电潜螺杆泵的安装.docx

Franklin Electric Artificial Lift ESPCP System Installation Instructions

***Note: Pictures displayed in this manual do not accurately represent every motor, pump, drive, etc. Different versions and models may have slight differences that need to be acknowledged.***

Tools
需要准备的工具如下:
· 电工改锥 – 十字和平扣的

· 长平扣改锥
· 中号的十字改锥
· 六角头螺丝刀

· 管钳
· ½” 开口扳手
· 内六方—公制和英制
· 电钻和钻头Drill and drill bits – Drill bits large enough for panel cable glands
· 锉刀
· 切线钳
· 刀
· 压线钳——4awg to 16awg.
· 剥线钳
· 酒精或CO清洁剂
· 硅润滑脂
· 导电脂
· Blue Loctite 242胶水
· Nickel tape
· Teflon tape
· Bander (electric or hand)
· Voltmeter
· Megger
· 地线夹具Ground Clamps

预先检查
1.) 安装前检查所有的部件，确定所有的部件号和部件正确。检查是否有设备在运输中损坏。
2.) 检查控制柜内的电缆连接，确定所有的连接都已经上紧。检查是否有螺丝在运输中松动
3.) 确保所有的设备都在室内避光保存。尤其是泵，必须在室温下下保存，阳光和高温会导致泵损坏。
4.) 水泥基础应该在安装前运达现场。
5.) 电网和发电机应该在安装前检查好。
6.) 现场要有合格的地线。
7.) 检查输入电压，确定其符合要求（380~400V）。
8.) 事先确定井的方向，油管和套管接触的方向视为下方，安装时电缆应该处于油管的上方。动力电缆和信号电缆下井时都需要电缆导向滑轮。
9.) 所有的螺丝、螺栓、螺帽、胶水、导电脂、垫片、硅润滑脂和接地线都应有额外的备件。

安装
10.) 首先要安装控制柜之间，将之间安装于水泥基础上并打上胀钉. 应该有胀钉、螺帽和垫片。

11.) 连接输入电缆。控制柜的输入电缆应该连接到下图中的位置。地线连接到地线端子上。用万用表测试最大和最小的输入电压，确保电压在许用范围内。

12.) 用电机引线将控制系统和电机连接起来，以便检查电机和控制系统。
电机引线和控制系统连接的顺序为， Ø1= Black, Ø2 = Yellow, Ø3 = Red. 别忘了连接地线。 之后启动电机，检查电机的转向——逆时针为正确的转向（从上往下看）。

13.) 进入电脑设置界面设置auto tune, 用网线连接控制系统，用或IE9以上或者 Google chrome浏览器.  输入IP地址172.16.0.1 ，进入界面后输入 Username (admin) and the Password (password) ，之后点击LOGIN.

之后点击Configure 界面. 设置WELL界面下的 the well name井名, well depth井深, and pump discharge vertical measurements泵挂（TVD） ，之后点击APPLY。注意，泵挂深度指的是垂直深度。

现在，进入Pump/motor界面来设置泵和电机。如果是电潜泵的话，最大电机电流就等于电机的安全电流。如果是电潜螺杆泵的话，最大电流就和变频器的马力有关，关系如下15hp=41.6A, 20hp=55.8A, 25hp=68.4A, 30hp=79.2A.  之后设置电缆调节参数，这是用来计算电缆导致的压降的，用电缆的型号和电缆的长度来推出电缆的压降，并对该压降进行弥补。用下面的表来推算出电缆调节参数的具体数值。注意：一旦输入了该数值，严禁更改。因为如果修改了这一参数，整个auto tuning系统都会重设。

不同泵型、电缆型号和电缆长度对应的LONG LEAD VOLTAGE的推算

点击APPLY，保存设置

进入SENSOR的截面，点击相应方框的对勾以打开该传感器。首先点击downhole sensor的对勾. 输入传感器的放置深度（TVD），之后输入最大量程。注意单位，如果切换单位后要重新计算并输入该单位下的最大量程。将ignore downhole sensor out of range 打上对勾，之后选择应用 。如果没有井下传感器，DOWNHOLE SENSOR的对勾就不用打上。

在右上方选择运行Operator 按钮.进入运行界面后，将停机液面设置 为5ft 恢复液面设置为 10ft.  你将看到当液面高于停机液面是，你可以启动电机。再次检查电机引线按照正确的顺序和控制柜连接，连接处均已上紧。确定电机有稳定的支撑，否则启动后会滚动或者倒下。之后按启动电机的按钮Start Motor, 你可以观察到电机数据的灯变成黄色，电机电流会不断变化。当你看到电机转动，并点击数据的灯变成绿色后，按停止stop motor 按钮。
注：如果水位没有显示，可以安装一个滑动电阻至井下传感器的接口上。

14.) 变频器现在已经处于auto-tuned的状态下. 现在需要关闭电源，断开输入电源，断开电机和控制柜之间的所有接线.
15.) 将螺杆泵从盒子中拿出，记得将润滑脂的小包也拿出。如果安装弹簧单流阀的话，要将泵出口上的球形阀取出。取出球形阀后，日后出现卡泵的话，可以使用bump starting 来反转解锁，此时螺纹管中的水可以回流，而不是被球形阀挡住。注意: 弹簧单流阀应该安装在2泵出口2英尺以上.
16.) 记下泵和电机的信息，特别是序列号.

17.) 将泵的转子上涂抹上润滑脂，要多涂抹一些。自带的不够的话就用备用的。之后轻轻的将转子推入定子。直至大约一英寸留在壳体外，这是为了对接电机和泵时能够更方便。.
18.) 检查电机上的4个螺栓，确定均已上紧，检查电机轴上的垫盘和橡胶套均安装好。之后涂抹白色润滑脂（电机自带）到电机轴的花键上.
19.) 在电机引线上涂抹润滑脂，之后轻轻的将引线推入槽中。上紧2个螺钉。注意：保护引线不要受到挤压和摩擦。要求现场有专人负责保护引线.
20.) 连接泵和电机。注意将四个螺栓孔对准，让出电机引线的位置。缓慢的安装泵，确保泵的花键套和电机的花键轴对准。之后将泵和电机完全对紧。

21.) 如果有锁紧螺母的话，使用锁紧螺母。注意安装垫片。不可完全上紧一个螺柱上的螺母，按顺序逐渐上紧4个螺柱上的螺母。直至最后再完全上紧，上紧后使用例句扳手，测试 (24 Nm)下螺母是否还能转动. 最后检查泵和电机是否完全贴近.

The figure below shows the correct way to use the Nord-Lock washer.

22.) 用绑带将引线绑在泵上。注意千万别挡住泵的四个呼吸口。

23.) 将电机引线完绑在泵上，小心注意不要损坏引线。引线要直。

24.) 现在安装导流罩，首先在螺纹管上螺纹上绑上生胶带，之后检查螺纹管内是否有杂质。将螺纹管和泵出口用管钳上紧。

25.) 在螺纹管另一端的螺纹上绑上生胶带，之后将导流罩悬挂器和螺纹管安装在一起。注意，上管钳时，不要压悬挂器的槽，管钳要打在悬挂器的上端而不是带螺纹的下端。悬挂器的槽是用来通过电机引线的。最好让它们在一条直线上，或者不要偏差太大。

26.) 同样，在单流阀的螺纹上绑生胶带，连接单流阀和悬挂器。注意单流阀的方向，箭头方向是冲上的。

27.) 这是，安装导流罩减震器。最新的要求是安装2个，一个安装在泵蓝色区域的中间位置，另外一个安装在筛网下方1一尺的位置。注意减震器的位置，不要挡住电机引线，要让电机引线直直的上来。之后再减震器上方涂抹润滑脂，以便安装导流罩罩体是能够更容易些.

28.) 用绿胶带将引线一直帮到悬挂器处。.

29.) 用SUPER 88 胶带在悬挂器接头处的槽附近，将4根引线包好，防止安装时破坏线皮.

30.) 再次检查电机引线，确保没有引线喽在外边或者有风险.
31.) 用管钳连接筛网和罩体.
32.) 连接电机密封件和罩体，密封件上的o环上涂抹润滑脂
33.) 筛网在前，密封件在后的顺序，将导流罩整体从电机方向网上推。电机可能会和电机密封件上的O环卡住。用一把长平扣螺丝刀帮助电机通过点击密封件的o环处。

34.) 对其六个孔，安装螺丝。也是顺序安装，不要完全上紧某一个后再上紧下一个。多转几圈上紧。

35.) 新式导流罩是后装O环。.
36.) 安装O环，2个黑色压紧环，之后安装金属固定夹。Insert the O-Ring, two black compression rings, and the metal retaining clip into the bottom shroud cap. Add Katie Fox’s photo here…
37.) 之后安装防撞器。间隔去下电机尾部的6个螺栓中的3个。在防撞器内装上金属短管。准备长螺栓和垫片。在螺栓前端涂抹胶水，之后安装螺栓。同样是顺序安装，不要一次性带紧。

38.) 现在，开始做电缆连接。首先安装油管短节。

39.) 电缆地线冲上，用螺纹卡子固定紧电缆。
40.) 事先考虑好电缆的旋向。如果需要的话用管钳让电缆扭转半圈。必须保证电缆下泵时处于直的位置。连接处尽量靠外，以防下次连接是引线不够长。.

41.) 电缆连接部分请见专门的教程。注意要拍照，以便后期判断相序时使用。Follow Franklin Electric’s tape splicing procedure found in the splice kit or located under the resources tab on the website: http://www.franklin- . Make sure to connect all 3 phases and ground and to keep track of which color phase from the motor connects to which phase of the drop cable. This will ensure you know the phasing at the other end of the drop cable so that the connection to the drive will be correct. The correct phases must be connected correctly or the motor will spin backwards and damage the pump. Make sure the ground is connected in the case there is only 3 conductors and no ground if steel tubing is used secure the ground to the metal tubing to be reconnected at the top. If armor cable is used connect the ground to the armor to connect at the top of the well.
42.) 电缆连接完成了，打开电缆固定。之后重新安装电缆固定，要注意电缆连接处附近要有一定得余量，不要绷紧。防止安装油管时被拉断。打2根电缆绑带在短接上，固定紧铠装电缆.
43.) 用绿胶带将引线绑在短接上。
44.) 在连接处上方打上一根绑带，之后再绑带上方安装一个扶正器。

45.) 在适当的位置安装传感器。在传感器上打2根绑带。之后再传感器上方和下方各安装一个扶正器。在下方的扶正器的上边，打一根绑带，防止扶正器网上推传感器.

46.) 水平井至少需要在每根油管上打扶正器，直井至少需要每2根油管上打一个扶正器。水平井推荐安装2个扶正器，一个在接箍下，下个在油管中间位置。动力电缆和信号电缆最好挨在一起。
47.) 信号电缆在动力电缆边上，这样动力电缆就可以保护信号电缆不会被刮到.
48.) 每10根油管，测量一次动力电缆和信号电缆的读数。Meg and check the resistance in the drop cable every 15 sticks or so to ensure there are no issues. If there is a way to check the downhole sensor cable every few sticks to ensure it is still in good working order, do it. Franklin Electric Artificial Lift field service engineers have a device to easily check that the downhole sensor is in good working order. The device allows the user to calculate the static water level during the install. Unfortunately, these sensor checkers are not being manufactured for sale at this time.
49.) 电缆到达井口是，需要做电缆穿越。此时拨开铠皮，将地线单独固定在油管上，固定前用锉刀把油管上的油漆打掉，之后用导电脂涂抹该位置，最后将地线绑紧在该处。最后用绿胶带缠绕该处。

50.) 信号电缆的穿越.

51.) 动力电缆的穿越.

52.) 同样，在井口之上，将地线和井口连接.用锉刀打油漆，涂抹润滑脂，不过不需要用胶带。

53.) 如果有接线盒的话，安装接线盒。如果没有的话，直接将电缆连到控制柜上。注意一定要确定电缆的相序。黑 黄 红的顺序一定要确认。

54.) 在控制柜上钻孔，孔的大小和密封套要一致。之后安装密封套，穿越电缆。

55.) 连接输入电缆和动力电缆。和测试时一致。. Ø1= Black, Ø2 = Yellow, Ø3 = Red.

56.) 同样，安装输入电缆和地线.

57.) 前三个端口是井下传感器的端口，按照顺序连接。

58.) 现在在井口处安装套压表。富兰克林提供½” 公扣螺纹，如果现场要求是M 20x1.5 的螺纹，应该提前通知富兰克林准备变径接头。变径接头安装需要上生胶带。安装信号线和密封件，.

See the table below for casing sensor connections.

FE Part #
Description
Connection to plumbing
Cable entry into head of sensor
106769101
Casing Pressure Transmitter - Non-Hazardous Areas
1/2" NPT Male
Thread 1/2" NPT
106769102
Casing Pressure Transmitter - Hazardous Rating = Ex d llC T6 Gb
1/2" NPT Male
Gland M 20x1.5

Keep in mind, an adaptor of some sort may be needed, depending on the plumbing, to connect the casing sensor to the existing plumbing on site. Make sure to purchase the correctly sized and threaded cable gland according to the table. The M20 and 1/2”NPT thread size cable glands can be found on McMaster-Carr, see below. Part numbers will vary depending on the cable diameter being used.

59.) 套压表的端口是 4th, 5th, and 6th. . (Terminal block 4 = +24V Power; Terminal block 5 = Signal; Terminal block 6 = Shield.)

60.) 其他 4-20mA 模拟信号传感器的安装端口见下表.

61.) 连接完所有电线后，记录控制柜的编号，关上柜门.

62.) Connect to the webpage. There are several ways to do this depending on which panel is used.
a. No Modem or Wifi – Follow these steps if no modem is installed in the panel. Connect a laptop directly to the Ethernet hub via an Ethernet cord. Open the internet browser and enter http://172.16.0.1 into the browser.

b. Wifi (No Modem) – This is how to connect to the webpage with the usb wifi adaptor. Open a laptop or phone and search the wireless networks available. The network will vary from panel based on the serial number of the panel. Find the panel serial number on the inside of the door and connect to the network that is named after that serial number. See the pictures below. The network password is ‘feals’. Once connected, open a browser and enter the following ip address: 172.16.0.1 into the browser.

The network name can be changed by going to the Configure tab on the website and clicking on ‘SYSTEM’. Change the ‘Computer Name’ from the serial number to anything you want and then click the ‘Reboot Now’ button at the bottom of the page This will change the network name to the same name.

c. Cellular Modem – Select “AlsIndustrialWifi” from the list of available networks and use password “fealsindustrial” to login. Once connected to this network, enter http://192.168.0.120 into a browser.

Each of the methods above should bring the webpage login screen up. Login using Admin = admin and Password = password.

63.) Once logged into the webpage, click on the ‘Configure’ tab. Settings will be filled in here.
Configure Webpage: Well

ITEM
DESCRIPTION
WELL NAME
Name or serial number of the well. This will be displayed on all webpages.
WELL DEPTH
Linear distance of well. Information only for operator webpage
PUMP DISCHARGE DEPTH
Vertical distance the top of the pump is to the wellhead (surface)
PERF TOP
Vertical distance the top perforation is from wellhead (surface)
PERF BOTTOM
Vertical distance the bottom perforation is from wellhead (surface)
UNIT OF MEASURE
Select FEET or METERS to change units for parameters above and all distance measurements on operator webpage.
APPLY
Select button to store and activate changes.
Configure Webpage: Pump/Motor

ITEM
DESCRIPTION
PUMP TYPE
Selection button between CENTRIFUGAL and PC. See CONFIGURE > ADVANCE for min and max speed settings.
PUMP MODEL
Drop-down list of PC pumps. Not needed for CENTRIFUGAL pump operation.
*MOTOR SELECTION: VOLTAGE
Nominal motor voltage in V AC at nominal motor frequency
*MOTOR SELECTION: FREQUENCY
Nominal motor frequency in Hz at nominal motor voltage
*MOTOR SELECTION: POWER
Nominal motor power in HP
MOTOR SELECTION: MAX MOTOR CURRENT
To create enough torque start a PC, the max motor current must be the max value possible for the drive. 15HP, 20HP, 25HP, and 30HP drives would have a max of 40.4A, 54.3A, 66.5A, and 77.0A. For an ESP, the max value should be the SFA of the motor.
*MOTOR SELECTION: LONG LEAD VOLTAGE ADJUSTMENT
A percentage increase of nominal voltage to take into account for the voltage drop of the long motor leads. Consult Franklin Electric representative for selecting value.
APPLY
Select button to store and activate changes.
*Changing value requires a ‘first-start’ run. See section ‘first-start’ for instructions.
Configure Webpage: Sensors

ITEM
DESCRIPTION
DOWNHOLE (check box)
Activates/deactivates input 1 for downhole sensor
DOWNHOLE: UNITS
Defines units of sensor: PSI, BAR, and MPa. Same units will be displayed on Operator Webpage.
DOWNHOLE: DEPTH IN WELL
Vertical distance between well head and downhole sensor
DOWNHOLE: SPECIFIC GRAVITY
Defines the specific gravity of the discharge fluid. Change this value if the discharge fluid is significantly heavier or lighter than water. This allows for more precise calculation of the water level (fluid level).
DOWNHOLE: FULL SCALE READING
Downhole Pressure value when sensor is at 20mA with respect to units selected.
DOWNHOLE: IGNORE DOWNHOLE SENSOR OUT OF RANGE
Enables feature to use full scale reading of downhole sensor when sensor is below or above 4-20mA input range. This will also allow you to auto tune without connecting a downhole sensor.
CASING PRESSURE (check box)
Activates/deactivates input 2 for casing pressure sensor
CASING PRESSURE: UNITS
Defines units of sensor: PSI, BAR, and MPa. Same units will be displayed on Operator Webpage.
CASING PRESSURE: WHAT IS YOUR CASING PRESSURE
Sets a static value of casing if casing pressure is not used. Only viewable if Casing Pressure (checkbox) is disabled.
CASING PRESSURE: TYPE
Select between GAUGE and ABSOLUTE. Gauge sensor readings are in reference to ambient pressure. Absolute sensor readings are in reference to 0 pressure.
CASING PRESSURE: FULL SCALE READING
Casing Pressure value when sensor is at 20mA with respect to units selected.
CASING PRESSURE: MAX PRESSURE LIMIT
Enables max pressure limit.
CASING PRESSURE: MAX PRESSURE VALUE
Sets the max pressure limit value. Only viewable when limit is enabled.
WATER LINE PRESSURE (checkbox)
Activates/deactivates input 3 for casing pressure sensor
WATER LINE PRESSURE: UNITS
Defines units of sensor: PSI, BAR, and MPa. Same units will be displayed on Operator Webpage.
WATER LINE PRESSURE: FULL SCALE READING
Water Line Pressure value when sensor is at 20mA with respect to units selected.
WATER LINE PRESSURE: MAX PRESSURE LIMIT
Enables max water discharge pressure limit
WATER LINE PRESSURE: MAX PRESSURE VALUE
Sets the max water discharge pressure limit value. Only viewable when limit is enabled.
WATER FLOW (checkbox)
Activates/deactivates input 4 for water flow sensor
WATER FLOW: UNITS
Defines units of sensor: GPM, BPD, LPM, and CMPD. Same units will be displayed on Operator Webpage.
WATER FLOW: FULL SCALE READING
Water Flow value when sensor is at 20mA with respect to units selected.
WATER FLOW: MIN FLOW
Enables min flow limit
WATER FLOW: MIN FLOW VALUE
Sets the min flow limit value. Only viewable when limit is enabled.
WATER FLOW: PRIME TIME
When Min Flow is enabled set the time required for water to reach surface. Only viewable when limit is enabled.
WATER FLOW: MAX FLOW
Enables max flow limit
WATER FLOW: MAX FLOW VALUE
Sets the max flow limit value. Only viewable when limit is enabled.
WATER FLOW: REGULATE FLOW
When enabled with system in Auto mode, the system operates in Water Flow Control mode. Must have a maximum flow rate when enabled.
WATER FLOW: DAILY LIMIT
Enables max daily volume limit
WATER FLOW: DAILY LIMIT VALUE
Sets the max daily volume limit value. Only viewable when limit is enabled. If limit is reached, the system will shut-down the motor and restart motor at midnight next day. If Water Flow Units is GPM, BPD, LPM, or CMPD, then units are gallons, barrels, liters, or cubic meter, respectively.

Configure Webpage: Sensors (Cont.)

ITEM
DESCRIPTION
INPUT 5 (check box)
Activates/deactivates input 5 for generic sensor
INPUT 5: NAME
Defines name of input 5 sensor. Name will be displayed on Operator Webpage.
INPUT 5: SENSOR TYPE
Select between SWITCH and ANALOG SENSOR for a switch connection or analog sensor (4-20mA) connection, respectively. See Error! Reference source not found. pag