Installation Manual - Model 5 - Tundra Process Solutions Ltd.

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REV D (10-22-10)INSTALLATION MANUAL – D5Table of ContentsSECTION 1. INTRODUCTION .............................................................. 2Scope of Document.......................................................................................................................... 2Description of Basic Components .................................................................................................... 2Pumping Unit .................................................................................................................................. 2Power Unit ...................................................................................................................................... 3SECTION 2. SITE PREPARATION ....................................................... 4Piers Setup ....................................................................................................................................... 5Skid Installation and Pumping Unit Placement ................................................................................ 5SECTION 3. TOOLS AND SPECIAL EQUIPMENT ................................ 6Recommended Tools ....................................................................................................................... 6Computer Equipment ....................................................................................................................... 7DynaPump Equipment ..................................................................................................................... 7Special Equipment ........................................................................................................................... 7First Aid Equipment .......................................................................................................................... 7Safety Equipment ............................................................................................................................. 8Hydraulic Oil Specifications ............................................................................................................. 8SECTION 4. UNPACKING AND PUMP UNIT PREASSEMBLY ............. 9Shipment Types ............................................................................................................................... 9Pumping Unit Final Assembly ........................................................................................................ 10Power Unit ...................................................................................................................................... 21Transportation of Assemblies to the Site ....................................................................................... 21SECTION 5. INSTALLATION ............................................................. 22Pumping Unit .................................................................................................................................. 22Pre-installation Well Head Verification ........................................................................................... 24Power Unit ...................................................................................................................................... 34Final Assembly ............................................................................................................................... 35Checking Phase Orientation of Wiring ........................................................................................... 40External Shutdown Option ............................................................................................................. 41SECTION 6. DYNAPUMP SERVICE .................................................. 42Service ........................................................................................................................................... 42Repair and Replacement Parts Service ......................................................................................... 42APPENDIX A - SITE LAYOUT & INSTALLATION DRAWINGS .......... A-1APPENDIX B - INSTALLATION CHECKLIST .................................... B-1APPENDIX C - HISTORICAL CONFIGURATIONS ............................. C-1i
REV D (10-22-10)INSTALLATION MANUAL – D5List of FiguresFigure 1. Relative Positioning of Piers, Skids and Pumping Unit .................................................... 4Figure 2. Piers Setup ....................................................................................................................... 5Figure 3. Installing Celesco Transducer Assembly ....................................................................... 10Figure 4. Aligning the Cylinder (Base side shown) ....................................................................... 10Figure 5. Securing the Cylinder (Base Side) ................................................................................. 10Figure 6. Securing the Cylinder (Pulley Side) ............................................................................... 11Figure 7. Installing the Wiper Ring ................................................................................................ 11Figure 8. Installing Wiper Tabs ...................................................................................................... 11Figure 9. Installing Cable Sheaves ................................................................................................ 12Figure 10. PVC and Downpipe Connection ................................................................................... 12Figure 11. Hoisting Pulley Assembly ............................................................................................. 12Figure 12. Attaching L-bracket ...................................................................................................... 13Figure 13. Pulley Installation in Cylinder ....................................................................................... 13Figure 14. Inserting the Chain through PVC Pipe ......................................................................... 13Figure 15. Passing the Chain through Transducer Sprockets ...................................................... 14Figure 16. Securing the Snap Spring ............................................................................................ 14Figure 17. Terminating Chain with Counterweight ........................................................................ 14Figure 18. Securing the Counterweight ......................................................................................... 15Figure 19. Position Sensor and Sensor Bracket ........................................................................... 15Figure 20. Transducer Wiring ........................................................................................................ 15Figure 21. Cable Attachment Location on Power Unit .................................................................. 16Figure 22. Cable Installation .......................................................................................................... 16Figure 23. Routing the Pulley ........................................................................................................ 16Figure 24. Cable Routing Diagram ................................................................................................ 17Figure 25. Routing Cable under Sheave ....................................................................................... 17Figure 26. Finalized Pulley Routing ............................................................................................... 18Figure 27. Installing Wedge Sockets and Cable Clamps .............................................................. 18Figure 28. Leveling Feet on Base ................................................................................................. 18Figure 29. Assembled Field Unit with Stowed Carrier Bar ............................................................. 19Figure 30. Pressurizing Counterweight Charge Valve .................................................................. 19Figure 31. Brace Removal on Base Unit ....................................................................................... 20Figure 32. Hydraulic Tank Location ............................................................................................... 21Figure 33. Lifting the Pumping Unit ............................................................................................... 22Figure 34. Site Glass ..................................................................................................................... 23Figure 35. Typical Well Appearance ............................................................................................. 24Figure 36. Well Design Requirements ........................................................................................... 24Figure 37. BHP Plunger Spacing ................................................................................................... 25Figure 38. Pulley to Carrier Bar Distance ....................................................................................... 25Figure 39. Barrel to Plunger Length Distance ................................................................................ 26Figure 40. Improper Installation Scenarios ..................................................................................... 29Figure 41. Skid System ................................................................................................................. 30Figure 42. Cylinder Alignment: Verticality ..................................................................................... 31Figure 43. Cylinder Alignment: Verticality Adjustment .................................................................. 31Figure 44. Cylinder Alignment: Side-to-Side (and Front-Back) ..................................................... 32Figure 45. Cylinder Alignment: Side-to-Side (and Front-Back) Adjustment .................................. 32Figure 46. Cylinder Alignment: Setback Distance ......................................................................... 33Figure 47. Power Unit to Pumping Unit Connections .................................................................... 35Figure 48. Hydraulic Hose Connections ........................................................................................ 36i
Page 1 and 2: Installation Manualfor the D5 Pumpi
Page 3: REV D (10-22-10)INSTALLATION MANUAL
Page 7 and 8: REV A (05-01-09)INSTALLATION MANUAL
Page 9 and 10: REV D (10-01-10)INSTALLATION MANUAL
Page 15 and 16: REV (-01-)INSTALLATION MANUAL - D5
Page 19 and 20: REV C (10-01-10)INSTALLATION MANUAL
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REV C (10-01-10)INSTALLATION MANUAL
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Installation Manual - Model 5 - Tundra Process Solutions Ltd.

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