Ace Reliance 1K User manual

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ACE RELIANCE SENSOR OPERATIONS MANUAL
ACE Reliance Sensor Operations Manual

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ACE RELIANCE SENSOR OPERATIONS MANUAL
Table of Contents
Contents
1. Product Description........................................................................................................................................... 3
2. Product Specifications....................................................................................................................................... 4
3 Installation tools and materials........................................................................................................................ 5
4. TEC cable preparation...................................................................................................................................... 9
5. 10 kPSI Sensor Model Installation................................................................................................................. 13
6. 1kPSI Sensor Model Installation.................................................................................................................... 18
6. Sensor and cable Integrity testing.................................................................................................................. 19
8. Surface Read-Out Unit Set-up........................................................................................................................ 20
9. Accessing downhole sensor data wirelessly from your device..................................................................... 24
10 Sensor and Cable Integrity Monitoring During Run in Hole ..................................................................... 31

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1. Product Description
ACE Reliance is a downhole sensor designed to be deployed in non-ESP wells (GasLift, PCP, Rod Lift, Hydraulic
Lift, naturally flowing wells …).
ACE Reliance sensor consists of two main components - a downhole instrument and a surface read-out unit. The
downhole instrument is a completely sealed, welded device. The instrument electronics are not exposed to
damaging well fluid caused by leaking threads, seals, O-rings or drain/fill valves. Power to downhole sensor and
communication is provided by a TEC cable.
Figure 1
Downhole instrument (10 K PSI models)
Figure 2
Downhole instrument (1K PSI model)
The surface readout (SRU) provides optically isolated RS-485 and RS-232 Modbus ports for remote
connections to virtually all wired SCADA control systems. The premium SRU2i readout includes all the features

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of the SRU then adds a higher resolution display, Ethernet, USB, analog outputs and relays plus built in data-
logging that will record unlimited readings from the downhole device to removable SD memory cards. The SRU2i
also includes insulation monitoring. The SRU3i adds direct Wi-Fi local connection plus direct connection to Baker
Hughes VSD’s. The SRU's operates from nominal 120 VAC50/60Hzline voltage. ACE Optix is a battery
powered, solar power capable version.
Figure 3
Surface read-out unit (SRU)
2. Product Specifications
Table 1
Downhole tool specifications
Reliance 1k
Reliance 10K
Reliance 10K HT
Pressure Range
0-1,000 psi
0-10,000 psi
0-10,000
Pressure Accuracy
0.2%
0.2%
0.2%
Pressure Resolution (0.01 to 1
PSI depending on readout)
0.0305 psi
0.305 psi
0.305 psi
Transducer Type
Silicon Strain Gauge
Silicon Strain Gauge
Silicon Strain Gauge
Data sampling frequency
11 sec
11 sec
1.4 sec
Temperature Range
32 - 257 deg °F (0–
125 deg °C)
32-257 °F (0–125 °C)
32-302 °F (0–150 °C)
Diameter
0.75”
0.82”
0.82”
Length
17”
17”
17”
Weight
1.34 lbs ( 610 g)
1.5 lbs ( 680g)
1.5 lbs ( 680g)
Material
SS316L
SS Duplex 2205
SS Duplex 2205
Thread at the pressure port at
the bottom of the sensor
1/8"-27 NPT
1/8"-27 NPT
1/8"-27 NPT
TEC cable recommended
1/8" TEC 316
1/4" TEC 2205 Duplex
AWG 16
1/4" TEC 2205 Duplex
AWG 16
Table 2
Surface Readout Unit Specifications
SRU2i
Srus2i-DC
ACE Optix
Power Required
115VAC +/-15% 50/60Hz
or
10-28 VDC 1A
10-32 VDC 0.25
A
Display Type
8 digit Alpha Numeric
LED
8 digit Alpha
Status LED
Modbus RS-485 ( isolated)
3 wire standard
3 wire standard
3 wire standard
Modbus RS-232
3 wire, no handshaking
required
3 wire standard
USB Modbus ( isolated)
Standard USB “B”
Standard USB-A

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Ethernet Modbus (
Isolated)
Standard CAT5E 8 Pin
connector
WiFi Interface
Standard
worldwide,
license fee 802.11
b/g/n
Analog Outputs ( isolated)
4x 0-20 mA User
configurable ( SRU2
sources power)
4x 0-20 mA User
configurable ( SRU2
sources power)
Relay Outputs (Isolated)
2x Form C User
configurable 240VAC / 8
Amps
2x Form C User
configurable 240VAC
/ 8 Amps
SD data logger
Up to 32 GB ( SDHC
mode supported)
Up to 32 GB
( SDHC mode
supported)
Internal
Internal memory
32 GB
32 GB
32GB
GPS
Internal +
External port
Operating Temperature
0 deg F –158 deg F ( -18
deg C –50 deg C)
0 deg F –158 deg F ( -
18 deg C –50 deg C)
0 deg F –158 deg
F ( -18 deg C –
50 deg C)
Dimensions
9.50” x 5.75” x 1.75”
9.50” x 5.75” x 1.75”
5.25”x1”x3.3”
Weight
2 lbs
2 lbs
2lbs
UL Certification
Conforms to UL Std. 610-
10-1
Conforms to UL Std.
610-10-1
N/A
CSA Certification
Certified to CAN/CSA
Std. C22.2 # 61010-1
N/A
N/A
3 Installation tools and materials
Wrench 9/16” (slim version; Proto J3430)
Wrench 5/8”
Wrench 1/2”
Wrench 3/4”
Wrench 11/16”
Petroleum jelly (lip balm)
Pins (included with the instrument)
ACE Downhole strip gauge Dual Seal ¼” (for 10,000 PSI sensors)
ACE Downhole strip gauge ¼” (for 1,000 PSI senso model)
Crimp tool
Vise grips
Tube cutter
Figure 4. Dual Seal ¼” TEC strip Gauge V1.4 (provided with the sensor). This strip gauge is to be used for installing
10 kPSI sensor model

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Figure 5. 1 ¼” TEC Strip Gauge. This strip gauge is to be used for installing 1 kPSI sensor model
WARNING: Ensure an appropriate strip gauge is used for 1,000 PSI and for 10,000 PSI sensor models. Using a wrong strip gauge will lead to
incorrectly stripped TEC cable which may cause a sensor failure.
Figure 6. Crimp tool

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Figure 7. Crimp tool (cont.)
Figure 8. Wire cutters

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Figure 9. Vise grips
Figure 10. Tube cutter

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Figure 11. Tube cutter
4.TEC cable preparation
4.1 Use ACE Dual Seal cable strip gauge to measure and mark the cut-off length (fig 12)
Figure 12. Measuring and marking the TEC tube cut-off length
4.2 Use tube cutter to make a groove in the tube (fig 13)

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Figure 13
4.3 Hold the TEC cable with wise grips on both ends of the groove and wiggle until the end section of the tube
breaks loose. Then remove the tube (fig 14 and fig 15).
Figure 14

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Figure 15
4.4 Use the cable cutter to remove a length of the Teflon insulation as per dimensions of the ACE cable strip gauge
(fig 16)
Figure 16. TEC cable stripping dimensions as per the ACE Downhole strip gauge
4.5 Insert the end of the TEC cable wire into the pin (fig 15).

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Figure 4
4.6 Terminate with a pin using the crimp tool (fig 18). If it is assembled but does not match the gauge, then cut off
Figure 18. Using the crimp tool to terminate the wire with the pin

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4.7 Use the dual seal ¼” strip gauge to doublecheck the dimensions of the terminated end of the TEC cable
Figure 19. Dual Seal ¼” strip gauge
5. 10 kPSI Sensor Model Installation
5.1 Unscrew the cover from the head of the sensor
Figure 20
Figure 21. The top cover is unscrewed
5.2 Remove the nuts from the cover and from the top of the sensors
Figure 22. The nuts are unscrewed
The top
cover

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Figure 23. Each nut contains a cone and a ferrule
5.2 Slide TEC cable through the nut, ferrule, and the cone. Then slide the TEC cable through the cover. Note the
correct orientation of the ferrules and the cones (figure 24)

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Figure 24. The ferrule and the cones must point toward the stripped end of the TEC cable
5.3. Insert the TEC cable into the head of the sensor
Figure 25. TEC cable inserted into the head of the sensor
5.4 Unscrew the nut and retrieve the TEC cable. Inspect the position of the compressed assembly of the ferrule
and the cone. It must seat on the stainless-steel tubing of the TEC cable as shown in the figure 26. In case the
compressed assembly of the ferrule and the cone seat on the insulation of the TEC cable, it means the TEC cable
was cut incorrectly. The cable needs to be cut and stripped again using the Dual Seal ¼” ACE strip gauge.

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Figure 26. Correct location of the compressed assembly of the ferrule and the cone
5.5 If you observe that the compressed ferrule the cone is situated on the stainless-steel tubing of the TEC cable it
means the cable was stripped correctly. Insert the cable into the heads of the sensor. Tighten the nut finger
tight and then apply 1 ¼” turns with a 9/16” wrench.
WARNING: DO NOT OVERTIGHTEN AS IT CAN DEFORM THE CONE
Figure 27
5.6 You can use a Swagelok gap inspection gage (p/n: MS-IG-400) to ensure the nut is tightened properly.

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Figure 28. Swagelok gap inspection gauge
5.7 Apply petroleum jelly (lip balm) on the thread (fig. 26) at the top of the sensor and screw the top cover
finger tight, after which tighten it using a ¾” and a 11/16” wrenches (fig. 27)
Figure 29
Figure 30. The top cover is installed
5.8 Tighten the nut finger tight and then apply 1 ¼” turns with a 9/16” wrench.
WARNING: DO NOT OVERTIGHTEN AS IT CAN DEFORM THE CONE
Apply petroleum
jelly (lip balm)
Insert a ¾” wrench into the grove
and tighten up the cover
Use a 11/16” wrench here to
hold the sensor in place

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Figure 31. The sensor is fully assembled
6. 1kPSI Sensor Model Installation
The installation procedure of the 1kPSI sensor model is similar to the one of the 10kPSI one. One difference is that
the 1kPSI model features fewer components (the 1K model does not have the top cover). The other difference is
that another ACE TEC strip gauge must be used to measure TEC cut-off distance.
Figure 32
Components that are not present in the 1kPSI sensor model are crossed out

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Figure 33
1kPSI sensor model and the TEC cable are ready to be connected
WARNING: The ACE ¼” Gauge Strip must be used to cut TEC cable for the 1kPSI model. If ACE Dual Seal TEC Strip
Gauge is used, this may cause to well fluid leak into the sensor and a failure. Please see the pictures of the two
types of ACE TEC strip gauges at the beginning of this manual.
6. Sensor and cable Integrity testing
During pressure testing in the shop, after the sensor and cable have been mated and been under pressure for
some time, use Fluke 1507 Insulation tester at the 1000V setting to verify 11 GOhm insulation resistance;
anything below that indicates a fluid transgression at some point (or insulation breakdown in the cable on the
spool).
Figure 34

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8.Surface Read-Out Unit Set-up
8.1. Connect a surface cable (from a junction box) and the DC power cable to the ACE Optix SRU.
Figure 35
Power and single wire connections for ACE Optix
8.2 ACE Downhole offers a GPS receiver. If AC mounted in a metallic container it’s possible the internal GPS will
not receive a signal, in this case the ACE Optix external GPS receiver may be plugged into the front of the ACE
Optix case as shown in the figure 36 below.
DC power cable
input
Signal cable input
(from a junction
box)
Ground wire
Signal wire