SIAM DUA-1 User manual

Tomsk Scientific Industrial Introduction Company “SIAM” LLC
AUTOMATIC WELL SOUNDER
«DUA-1»
OPERATING MANUAL
Russia

Automatic well sounder “DUA-1”
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Automatic well sounder “DUA-1”
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CONTENTS
1. GENERAL PRODUCT INFORMATION 5
1.1. Designation 5
1.2. Basic specifications 6
1.3. Design and operation of the product 7
1.4. Safety and environmental instructions 8
1.5. Marking 8
1.6. Package 8
2. INTENDED USE OF THE PRODUCT 10
2.1. Operational limitations 10
2.2. Ensuring explosion-proofness of the product. 11
2.3. Measures to ensure and keep the device explosion-proofness during
the assembly, disassembly and repair of the device. 12
2.4. Preparation for use 13
2.5. Use of the product 14
2.6. Well sounder disassembly 18
3. MAINTENANCE 19
4. DEVICE REPAIR 24
5. DEVICE STORAGE 24
6. DEVICE TRANSPORTATION 24

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The certificate applies to “DU-1” well sounders (hereinafter
referred to as the device) designed for operation at the wellhead in oil and
gas fields.
The device is explosion-proof designed (intrinsically safe circuit
type of protection) in accordance with the requirements of GOST 31610.0-
2014 (IEC 60079-0:2011), GOST 31610.11-2014 (IEC 60079-11.), GOST
31610:2011), and have 1Ex ib IIB T3 Gb Хexplosion proof mark.
“DUA-1” automatic well sounder is designed for indoor and outdoor
installation in hazardous areas where atmospheric explosives of IIA, IIB
categories and T1, T2, T3 groups can form according to GOST R IEC
60079-20-1-2011 in the operating temperature range from -40 ºC to +50
ºC. The device design is comply with the assigned explosion proof mark,
with the requirements of GOST IEC 60079-14-2013 and other regulatory
documents governing the use of electrical equipment in hazardous areas.
The operating manual contains information about the design,
principle of operation and specifications of the device as well as
instructions necessary for proper operation, maintenance, transportation
and storage of the device.
Observe the requirements of the Federal norms and regulations in
the field of industrial safety "Safety rules in oil and gas industry" as well as
this manual, when operating, maintaining and repairing the device.
The device may only be operated by specially trained personnel
who have studied the operating documentation for the device, received the
relevant safety instructions and permission to work.

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1. GENERAL PRODUCT INFORMATION
1.1. Designation
1.1.1 The automatic well sounder “DUA-1” is designed for operation
at the wellhead in oil and gas fields
1.1.2 The device is explosion-proof designed (intrinsically safe
circuit type of protection) in accordance with the requirements of GOST
31610.0-2014 (IEC 60079-0:2011), GOST 31610.11-2014 (IEC 60079-
11.), GOST 31610:2011), and have 1Ex ib IIB T3 Gb Хexplosion proof
mark. “DUA-1” automatic well sounder is designed for indoor and outdoor
installation in hazardous areas where atmospheric explosives of IIA, IIB
categories and T1, T2, T3 groups can form according to GOST R IEC
60079-20-1-2011 in the operating temperature range from -40 ºC to +50
ºC. The device design is comply with the assigned explosion proof mark,
with the requirements of GOST IEC 60079-14-2013 and other regulatory
documents governing the use of electrical equipment in hazardous areas.
1.1.3 Automatic well sounder provides static and dynamic level
control, automatic registration of drop and recovery curves, automatic
registration of gas pressure in annular space at wellhead.
1.1.4 The automatic well sounder can be used for automatic fluid
level control (without operator's participation, if the level value is more
than 20 m) during well operation, as well as during well start-up after
repair or downtime.

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1.2. Basic specifications
1.2.1 The automatic well sounder “DUA-1” meets the requirements
of technical specifications TU 4273-101-20690774-2018.
1.2.2 The basic specifications are given in Table 1.
Table 1
Parameter name
Norms on specifications
Explosion proof mark
1Ex ib IIB T3 Gb X
Climatic modification
tropical climate
Level control range, m
от 20 до 3000 (6000)
Resolution capacity of the level control,
m, max
1
Pressure measurement range, kgf/сm2
from 0 to 150
Resolution capacity of pressure
control, kgf/sm2, max
0,1
Maximum magnetic valve actuation
pressure, kgf/сm2, max.
50
non-volatile memory capacity
- for symbolic reports
- for graphics
3008
310
Number of measurements with
magnetic valve after the full charge of
the battery under normal climatic
conditions
400
Charging time of a discharged battery,
h, no more
10
Operating temperature range, С
From - 40 to + 50
Approved battery type
Boston Swing 5300
Battery voltage rating, V
3,65
Minimum Battery Voltage, V
2,7
Service life, years, min
5
Weight, kg, max.
8

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1.3. Design and operation of the product
1.3.1 Product design
The product has a single block and consists of the following main
parts:1) swivel removable manual valve;
2) well sounder housing;
3) "Power supply" LED;
4) "Charging" LED;
5) power on/off button;
6) plug for connecting the mains adapter from 220 V or the car's on-
board network adapter to charge the built-in lithium battery;
7) solenoid valve nozzle;
8) electromagnet;
9) solenoid valve control unit;
10) swivel nozzle lock screw;
11) electromagnet screw;
12) electromagnet housing;
13) mounting clamp;
14) threaded connection coupling.
1.3.2 Product operation principle
The device is installed directly on the measuring branch pipe of
wellhead fittings and does not require measuring cables. The product
performs acoustic pulse generation in annular space, reception,
transformation and analysis of acoustic response (echo signal), fluid level
determination, pressure control at wellhead. The product operates under
the internal program under the control of the built-in microcontroller,
which processes information from primary sensors, performs level
calculation, records the values of controlled parameters (pressure and
level) in its long-term memory, and provides communication with external
devices (PC).
The level sensor is automatically supplied by the built-in lithium-ion
battery. For its charging the product has a built-in charger with software
control, allowing you to properly maintain the battery. The lithium-ion
battery does not need to be discharged before it can be recharged, so once
the battery is powered up, the product will start to charge immediately.

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1.4. Safety and environmental instructions
1.4.1 The product meets the safety requirements of CUTR 012/2011,
GOST 31610.0-2014, GOST 31610.11-2014, GOST 12.1.019 79, GOST
12.2.003 91, GOST 12.2.007.0 75.
1.4.2 The product does not create any harmful or hazardous factors,
does not require special means of protection of service personnel.
1.4.3 The Product does not have any harmful impact on the
environment during transportation, storage and operation.
1.4.4 The Product does not contain any fire and explosion hazard
elements.
1.4.5 The product does not use voltage exceeding the safe level (AC
voltage 42 V, DC voltage 110 V).
1.5. Marking
1.5.1 The main marking is located on the product body and contains:
trade mark or the name of the manufacturing company;
name of the product;
the serial number of the product according to the numbering system
of the manufacturing company;
year of manufacture;
special explosion-proof mark "Ex", according to Annex 2 CUTR
012/2011;
number of the certificate of conformity with the requirements of the
Technical Regulations of the Customs Union of the CUTR
012/2011;
explosion-proof marking;
name or mark of the certifying authority;
special application conditions.
1.5.2 The transport container is marked with manipulation marks
"UP", "WARNING! CAPABLE OF BEING BROKEN" and "PROTECT
FROM MOISTURE" in accordance with GOST 14192 96.
1.6. Package
1.6.1 Device, network adapter, car adapter, USB cable, ball-type
nozzle head, rotating nozzle, exhaust receiver with rubber ring, flash drive
with software "Siam Service 2", set of ZIP, certificate, operating manual

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and user’s guide "Siam Service" v.2.10" are packed in separate plastic
bags. Units and documents are packed inside the bag for carrying the
product. The bags with the devices are stacked inside the transport
container manufactured according to the drawings of the manufacturer.
1.6.2 A packing list containing the following information is enclosed
in the transport container:
name, address and country of the manufacturer;
name and serial number of the product;
name and number of component parts to the product;
date of packing;
the signature of the packer and the seal of the manufacturer.

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2. INTENDED USE OF THE PRODUCT
2.1. Operational limitations
2.1.1 The following persons are allowed to work with the product: oil
and gas production operators of not lower than the fifth category; well
research operators of not lower than the fourth category. Personnel must be
trained to operate the product. Training is carried out by the employees of
the manufacturer directly at the workplace.
2.1.2 During the operation of the product use this operation manual,
"Safety rules for exploration work", Federal norms and rules in the field of
industrial safety "Safety rules in oil and gas industry", as well as approved
by the head of the company instructions for maintenance and research of
wells, taking into account the specifics of the object of study and
technology of work.
2.1.3 Preventive maintenance and repair of the product shall be
performed outside the explosion hazard zones. Comply with fire safety
regulations, work in the open air or in a well-ventilated room when using
highly flammable liquids to clean the product.
Observe the requirements of the "Maintenance" section of this
document when operating the product. Do not allow severe contamination
of the internal parts of the product, especially the acoustic sensor, valve,
and taper connection threads, resulting in poor product performance and
reduced service life.
2.1.4 The product must not be used in excess of the operating
conditions specified in this manual.
2.1.5 Requirements to the object of investigation
Well arrangement and operation shall be performed in accordance
with the "Safety Regulations for Oil and Gas Industry".
The investigated well, regardless of its purpose and method of
operation, shall have a technological branch with a gate valve and a branch
pipe for connecting a volumetric device. Determination of the fluid level is
possible only in the well space (tubular, inter-tube, annular, bent), which
connects to the technological branch used. While making measurements,
the technological branch should not have sharp contractions (fittings,
pipettes and similar devices). Pipe branch should have a pipe cone thread
60 in accordance with GOST 633 80, should be located at a height of 0.2 to
1.8 m above the ground. If the height is more than 1.8 m, use stationary or
portable sites provided that they meet the requirements of the “Safety

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Rules in the oil and gas industry”. Unused pipe branch shall be closed with
a process plug.
No more than two bends of the pipeline at an angle of 90 at a
distance of up to 20 m from the pipe branch are allowed on the way of
sound pulse.
2.2. Ensuring explosion-proofness of the product.
2.2.1. Explosion-proofness of the device is provided by the type of
protection "intrinsically safe electric circuit" “ib” level, according to the
requirements of GOST 31610.11-2014 (IEC 60079-11:2011), which is
achieved by the following:
Basic circuit diagram includes the protective component
“Fib”. The protective component “Fib” is an intact spark protection unit
with the short-circuit current limitation at 2.25 A (maximum), using
current limiting resistors and semiconductor fuses in series. Double
redundancy is used in the “Fib” protective component to ensure greater
reliability. The “Fib” component is integrated into the battery compartment
of the device. The design of the protective component “Fib” is met with the
requirements of GOST 31610.11-2014 (IEC 60079-11:2011), including
leakages and clearances. The minimum width of conductors on the PCB is
0.2 mm, copper thickness is not less than 18 µm. Thus, the electrical circuit
coming out of the battery compartment of the device is intrinsically safe.
The electrical circuit principal and applied third party
components provide maximum power consumption not more than 0.45
W from the internal battery with maximum possible voltage on it 4 V.
The total maximum capacity of the electrical circuit is 330 μF,
maximum inductance is not more than 20 µGn. The maximum current
in the circuit during normal operation is not more than 100 m.
The well sounder uses Boston Swing 5300 battery cell.
The battery has special made contacts which exclude the possibility of
its incorrect switching on (polarity reversal) and is located in the
internal battery compartment of the device. The design of the battery
compartment ensures that the battery does not fall out of the device. Do
not replace the battery and do not charge it in the hazardous area. For
this reason, in order to inform the user about special conditions of use
of the device, the identification plate of the device is marked with an

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"X" sign indicating special conditions of safe operation.
The maximum temperature of overheating of components and
connections in the circuit diagram during normal operation is 15 °C max.
Thus, the surface temperature of conductors and elements during operation
and at maximum operating temperature plus 50 ° C is not more than 65 °
C. Device enclosures are made with the degree of protection against
external influences not lower than IP54 according to GOST 14254-2015.
2.3. Measures to ensure and keep the device explosion-proofness
during the assembly, disassembly and repair of the device.
2.3.1. Measures to ensure explosion-proofness before the
production process:
- The elements used in the protective component of “Fib” are
subjected to an acceptance test:
- resistors are tested for their nominal resistance;
- the fuses are checked against the short-circuit current limit;
- Materials used for casting the protective component “Fib”
are subjected to an acceptance test according to the certificates
presented.
2.3.2. Measures to ensure explosion-proofness during production:
- The protective component “Fib” with the installed battery is
subjected to an outgoing inspection:
- the short-circuit current and open circuit voltage at the output of
the protective component are checked;
- visual inspection of the filling location is carried out in order to
confirm the absence of any foreign inclusions, bubbles, cracks or
stratification.
2.3.3. Measures to ensure explosion-proofness during operation:
- Check that the cover of the battery compartment and the
compartment itself (including the threaded connection) are free from
mechanical damage and corrosion. In case of corrosion or mechanical
damage, do not operate the device;
- meet the requirements specified by the "X" sign in the explosion
proof mark.
2.3.4. The "X" symbol in the explosion proof marking indicates
special conditions for safe operation:

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1) Do not open the instrument cover and therefore the battery
compartment cover in hazardous areas;
2) Do not replace the battery and operate the computer in hazardous
areas; 3) Do not charge the battery in explosion hazard area;
4) Only the types of batteries specified in the manufacturer's
technical documentation may be used as power sources;
5) Constituents and circuits ensuring intrinsically safe design shall
not be repaired and in case of failure shall be replaced by new ones
supplied by the manufacturer;
6) The device's operability is maintained at ambient temperature
from minus 40 to plus 50оС.
2.4.4. Measures to ensure explosion-proofness during repair:
- the device must be repaired only by the employees of the
manufacturer.
Repair by third parties or individuals is prohibited.
- the protective component “Fib” is not to be repaired. It is made
intact and must be replaced in case of failure. Repair of the “Fib”
component is not permitted.
- after repair, the device must be tested according to the test
procedure, with the “Fib” component tested for short-circuit current
and open-circuit voltage (together with the battery installed).
2.4. Preparation for use
Unpack the product (remove it from the transport container, remove
the packing bags), check the completeness of the product in accordance
with the "Completeness" section of the certificate IZM 5.173.024 PS.
If the product has been previously used, clean it from contamination
and check the threaded part of the connecting coupling of the product. In
case of severe wear, corrosion or damage to the threaded part, installation
of the product is not allowed.

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2.5. Use of the product
2.5.1. Switching the product on and off
The level sensor automatically switches on with a short press on the
power button. The "Power" LED starts to glow green.
Automatic well sounder switches off by pressing the power button
for a long time (more than one second). The "Power" LED flashes red
twice and goes out.
In addition, the product is automatically switched off:
if the power button was not pressed for more than 100
seconds or there was no exchange with the secondary device
during the same time;
if the battery voltage drops below 2.5V.
In the latter case, all information in the product is stored, but the
battery must be recharged to prevent deep discharge (see 2.3.6).
2.5.2. Fluid level control
To control the level, the product should be installed on the measuring
pipe branch of the wellhead valve. Turn on the power to the product.
Start the "DB SIAM" program on your notebook. Select the
"Settings" tab. Press the "ZigBee" button. Select the "Add Sensor" mode.
After connecting the sensor, select the mode "Work with sensor". Click the
upper right icon "Device Management". Then you may choose the modes:
"Information", "Projections", "Start".
Further you can connect to the sensor by choosing from the list your
type and number of the device, and the mode "Work with device". If the
sensor has not been connected for a long time, the connection may take
place within one minute.
In the "Information" mode the overpressure value, voltage and
battery capacity of the product are displayed.
In the "Start" mode you have to choose the valve (automatic or
manual) from which the survey will be carried out. Start the fluid level

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control test. For the automatic valve the countdown to burst will start and
then the automatic valve will trigger.
For manual valve, the "Power" LED will start blinking once every
half second. After a second, generate an acoustic impulse by pressing the
manual valve knob of the product until it stops. The "Power" LED will
light up red.
Within 20 seconds, the product will record acoustic information from
the well, than determine the well fluid level and the "Power" LED will turn
green. The inscription "Survey is complete" will appear.
In order to import information to the "DB SIAM", enter the import
mode (tab "Devices") and press the "Import" button. If there is a large
amount of data, the "Instrument does not respond" message may appear.
To resume import from the interrupted place, press the "Import" button.
2.5.3. Automatic removal of level recovery or drop curve
Mount the product to the wellbore branch pipe.
For automatic removal of the recovery curve or level drop, set the
type of investigation LRC (level recovery curve) or LDC (level drop
curve). Set the acoustic pulse generation by solenoid valve. Set the period
of activation of the well sounder and the number of measurements in the
first interval. If one interval is not enough, set the necessary activation
periods and number of measurements in all necessary intervals. To start the
automatic mode, press the "Start" button on the "Start" tab.
In 5 seconds, on the "Information" tab, you will be able to observe
the current interval and the time before measurement. Then you can turn
off the product. The product will be switched on automatically with the
period specified in the first interval. After the number of measurements in
the first interval, the product will turn on with the period set in the second
interval, and so on until the fifth interval is completed or the next interval
is zero.
In automatic mode, the device records an echo together with a
symbolic report in a memory area designed to record 310 echoes. In this
case, the symbolic report is duplicated in the memory area designed to

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record 3008 symbolic reports. Even after the memory area for recording
310 echoes has been used up, the symbolic report will remain in the
memory for 3008 symbolic reports.
To save memory and battery consumption, set the switch-on period
from 30 to 90 minutes, number of measurements 9, 15.
To save battery and valve life, to remove LRC or LDC it is
recommended to set interval mode as follows:
- first interval - period of switching on 5 minutes, number of
measurements - 10;
- second interval - period of switching on 10 minutes, number of
measurements - 20;
- the third interval - period of switching on 30 minutes, number of
measurements - 20;
- the fourth interval - the period of inclusion 60 minutes, the number
of measurements - 20;
- the fifth interval - the period of inclusion 180 minutes, the number
of measurements - 7.
With the enabled resolution of the transition from the LRC, LDC in
the mode of automatic pressure recording, if the fluid level falls below 50
m and the number of reflections greater than eight, the transition to the
mode of automatic pressure recording will occur.
At deep discharge of the accumulator there is an automatic
switchover to the mode of automatic pressure registration.
For the mode of automatic pressure recording, the switch-on period
and the number of measurements are set separately.
2.5.4. Automatic recording of gas pressure in annular space at
wellhead
Mount the product to the wellbore branch pipe.
On the "Start" tab set the type of LRC investigation, the frequency of
switching on and the number of measurements. Click the "Start" button.
In 5 seconds on the "Information" tab you will be able to observe the
current interval and the time to measure. Then you can turn off the product.

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The product will automatically switch on after a specified period of time,
work about 0.2 seconds (measure pressure, record the measurement in
memory), automatically switch off and so on.
It is recommended to choose the measurement period so that no more
than 3008 measurements were made during the total planned operation
time.
2.5.5. Cancel the automatic mode of HLC, CPU, KVD
In the modes of LRC, LDC, LRP you can turn on the product, view
modes, perform data transfer to your computer.
To cancel the automatic mode, set the examination type DYN or
STAT.
2.5.6. Battery charge
Do not charge the battery at temperatures below 0C.
To charge the battery, connect the mains adapter to the 220 V / 50 Hz
network or the car adapter to the cigar lighter socket from the car's on-
board 12 V network. Connect the USB cable to the automatic well sounder.
The "Charge" LED will light up red. Charging a discharged battery takes
on average 10 hours. After the battery is charged, the "Charging" LED will
glow green as long as the adapter is connected to the power supply.
2.5.7. Connecting to another grid
To reconnect to another grid of the radio channel, briefly press the
power on button seven times. The "Power" LED will light up red for 4
seconds. After that, turn off and on the product.

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2.5.8. Testing the product
When the power is turned on, the product performs a self-diagnosis
and may detect malfunctions. At the same time, the "Power" LED starts
flashing red (if no malfunction is detected, the LED lights up green). The
number of flashes per second equals the fault number. After ten seconds,
the flashing cycle is repeated.
1 - loss of setting factors. At short pressing of the power button, the
setting factors (sensitivity of the pressure sensor, etc.) are filled with the
initial values. Usually this malfunction is displayed at the factory when the
product is put into operation for the first time;
2 - ferromagnetic memory malfunction;
3 - analog-to-digital converter malfunction;
4 - no response from the radio channel module;
5 - clock fault;
6 - clock malfunction;
7 - flash memory malfunction.
When highlighting faults 2, 3, 4, 6, 7, send the product for repair.
2.6. Well sounder disassembly
Turn off the device.
Close the gate valve of the technological branch.
Open the device outlet valve and bleed excess pressure from the
working volume.
Unscrew the product and remove it from the branch pipe. Drain the
condensate from the working volume, clean the threaded part and put the
product in a regular bag.
Close the branch pipe with the technological plug.

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3. MAINTENANCE
3.1. Order of Well sounder Maintenance
Provide the maintenance of the device according to the Table 2.
Table 2
Type of works
Period
Personnel
Cleaning of the tapered connecting
thread, the acoustic sensor, the well
sounder and the case (see p. 3.2)
every week
Operating
personnel
Maintenance of the exhaust valve
(see p. 3.3)
every month
Operating
personnel
Cleaning of accumulator charging
socket (see p. 3.4)
every month
Operating
personnel
Performance monitoring (see
p. 3.5)
every 6 months
Service center
or “TSIIC
SIAM” LLC
certified
specialists
Pressure tests (see p. 3.6)
every 6 months
Service center
or “TSIIC
SIAM” LLC
certified
specialists
Replacement of the valve sealing
ring * (see p. 3.7)
every 12 months
Service center
or “TSIIC
SIAM” LLC
certified
specialists

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* The valve sealing rubber ring ( p.5 figure 1) is possible to be
replaced by operating personnel
3.2. Cleaning Tapered Connecting Thread, Acoustic Sensor, Well
sounder and Sensor Case
Cleaning is done using pure gasoline, a brush and a cleaning rag. It
is allowed to pour a small amount (50…100ml) of gasoline inside the
threaded coupling cavity while cleaning. However, do not immerge the
well sounder housing in the cleaning liquid, and do not let its ingress in the
connector. When cleaning a very dirty thread, application of metal tools
(an awl, a screwdriver, etc.) is allowed, but do not apply an excessive force
not to damage the thread.
It is strictly forbidden to use a metal tool for cleaning the acoustic
and pressure sensors. Moreover, be careful not to apply much force during
cleaning. Acoustic sensor housing is covered with a protective varnish, do
not damage it! It is forbidden to insert foreign objects in the pressure
sensor hole!
Wipe the surfaces with a rag after washing. Cleaning should result
in a metallic lustre on the coupling surfaces, connecting thread, acoustic
sensor, and clean holes of pressure sensor and fitting.
The outer surfaces of pressure sensor are wiped with a clean rag,
wetted in a small amount of gasoline, and then wiped dry.