................................................26 Function & Insulation Testing ....................... 48
Function Checks ............................................27 Ground Fault ................................................. 49
Ground Fault .................................................28 Open/Cable Fault .......................................... 49
Open/Cable Fault ..........................................28 Sensor Fault .................................................. 50
Sensor Fault ..................................................29 Removing from the motor ............................ 50
Low Insulation ...............................................30

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Overview
Designed for the most demanding well conditions, the RMSpumptools ESP Sensor is a robust tool
that provides accurate measurement of:
 Discharge Pressure (data2 model only)
 Intake Pressure
 Intake Temperature
 Motor Oil Sump Temperature
 Motor Winding Temperature
 Vibration on 3 axis (X, Y and Z)
 Current Leakage

The ESP Sensor offers two continuous temperature ratings, the standard offering is 150°C and the
High Temperature (HT) model provides a 175°C upper limit.

Each RMSpumptools ESP sensor undergoes a rigorous test programme prior to being shipped to
ensure that each sensor is ready to be installed, with confidence, by our customers.

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Dimensions

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Functional Description

Callout

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High Voltage Lead

Supplied with the Sensor is a length of HV, with an unfitted boot kit. You can splice this wire to a
wire from a shorting ring, fit a different boot kit to your shorting ring’s wire or fit the supplied boot
kit to your wire (if compatible). See section 6 “Sealing Boot Assembly” for instructions to fit boot kit.

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Sealing Boot Connections

All 3 connections use sealing boots. The wire AWG and outer insulation must be correct for the boot
kit. Ill-fitting boots will cause premature loss of data.

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Pressure Connections
On the neck of the discharge sensor are two identical looking pressure ports: well pressure and
discharge pressure.

You can tell which port is which by is looking at the stamping next to each port (Pi and Pd.
The discharge line connection is made up of a 1/8” NPT to 1/4” tube fitting.
You can confirm both the intake and discharge pressure range by connecting a TransCVR and waiting
for the sensor manufacture information to be sent to surface.

Single Pressure Connection

If your sensor has only a single port on the sensor neck, then discharge pressure is not fitted.

Temperature Probe
A 1m long probe is supplied with the sensor.
Boot kits are also supplied with the probe and are to be fitted during installation if thermocouple is
not pre-fitted to motor.
The probe is polarity sensitive and the connection plate shows how to connect.

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Discharge Pressure
The second pressure port is typically connected to pump discharge (it may be left open to the well to
give a 2nd well pressure measurement). It is an NPT port on the neck of the sensor and connects to
any remote pressure point using 1/4” OD capillary tube.

If no capillary line is fitted then this second pressure will measure a second well pressure.

On the neck of the sensor the second pressure is the right most port when looking directly at the
rating plate when the sensor is upright.

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Motor Oil Temperature

Every sensor is fitted with a motor oil temperature probe. This measures the temperature
approximately 2” above the bottom of the motor sump.

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Motor Winding Temperature

Typically, you will use the J-Type thermocouple method. Highest accuracy uses the RTD probe.

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Vibration Measurements
Each sensor measures vibration in all 3 axis: x, y, z. This is translated to the Rotational and the
Longitudinal vibration.

Diagnostic Measurements
The sensor gathers a large number of diagnostics inside the sensor including the various
temperatures on the circuit, the level of voltages, amount of current flow and the temperature of
the two pressure transducers.
Diagnostic information is available via Modbus from the Transceiver and is recorded in logs
generated by the TransCVR.

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Additional Data

Category Format
Part Number Manufacture Detail XXXX
Serial Number Manufacture Detail XXXX
Firmware Manufacture Detail XXXX
Max Well Pressure Manufactured Rating XXX psi
Max Discharge Pressure Manufactured Rating XXX psi
Max Temperature Manufactured Rating XXX°C
Service TAG Tracking Reference XXXX

These are sent to surface when the sensor is powered to allow tracking and quality assurance
procedure compliance.

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Insulation Testing
Test Voltage
The Sensor can be insulation tested up to 5,000 VDC.

Test Lead
Never connect an alligator clip or test lead directly to the Sensor. This can lead to pin damage. A
loose test clip can also disconnect and made contact with the Tmwt pins damaging the sensor.

Use a Test Lead comprising a length of wire with a crimp fitted on one end.

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Tester Polarity
First check polarity of your insulation tester.
Connect your insulation tester to a multi-meter and set the tester range to within the range of the
multi-meter (e.g. 250 V). Connect red to red and black to black.
Now test: switch on your insulation tester.
If the multi-meter says “+” (or shows no polarity) then red is positive. If it shows “-” then red is
negative.

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Testing
Connect +ve to the Sensor chassis and negative to the High Voltage Lead (or cable) when insulation
testing.

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Function Testing
Test Lead
Never connect an alligator clip or test lead directly to the Sensor. This can lead to pin damage. A
loose test clip can also disconnect and made contact with the Tmwt pins damaging the sensor.

Use a Test Lead comprising a length of wire with a crimp fitted on one end.

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Function Checks
With the specification known we recommend a function test:
 well pressure
 discharge pressure
 motor winding temperature

These check the calibration and, importantly, checks sealing of the discharge port connection and
that you have the motor winding temperature probe fitted the correct way.

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Ground Fault

If you receive a Ground Fault LED warning on the Transceiver (or on the Display) there is a phase (or
the motor wye point) connected to ground. This may be a
cable fault
splice fault
water ingress to motor

The completion needs to be pulled and the problem rectified. Confirm the fault using your insulation
tester.
Check that the cable phase is not grounded at the test lead. Check that one of the other phases is
not touching ground and causing the fault. Check that your Test Box (or Transceiver) is working by
testing with a Simulator.

Open/Cable Fault

A Cable Fault indicated on the Transceiver indicates the Transceiver cannot connect to the Sensor.
This is most likely to be that a test lead is disconnected although may be the wye point is
disconnected or the cable from the wye point to the motor is disconnected.
Check that the test leads are making good contact with the cable armour and the cable phase. Check
that your Test Box (or Transceiver) is working by testing with a Simulator.34

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Sensor Fault

When the insulation to ground is good and the Sensor is detected by the Transceiver you may still
get a Sensor Fault. This requires the Sensor to be replaced and serviced.
Check that your Test Box (or Transceiver) is working by testing with a Simulator.
Service any Sensor which indicates a Sensor FAULT on the display or transceiver.

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Low Insulation
Should you read a low insulation either using an insulation tester or the display (or transceiver)
indicates a Ground Fault you should first remove the Sensor and re-test.
Once the adapter is separated from the motor you should remove the Motor Shorting Ring and
ensure it is not touching the Sensor chassis. Now re-test: a pass suggests the Motor Shorting Ring
has a fault.
Next inspect the High Voltage Lead for damage.
You may wish to cut the High Voltage Splice out and check the Sensor directly without the Motor
Shorting Ring attached.

If the problem persists your Sensor should be serviced.

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Sensor Measurement Error

Should the Sensor pass all the tests (good insulation, data received, Sensor recognised) and you feel
the measurements require re-calibration the Sensor should be serviced.

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Shorting Ring
Method A: Pre-Fitted Suitable Wire
Your Shorting Ring may come with a wire moulded-in. If the wire is not suitable for the HV boot kit
supplied you must splice the Shorting Ring wire to the wire supplied with the sensor: refer Method
B, Splice.
Your wire must meet these specifications:

Dimension
Insulation OD 0.14” (3.5mm)
Wire AWG 18AWG

Each sensor comes with a boot kit pre-fitted to a length of wire plus a spare crimp. To re-use this kit,
first cut off the crimp. Now slide off the insulator and the boot.
Fit the boot kit to your molded-in wire (refer section on Connector Assembly).

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Method B: Splice
If the wire from your Shorting Ring is not long enough or has the wrong OD/AWG you should splice
on the length of wire supplied with the sensor.
The sensor includes wire and a boot kit, which must be fit to the wire before connection.

You will have to ensure this is a strong, well-insulated splice. This is a high voltage connection and
you need to make this barrier to prevent wet sump fluid entering here and resulting in a ground
fault.

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Sealing Boot Assembly

Three rubber boots used with each Sensor: 1 high voltage, 2 low voltage (for motor winding
temperatures). These are sealing rubber boots and a seal is created between the wire and boot and
between the boot and the connector pin.
Boot kits are supplied by Greene Tweed.
The crimp tool is specialist and manufactured by Daniels Manufacturing Corporation.

Before Starting
Make yourself familiar with the parts.

Wire
Your motor winding temperature wire or wire from the motor shorting ring. The boot kits used
MUST be correct for both the wire AWG and the outer insulation diameter.

Rubber Boot
Flexible rubber boot which must be selected to suit not only the pin but also the wire’s outer
insulation diameter.

Insulator
A white PTFE insulator required to maintain the high voltage operation of the connector system. It
must be used.
Low voltage connectors (for motor winding temperature) may be supplied with or without the
insulator. If supplied they must be used.

Crimp
This has to be selected to suit the AWG conductor size of the wire. One end is for the wire and the
other connects onto the pin.

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Compatibility
Wire AWG and outer insulation must be correct for the boot kit. Ill-fitting boots will cause premature
loss of data and could lead to premature ESP failure if the HV boot fails on a grounded ESP system.

Seal Fit
Boot kits are designed to seal in two ways. First, they are to seal between the outer insulation of the
wire and the boot. Second, they seal between the boot and the lower metal of the connector pin.
If there is not a seal between the wire’s outer insulation and the boot you will eventually get a fault.
You will find that putting the boot over the wire is difficult. Use lubricant on the wire or heat the
boot up if it is cold but NEVER
 drill out the boot
 scrape insulation from the wire
 use a loose-fitting wire

Should the high voltage boot seal fail you will likely get a ground fault when wet sump fluid settles in
this area. This may simply cause loss of Sensor data or may cause catastrophic pin damage requiring
Sensor rebuild.

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Re-Use of Boots
If the boot is still connected to the wire you can re-use the boot. Simply inspect for damage and
replace if it has become hard, brittle or appears no longer to be sealing the wire or “clicking”
securely onto the connector pin.
If the boot (and associate crimp and insulator parts) have been removed and are used our
recommendation is to replace with a new kit.

Step 1: Fit Boot to Wire

First, strip a lot of insulation and put this through the boot. Lubricate (silicon grease, motor oil) the
outer insulation of the wire.
Next twist the bared conductors onto pliers and use this to firmly grip the wire whilst twisting the
boot over the insulation.

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Step 2: Insulator
With the boot on the wire push the white insulator block into the boot. This should be a close but
not tight fit on the insulation.

Step 3: Spring Crimp

Trim the bare conductor to the length required for the crimp (check the length by trimming and test
inserting into the crimp - the insulation should touch the end of the crimp).
Crimp using the DMC crimp tool.

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Step 4: Lock in Place

With the crimp securely on the wire, pull firmly on the wire to pull the crimp into the white insulator.
It will click in. Finally, keep pulling until the white insulator block is locked into the boot.

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Discharge Pressure
Pressure Take-off
If your sensor comes with Discharge Pressure, then you will connect a capillary line from the sensor
to a discharge pressure take off. This will be located above the pump discharge.

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Capillary Line Connection

All sensor pressure ports (intake, discharge, test cap, body seals) use a 1/8” NPT fitting. PTFE tape
should be applied to the NPT thread before fitting to sensor.

Capillary Line Protection

You will likely use MLE Protectolisors during the ESP installation. This is the preferred method for
protecting both the MLE and the 1/4” discharge pressure capillary line. A range of Protectolisors are
available from RMSpumptools.
Once the capillary line is at the pothead you can run the line to the side of the MLE. If you use
Protectolisors at the ESP flanges, then you need to have these designed to accommodate the
capillary line.
When fitting Protectolisors it is essential that the capillary line runs alongside the MLE and does not
cross over or under it at any point. If cable bands are used, then the same care should be taken.

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Running in hole
Preparation
The Sensor will normally have been fitted to the motor and tested before shipping to the well-site. If
you are fitting or replacing a Sensor on a well-site take extra precautions - you are working with high
voltage electrical connections which will, when installed, be under pressure, be at high temperature
and submerged in sump fluid which, potentially, will be wet.
On site you need to service the motor through the Sensor adaptors Drain & Fill Port and conduct
multiple insulation and function tests.

Motor Ohms

Insulation Testing
Refer “Insulation Testing”.

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Bullnose and Centralisers

On the bottom of the sensor is a 2 3/8 EUE 8R Short Box connection. When attaching tubing to this
connection make sure to grab the very bottom of the sensor. Fit this either with the sensor vertical
or horizontal.

There is a threaded connection between the housing and the sensor base and you must exercise
caution to not unscrew this. Also, gripping on the housing may cause damage to the housing and
cause loss of sealing.

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Motor Pick Up
Pick up the motor as normal - no precautions are required other than those customary for motor
pick up.

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Discharge Line Installation

If your sensor has discharge pressure installed, then you will need to connect a capillary tube from
the sensor to the pump discharge.

You can pre-fit the tube fitting to the capillary line. Make sure to fit the ferrules correctly.

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On site, secure the tube fitting into the discharge pressure port. The sensor’s discharge port should
be lined up to the side of the motor pothead. This will mean the hydraulic line will run alongside the
MLE. When using a Protectolisors please ensure that the MLE and capillary line are situated
correctly.
If banding is being carried out, when you reach the pothead you should run the capillary alongside
the MLE and secure it in the same bands or centralisers if you use them.

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Capillary Line Test

Now, pressure test the line and connection into the sensor by connecting a hydraulic test pump to
the opposite end of the capillary line.
Connect a Test Box and record the pressure measured.

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Function & Insulation Testing

Use an Insulation Tester and an RMSpumptools Test System to check the Sensor before and during
running-in-hole.

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Ground Fault

If you receive a Ground Fault LED warning on the Transceiver (or on the Display) there is a phase (or
the motor wye point) connected to ground. This may be a
 cable fault
 splice fault
 water ingress to motor

The completion needs to be pulled and the problem rectified. Confirm the fault using your insulation
tester.
Check that the cable phase is not grounded at the test lead. Check that one of the other phases is
not touching ground and causing the fault. Check that your Test Box (or Transceiver) is working by
testing with a Simulator.

Open/Cable Fault

A Cable Fault indicated on the Transceiver indicates the Transceiver cannot connect to the Sensor.
This is most likely to be that a test lead is disconnected although may be the wye point is
disconnected or the cable from the wye point to the motor is disconnected.
Check that the test leads are making good contact with the cable armour and the cable phase. Check
that your Test Box (or Transceiver) are working by testing with a Simulator.

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Sensor Fault

When the insulation to ground is good and the Sensor is detected by the Transceiver you may still
get a Sensor Fault. This requires the Sensor to be replaced and serviced.
Check that your Test Box (or Transceiver) is working by testing with a Simulator.

Removing from the motor

Care must be taken when removing the sensor from the ESP in any circumstances.

- Each RMSpumptools sensor has six captive bolts for mounting to the motor crossover
(unless otherwise specified)
- Remove these bolts from the crossover threaded holes

o Do not fully remove the bolts during removal of the sensor

o They should back out of the holes on
the crossover, but be retained in the
sensor flange by the captive threads
o Make sure all bolts are completely
removed from the crossover before
attempting to remove the sensor

- Once all the bolts are free of the crossover, pull the sensor out gently and evenly
o Do not allow movement of the sensor in any direction other than concentrically with
the motor

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o The O-rings may provide a lot of resistance

- When the sensor comes loose, keep it concentric with the motor with a couple of inches
between the flange of the sensor and base of the crossover

o This should expose the thermocouple and power wires

o While safely supporting the sensor, gently pull the boots off the pins
o Do not bend or apply lateral force to the boots, as this may break the pins

- Once the wiring is removed clean up the sensor flange and connections and replace the
shipping cap that was provided with the sensor.

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