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ePIC Rod Pump Controller
Quick Links to Information Below
- Intelligent Rod Pumping Control for Production Optimization
- Exceptional Intelligence and Well Site Control with the ePIC Rod Pump Controller
- Simplified Setup and Maintenance with the ePIC Rod Pump Controller
- ePIC Rod Pump Controller Enhanced I/O Configuration
- Field-Proven Technology of the ePIC Rod Pump Controller
- Open Technology of the ePIC Rod Pump Controller
- Advanced Features of the ePIC Rod Pump Controller for Intelligent Control
- Specifications of the ePIC Rod Pump Controller
- ePIC Rod Pump Controller Expansion I/O Boards
| ePIC Rod Pump Controller Highlights |
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Controller commissioned with minimal effortPDF Documents
- ePIC Rod Pump Controller
- ePIC Rod Pump Controller - Portuguese Version
- ePIC Rod Pump Controller - Spanish Version
Intelligent Rod Pumping Control for Production Optimization
Access to accurate, timely information is the key to preventing an uninformed, costly decision. eProduction Solutions (eP) has developed the ePIC rod pump controller (RPC) as part of eP’s mission to provide improved decision making opportunities for operators of today’s oilfields.
The ePIC RPC is part of eP’s complete rod pump solution. eP provides the unique combination of intelligent hardware controllers, communication systems, advanced desktop analysis, training and support.
Exceptional Intelligence and Well Site Control with the ePIC Rod Pump Controller
eP's proven technology has been expanded and enhanced in the ePIC RPC to provide the following advanced functions:
- Well site alarms and system diagnostics.
- Selected pumping system alarms based on host analysis of well conditions.
- Card area alarms for deep rod part detection and downhole friction identification.
- Programmable Intelligent Control Language (PICL) which provides users the flexibility to modify the control mechanism to adapt to site and well specific conditions.
- Well site valve checks and CBE determination, available to host analysis systems.
- Improved data storage and trending.
- Enhanced data-logging function which allows any register to be logged and used in application logic.
PICL is a simplified way to create well site applications that provide well site intelligence.
- Event and time based control language.
- Read/modify any numeric parameter, execute command parameters.
- Integer math - add, subtract, multiply, divide, modulus.
- Logical operators - AND, OR, XOR, NOT. Both Boolean and binary (bitwise) forms available.
The controller, using patented automatic idle time optimization, can be used to continuously optimize cycle time, even adjusting for power outages, pump wear, tubing leaks or production “kicks”. Air balance control automatically balances pumping units. The peak energy control option can inhibit well operation during peak periods of higher energy costs. The power fail recovery method allows wells to pump down high fluid levels after power failures, and the motor restart protection function prevents motor restart when condensation is present on motor windings.
When a pumping system malfunction or alarm is detected either by the well site RPC or the host software, the controller can be configured to respond in a number of ways - from illuminating a flashing light on the controller box to shutting the well down. The ePIC clearly defines both the identified fault and the action taken by the controller so that the operator can quickly and easily analyze the situation. Time consuming trouble-shooting guesswork is eliminated.
Dynamic Interaction with Analytical Tools
The registers are all available for analytical tools to read and write. This makes the results of any program written in the controller available to host-based analytical programs. The accuracy derived from this architecture allows for more exact analytical control at the well site and more exact analysis at the desktop.
The ePIC gross fluid production calculation includes user-defined pump efficiency values for both deep and shallow wells as well as utilizing the calculated downhole pump stroke information from host software analysis of deep wells.
Simplified Setup and Maintenance with the ePIC Rod Pump Controller
- Improved and expanded well site configuration screens.
- New three step load sensor calibration method.
- Improved RPC interface access to “Energy Management” feature, communication diagnostics, continuous position sensor diagnostics, and load cell setup and diagnostics.
ePIC Rod Pump Controller Enhanced I/O Configuration
The ePIC includes programmable I/O for unique analog, meter, and discrete monitoring and control applications. With the ePIC, operators can fine-tune their wells using operational set points and are notified of load-based and other alarms immediately.
- Simple new I/O configuration menu.
- Improved analog I/O logging method.
- Auto-acting I/O functions provide easily configured control capabilities.
- Expanded event action options.
Field-Proven Technology of the ePIC Rod Pump Controller
eP is known worldwide for manufacturing and supporting reliable, stable, and accurate electronics. The ePIC rod pump controller takes the knowledge and experience gained from the CAC line of rod pump control products and combines them with new, innovative features to create a state-of-the-art RPC. Much of the ePIC technology is included in eP’s CAC product line currently used by over 22,000 wells worldwide.
With inventive manufacturing processes based on years of experience, eP has made this controller both robust and affordable. It provides the stability and durability needed for harsh operating environments without sacrificing the latest technological advances for advanced rod pump control.
Open Technology of the ePIC Rod Pump Controller
ePIC controls virtually any rod pumped lift system, including improved geometry pumping units, long stroke units (Rotaflex) and even wells using two stage downhole pumps.
Backwards Compatibility of the ePIC Rod Pump Controller
The ePIC RPC is fully compatible with all generations of eP RPC products. This design feature allows the ePIC to be installed using existing register configuration as a base. The configuration can then be expanded with the new features.
Software Interfaces of the ePIC Rod Pump Controller
The ePIC is highly integrated with many of the industry leading host-based monitoring and analysis software packages (i.e. Case Services csLIFT, Shell Services International, Theta XSPOC™, SOFS, etc.). It also can be integrated directly to HMI applications such as Wonderware and Intellution®. With multiple communication protocols available, eP’s ePIC is easily integrated into any host system.
Advanced Features of the ePIC Rod Pump Controller for Intelligent Control
| Features |
Benefits |
| Control |
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| Patented air balance control |
Automatically optimizes and controls air cylinder pressure on air-balanced units. |
| Peak energy control functionality |
Inhibits well operation during peak periods of high energy cost as determined by the operator. |
| Motor restart protection |
Prevents motor restart when condensation is present on motor windings. |
| Power fail recovery method |
Inhibits selected load alarms following a loss of power to allow a well to pump down a high fluid level. |
| Programmable (auto-acting) I/O |
Unique monitoring and control applications using analogs, meters, and discretes. |
| Multiple control methods |
Point or quadrant, for lower right or upper left hand portions of the surface cards, and reverse pump-off. |
| Automatic idle time optimization |
Improved determination of idle time adjusted for inflow based production. |
| Pump-up delay timer |
Eliminates immediate pump-off due to incomplete pump fillage following well idle time. |
| Monitor only mode |
Monitor dyno cards without regard for control set points or speed ranges. Ideal for dyno card generation with VFD controlled pumping system. |
| Works with all kinds of wells |
Companies can standardize on one controller for heavy oil, sand, deviated holes, etc. |
| Analysis |
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| Gross fluid or inferred production calculations |
Accurate estimates of total fluid production from shallow and deep wells without complex well site configuration. |
| Available ESP operating mode |
Allows the RPC to monitor submersible pump controllers. |
| System load analysis |
Host based detection of load cell drift on changing downhole conditions. |
| Cycle and run time buffers |
Easy access to historical data at the well site or using the host software. |
| Dynamometer card buffers |
Access to event cards (Full, Current, Shutdown, etc.) and several cards stored leading up to the event. |
| Expanded alarm features |
Host based alarms (torque, stress, pump efficiency, prime mover size, unbalance, etc.). |
| New stored card types and associated alarms |
Card Area Alarm; Excessive Card Areas; and Hi-Hi, Hi, Low-Low, and Low loads. |
| Alarm |
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| Extensive communications debugging capabilities |
Capable of analyzing data at the well site to diagnose data transmission problems due to faulty radios, etc. |
| System Configuration |
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| Improved well site configuration |
Simple menu for configuration, data management, system diagnostics, and load cell calibration. |
| Upgradeable modular hardware design |
Auxiliary I/O, communications, and local user interface options can be added in the field. |
| Flexible, expandable I/O |
Three options available to allow the best match for individual well site applications. |
| Backward compatible parameter structure |
Prevents incompatibility issues with older eP RPC equipment. |
| Basic three level password protection scheme |
Provides security for access to critical RPC setup parameters and well control commands. |
| Optional enhanced graphic display and keypad |
Menu driven user interface for configuration and review of system data including dyno cards, valve checks, and run times. |
| Available ESP operating mode |
Allows the RPC to interface to submersible pump controllers. |
| Local graphic display |
Provides readily understood messages relating to pump system conditions. |
| Digital rod load calibration |
Operator no longer has to manually adjust potentiometers to calibrate the load sensor. |
| Automatic beam mounted load calibration |
Simply enter the correct maximum and minimum loads, no complex multi-step program required. |
| Integrated “single package” design |
Simplifies installation with all components in one unit. |
| Rugged hardware design |
Manufactured to strict standards to ensure long life and reduced cost of ownership. |
| Sensor options |
Position switch, continuous position sensor, polished rod load cell, and beam mounted sensor. |
Specifications of the ePIC Rod Pump Controller
| Rod Pump Controller |
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| Enclosure |
NEMA 4 |
| Weight |
Approximately 22 pounds |
| Input Voltage Range |
120/240 Vac or 12 to 24 Vdc |
| Frequency |
47 to 63 Hz |
| Relay Output |
12 Vdc |
| Operating Temperature |
-40° to +185°F (-40° to +85°C) |
| Printed Circuit Boards |
Conformally coated to protect against moisture, H2S, and salt air |
| Communication Protocol |
Operator selectable, CAC 8500 native, Modbus™ RTU, or Modbus ASCII |
| Transient Protection |
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| Overvoltage/Transient |
Meets ANSI/IEEE C37.90.1-2989 protection specifications |
| Dynamometer Card Resolution |
Samples and stores load and position data at 20 times-per-second for downhole analysis |
| Analog-to-Digital Conversion |
Monolithic, successive approximation 12-bit A/D converter |
| Oilfield Sensors |
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| Clamp on Beam Load Transducer (Beam Sensor) |
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| Operating Temperature |
-60° to +212°F |
| Temperature Effect on Zero |
±0.19uV°F |
| Temperature Effect on Output |
±0.0008% of full scale/°F |
| Combined Accuracy |
0.5% to 1.0% full scale |
| DPS (Dual Position Sensor) |
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| Analog Output |
0 to 5 Volts |
| Tilt Range |
±45° to ±22° |
| Accuracy |
0.1 degree of tilt |
| Filters |
Four selectable digital filters |
| Input Voltage |
8 to 15 Vdc @ 14 mA |
| Polished Rod Load Cell |
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| Class |
Quantitative strain gauge |
| Range |
0- to 30,000 lb. or 0 to 50,000 lb. |
| Maximum Error |
±0.5% full scale |
| Operating Temperature |
-70° to +190°F (-55° to +88°C) |
ePIC Rod Pump Controller Expansion I/O Boards
Board
NumberAnalog
InputsDigital
InputsDigital
OutputsAnalog
Outputs1
2
2
2
0
2
4
4
4
0
3
8
4
4*
1
*Can be configured as DI or DO
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Copyright © 2007 eProduction Solutions, Incorporated. All rights reserved. |
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