Hydraulic Lift - BHGE · Hydraulic Lift Traffic Map 4 1.7 Training 4 2. Hydraulic Lift Unit...
Transcript of Hydraulic Lift - BHGE · Hydraulic Lift Traffic Map 4 1.7 Training 4 2. Hydraulic Lift Unit...
DISCLAIMER: ORIGINAL TRANSLATION
DOCUMENT CONTAINS IMPORTANT SAFETY INSTRUCTIONS AND INFORMATION. DO NOT DISCARD.
bhge.com
Hydraulic Lift Installation and Operation Manual
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | A
Foreword Baker Hughes, a GE company (BHGE), offers the Hydraulic Lift Unit (HLU) which is a single acting hydraulic cylinder
controlled by a computer program built to maximize the productivity of each stroke. The system uses unique technology
to precisely monitor and control the entire movement of the cylinder’s piston. The unit utilizes a manifold valve capable of
controlling the acceleration and deceleration of the polished rod which increases the life of the downhole equipment by
minimizing fluid pound which can cause excessive wear. The HLU converts rotational energy of a prime mover to
reciprocating vertical movement by utilizing fluid power created by a hydraulic pump. The HLU will offer dependable
service when properly installed, maintained, and operated within the system’s ratings. This manual is provided as a
reference guide for the operation of a Hydraulic Lift Unit (HLU). It does not cover all aspects of transportation, installation,
operation, decommissioning, and safety, or replace the need for trained BHGE service personnel to help ensure proper
setup and performance of this unit.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | C
Applicable Models
Overall Model Code: 01 02 03 04 05 06
HLU - - -
Sub-System Model Codes: 01 02 03 04 05 06
HLU - HLU - HLU - Tower Assembly Prime Mover Assembly Hydraulic Power Unit Assembly
Tower Assembly Designators
01 Artificial lift stroke length in 72 96 144 168 300
cm 182 244 365 426 762
02 Tower mounting style Pedestal Mount • • • • - PM
Direct Mount - • • • • DM
Prime Mover Assembly Designators
03 Maximum capable horse power of unit hp 40 75 100 200
kW 30 56 75 150
04 Prime mover power source Electric Motor • • • • EM
Natural Gas engine • • • • NG
Hydraulic Power Unit Assembly Designators
05 Maximum hydraulic oil capacity of system gal 165 240 445
L 625 908 1685
06 Enclosure type and style Enclosed system • • • N
External system • • - X
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | E
Applicable Ratings
USA and Canada Ratings
Tower Rating (Rated for Hazardous Locations)
UL Class 1, Division 1, Group D, T4
Prime Mover Rating (NOT rated for Hazardous Locations)
Hydraulic Power Unit Rating (NOT rated for Hazardous Locations)
European Union Ratings
Tower Rating (Rated for Hazardous Locations)
II 3 G Ex ia IIA T4 Gc
ATEX certificate applies to the
electrical components of the tower
and does not cover the non-
electrical components.
Certificate Number: DEMKO 17
ATEX 1845 (Standards Used for
Evaluation: EN 60079-0, EN 60079-
11)
Prime Mover Rating (NOT rated for Hazardous Locations)
Hydraulic Power Unit Rating (NOT rated for Hazardous Locations)
General Ratings Ambient Temperature Rating -20ᵒC to +40ᵒC
Prime Mover Electrical Ratings
1. Electrical ratings to be considered only for Electric Motor Prime Mover driven systems. 2. Reference: Sprecher + Schuh, Catalog # PCS-251-BBD54R1-SPL.
Model Max Input Voltage (V) Frequency (Hz) Phase Max Input Current (A) Max Output Voltage (V)
HLU-200EM 230/460 50/60 3 455/228 230/460
HLU-100EM 230/460 50/60 3 227/113 230/460
HLU-75EM 230/460 50/60 3 168/84.1 230/460
HLU-40EM 230/460 50/60 3 93.1/46.5 230/460
Prime Mover Natural Gas Engine Ratings
Model Operating Speed (RPM)
HLU-200NG 1800
HLU-100NG 1800
HLU-75NG 1800
HLU-40NG 1800
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | G
Contents
Foreword A
Applicable Models C
Overall Model Code: C
Sub-System Model Codes: C
Applicable Ratings E
General Ratings E
USA and Canada Ratings E
European Union Ratings E
Contents G
1. Safety Information 1
1.1 Hazard Identification 1
1.2 Potential Hazards/Risks 2
1.3 Emergency Stop 3
1.4 Lockout/Tagout (LOTO) 3
1.5 Personal Protective Equipment 4
1.6 Hydraulic Lift Traffic Map 4
1.7 Training 4
2. Hydraulic Lift Unit Overview 5
3. Standard Shipping Configuration 6
4. Installation 7
4.1 Fastener Torqueing 8
4.2 Fitting and Hose Torqueing 9
4.3 System Handling 10
4.4 Wellhead Preparation 12
4.5 Hydraulic Lift Unit Layout 14
4.6 Hydraulic Power Unit Install 15
4.7 Pedestal Mount Tower Install 19
4.8 Direct Mount Tower Install 26
4.9 Electric Motor Connection 30
4.10 Natural Gas Engine Connection 31
5. Operation 33
5.1 Electric Motor 33
5.2 Natural Gas Engine 34
5.3 Hydraulic System 34
6. Maintenance 35
Daily Maintenance 35
Weekly Maintenance 36
30 Day Maintenance 36
60 Day Maintenance 37
90 Day Maintenance 37
Biannual Maintenance 37
Yearly Maintenance 37
7. Troubleshooting 39
On Startup 39
During Operation 40
Unplanned Shutdown 42
Resetting the HLC 44
8. References 46
Office Locations 48
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 1
1. Safety Information Before proceeding with the installation, operation, or maintenance of the Hydraulic Lift Unit (HLU), familiarize yourself
with all Federal, State, and Local Laws, your company’s safety regulations, and the safety section of this manual. For your
protection, for correct unit operation, and avoiding unit damage, please heed all product safety signs attached to the HLU.
1.1 Hazard Identification
The signage will conform to the current industry’s signal word standards and regulations of the country the equipment is
sold into. For product in the United States, Canada, and European Union, the ANSI Z535 and ISO 3864 standards should
be used for all Signal Word signage.
The below Signal Word box will be present throughout the document, drawing attention to specific items one should know
or adhere to during the transportation, installation, operation, maintenance, or decommissioning of the system.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in serious injury or death.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death.
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in a minor to moderate injury or damage to the unit.
NOTICE indicates information considered important but not hazard related, such as possible machine damage or environmental, site, or facility signage.
Note: NOTE indicates an item to aid in the interpretation of this manual.
2 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
1.2 Potential Hazards/Risks
The Hydraulic Lift Unit (HLU) should be properly maintained and regularly serviced for the best reliability. HLU systems
have moving parts, high voltage, high pressure hydraulics, a mechanical rod lift system, and some Pedestal Mounted
towers have guy wires for anchoring against wind loads. Each of these technologies will have some potential hazards/risks
associated with their use. These hazards/risks can be reduced if the system is properly transported, installed, operated,
maintained, and finally decommissioned. Should any questions arise concerning the transportation, installation,
operation, maintenance, or decommissioning of the system, see contact information on the back of the manual.
1. Proper mating and tightening of all hydraulic hoses and torque values of all bolted connections must be maintained
at assembly. (See section 4.1 and 4.2 for torqueing values)
2. Hydraulic Lift does not recommend installation of, or maintenance of, units during thunderstorms, or any inclement
weather with rain, ice, snow, fog, or climate conditions that might cause personnel to be at risk due to lack of visibility
or possible slipping/falling.
3. Hydraulic Lift Units have pressurized hoses and components along with heavy moving parts. Even a temporarily
stationary system has components that can start moving from the effects of gravity. Extra CAUTION should be taken
during unit installation, general unit maintenance, and well servicing.
4. Do not assume a stationary HLU is not operational. Automatic timers can start units without warning.
5. Never stand under any type of lifted load. Cranes required for setting the units must be used with CAUTION, training,
and knowledge about heavy load lifts. Qualified lifting specialists to operate cranes. Customary practices for crane
operations should be followed.
6. Prior to moving the tower assembly, ensure the drain on the hydraulic cylinder is plugged to prevent the piston from
sliding out.
7. Lockout/Tagout all energy sources during any installation and servicing. All personnel must stay alert and keep clear
of potential moving parts.
8. The use of tag lines must be a standard practice for setting up different heavy load products.
9. Be aware of power line locations, keeping unit and service equipment away at a minimum distance of twenty feet.
10. Keep pumping unit at least twenty feet away from all overhead electric cabling.
11. All electrical work must be performed by a qualified electrician. Regularly inspect electric motors, automatic timers,
or any other electrical device.
12. Fuel for engines is highly combustible.
13. Check for gas leaks prior to any work or service on the unit.
14. All external fuel storage vessels must be placed a minimum of 50 feet away from the Prime Mover and are to include
isolation valves.
15. All external supplied fuel lines supplying Propane, CNG, LPG, or Natural Gas should be installed in accordance to all
local and regulatory governing bodies by qualified individuals.
16. H2S and other corrosive substances in the fuel lines will cause damage to the unit and possibly lead to personnel
injury or death.
1. Failure to heed SIGNAL WORD and SIGNAGE WARNINGS could result in severe bodily injury or death. 2. Failure to heed Potential Hazards/Risks could result in severe bodily injury or death.
1. Personnel who install, operate, or maintain the system must read this manual and must be trained in its use by
qualified HLU service personnel.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 3
1.3 Emergency Stop
Each Hydraulic Lift Unit is equipped with a minimum of two Emergency Stop Buttons (ESB). One is located on the Hydraulic
Lift Controller and the other on the hydraulic bulkhead as to be more easily accessible from outside the power unit. Electric
units will have an additional Emergency Stop Button located on the electrical control panel near the electric motor.
1.4 Lockout/Tagout (LOTO)
Lockout/Tagout (LOTO) refers to practices to safeguard employees during “the servicing and maintenance of machines
and equipment in which the unexpected energization or startup of the machines or equipment, or release of stored energy,
could harm employees.” (1)
Before working on or servicing any equipment on the unit, make sure proper LOTO procedures are followed. Possible LOTO
locations for the two Prime Mover options are shown below.
For Electric systems, follow the power supply back to ensure main disconnects are off to the entire unit.
For Natural Gas engine systems, ensure to follow the fuel supply back to the source and close off all isolation valves in
between.
Figure 4 - LOTO on Electric system Figure 5 - LOTO on Natural Gas Engine system and ball valve
Figure 1 - ESB on the Hydraulic Lift Controller
Figure 2 - ESB on the bulkhead Figure 3 - ESB on the electrical control panel
4 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
1.5 Personal Protective Equipment
Review and adhere to all site and governmental safety regulations. Snug fitting clothing recommended. Fire Retardant
Clothing (FRCs) is a typical requirement for well-site work. Remove all jewelry. Wear hard hats, side-shield safety glasses,
H2S gas monitor, hearing protection, and safety shoes. Anytime you perform work at such a height a fall could possibly
inflict injury, you should wear a safety harness. When possible, use a man lift or some other type of approved safety basket.
Refer to your company's safety regulations concerning clothing and tools.
Use proper tools for the job. Tools are designed for specific purposes and must be used properly. Always keep tools clean
and in good condition.
1.6 Hydraulic Lift Traffic Map
Figure 6 - Hydraulic Lift Traffic Map. Full size version is included with the unit.
1.7 Training
It is essential only properly trained personnel, under competent supervision, be allowed to work with this equipment.
Training programs are an important part of safe and correct operation. Training also provides the knowledge necessary to
maximize the performance of your equipment. GE recognizes the importance of training and conducts training sessions
to help familiarize your personnel with safe operating and maintenance procedures. These training sessions are held at
the Hydraulic Lift facility. There is a charge for this training and the dates for each session are chosen based on demand.
See contact information on the back of the manual to inquire about a session.
1. It is recommended that the provided HYDRAULIC LIFT TRAFFIC MAP (copy is displayed in Figure 6) be posted at
the entrance of all sites containing a Hydraulic Lift Unit for increased safety and awareness of the installed equipment.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 5
2. Hydraulic Lift Unit Overview
Note: 1. A Pedestal Mounted Tower with an Enclosed Hydraulic Power Unit is shown.
Hydraulic Power Unit
Cylinder
Pedestal
Power Hose
Polished Rod Coupling
Homerun Cable
Polished Rod
Vent Lines
Wellhead
6 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
3. Standard Shipping Configuration
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 7
4. Installation
1. Substitution of unapproved components may impair Intrinsic Safety. 2. Use of derricks or cranes without qualified and certified personnel is illegal and dangerous to workers. 3. Site grounding and proper PPE will be used to neutralize static discharge in zoned area. 4. A site plan for management of site risks and hazards and the location of all zoned areas is the responsibility of
the owner operator of the well site. 5. Death may occur. Cellar applications require testing before worker entry for presence of H2S gas or natural gas.
Cellars are confined spaces and entry is permitted to authorized personnel. 6. Removal of shaft guards during operation may cause injury or death. All guarding should be in place during
operation. 7. All personnel will be equipped with a personal H2S monitor. 8. Release of pressure can cause injury or death. If valves remain closed on the main hydraulic line at shutdown and
LOTO, it will be holding pressure.
1. Tall wellheads have to be accessed with a man-lift for personnel safety in installation. 2. Lifting products with an unknown weight or lift method should not be done. 3. Tripping and falling hazards exist at well sites. 4. Wildlife may cause injury or death. Snakes and other wildlife may be around or under machinery.
1. Upon delivery of the Hydraulic Lift Unit at the location and before installation, check condition of all components
for possible damage during transit. 2. Before proceeding with the installation of a pumping unit, you and your crew should fully discuss the upcoming
job. Make sure everyone is aware of the dangers involved. Review the Safety Information in section 1 prior to starting.
1. Unit installation is to be carried out by qualified personnel who are competent in hydraulics, electrical,
mechanical, gas engines, micro circuitry, and product applications.
8 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
4.1 Fastener Torqueing
Proper preloading torque in a bolted connection is crucial for maintaining the joint’s overall integrity. The surfaces under
the bolt head, nut, washer, and the contacting surface must be flat, clean, and free of burrs so the bolted members join in
“metal-to-metal” contact. Bolts, which are properly tightened during unit installation, and retightened a week later, will
retain their grip under normal operating conditions. Improperly tightened bolts may fail due to fatigue and may cause
serious injuries to personnel. The following tables provide torque ranges, dependent on joint lubrication status and bolt
grade and size, for the joints in the application.
Table 1
Preload Torque, Dry [ft.-lbs.] Preload Torque, Lubricated [ft.-lbs.]
Bolt Size Minimum Maximum Minimum Maximum 3/8” – 16 UNC 19 21 15 17
7/16” – 14 UNC 30 34 24 27 1/2” – 13 UNC 46 51 37 41
Grade 2 Low or Medium
Carbon Steel
5/8” – 11 UNC 92 102 74 82 3/4” – 10 UNC 164 181 131 145
7/8” – 9 UNC 158 175 127 140
1” – 8 UNC 237 262 190 210
Table 2
Preload Torque, Dry [ft.-lbs.] Preload Torque, Lubricated [ft.-lbs.]
Bolt Size Minimum Maximum Minimum Maximum 3/8” – 16 UNC 29 32 23 26
7/16” – 14 UNC 47 52 38 42 1/2” – 13 UNC 72 79 57 63
Grade 5 Medium Carbon Steel, Quenched and Tempered
5/8” – 11 UNC 143 158 114 126 3/4” – 10 UNC 253 280 203 224
7/8” – 9 UNC 408 451 326 361
1” – 8 UNC 611 676 489 541
Table 3
Preload Torque, Dry [ft.-lbs.] Preload Torque, Lubricated [ft.-lbs.]
Bolt Size Minimum Maximum Minimum Maximum 3/8” – 16 UNC 41 46 33 37
7/16” – 14 UNC 66 73 53 59 1/2” – 13 UNC 101 112 81 89
Grade 8 Medium Carbon
Alloy Steel, Quenched and
Tempered
5/8” – 11 UNC 201 222 161 178 3/4” – 10 UNC 357 395 286 316
7/8” – 9 UNC 576 636 461 509
1” – 8 UNC 863 954 691 763
1. Proper eye protection must be worn. Flying metal could cause damage to the eyes.
1. Bolts are more apt to fail in fatigue from inadequate torque than shearing apart from excessive torque. 2. Below recommendations apply to Floating Fastener joints. If the male/female threads of the application contain
dissimilar metals, contact engineering to verify if the below preload values are applicable.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 9
4.2 Fitting and Hose Torqueing
4.2.1 PTFE (Teflon) Sealing Tape
If PTFE (Teflon) sealing tape is used it should be wrapped 2 to 3 turns in clockwise direction when viewed from the pipe
thread end. Make sure to not overlap the end of the fitting. Stretch tape enough to pull into the thread without causing
the thread tape to shred.
4.2.2 JIC Fitting Torqueing
Tighten the fitting lightly with a wrench (approximately
30 in lbs.), clamping the tube flare between the fitting
nose and the sleeve. This is considered the Wrench
Resistance (WR) position.
Starting at Wrench Resistance, tighten the fitting further
by the number of Flats listed in Table 4.
Table 4
Dash Size Fitting Size FFWR
-02 1/8” JIC 2.0
-04 1/4” JIC 2.0
-06 3/8” JIC 2.0
-08 1/2” JIC 1.5
-10 5/8” JIC 1.5
-12 3/4” JIC 1.5
-16 1” JIC 1.5
-20 1 1/4” JIC 1.0
-24 1 1/2” JIC 1.0
-32 2” JIC 1.0
FFWR: Flats From Wrench Resistance
1 Flat = 60° or 1/6 of a turn
4.2.3 NPT Fitting Torqueing
Use sealing tape on NPT fittings. Tighten the fitting until
it is finger tight ensuring the threads are properly aligned
and not cross-threaded. This is considered the Finger
Tight (FT) position.
Starting at Finger Tight, tighten the fitting further by the
number of full Turns listed in Table 5.
Table 5
Dash Size Fitting Size TPFT
-02 1/8” NPT 1.5-3.0
-04 1/4” NPT 1.5-3.0
-06 3/8” NPT 1.5-3.0
-08 1/2” NPT 1.5-3.0
-10 5/8” NPT 1.5-3.0
-12 3/4” NPT 1.5-3.0
-16 1” NPT 1.0-2.5
-20 1 1/4” NPT 1.0-2.5
-24 1 1/2” NPT 1.0-2.5
-32 2” NPT 1.0-2.5
TPFT: Turns Past Finger Tight
1 Turn = 360° or 1 full turn
1. Proper eye protection must be worn. Flying metal could cause damage to the eyes.
10 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
4.3 System Handling
4.3.1 Lifting the Tower Assembly
The smart cylinder Pedestal Mount and Direct Mount towers are lifted using a forklift.
Figure 7 – Pedestal Mount tower lifted by a forklift
4.3.2 Lifting the Hydraulic Power Unit (HPU) and Prime Mover
Open skid HPU can be handled by:
• Using a forklift.
Figure 8 – Forklift lifted Open Skid
1. Use of derricks or cranes without qualified and certified personnel is illegal and dangerous to workers. 2. Forklift operators should be certified for lifting operations. It is a danger to workers to use uncertified lift
personnel.
1. Perform all necessary safety precautions before beginning any work on or around the HLU. Failure to follow all
safety precautions can lead to damage to the equipment, personal injury or death.
1. Check the load before lifting. Make sure the total weight of the load and its center of gravity is secure.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 11
• Using crane shackles at the lifting points.
Figure 9 – Lifting Points on Open Skid
Power unit in a housing container should be lifted by a forklift only.
Figure 10 – Forklift Pockets on Container
Figure 11 – Lifting Lugs on Container
1. The lifting lugs provided on the container should not be used for lifting purposes.
12 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
4.4 Wellhead Preparation
1. Space out rods to allow the HLU to achieve full stroke.
2. Install BOP onto wellhead (if ordered).
3. Install flow tee (if required).
Figure 12 – BOP & Flow Tee
1. Proceed with care as the well may be under pressure. 2. Do not stand under load while it is being installed.
1. Use only flanged pressure rated steel BOP’s. Cast iron or ductile iron BOP’s are not suitable due to extreme forces
from wind loads and hydraulic loads. 2. Use only flanged pressure rated steel Tee’s. Cast iron or ductile iron Tee’s are not suitable due to extreme forces
from wind loads and hydraulic loads.
1. Cylinder to wellhead alignment should always be perpendicular.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 13
4. Review the mounting style chosen, EUE baseplate or flange baseplate.
5. Install the polished rod clamp.
6. Remove fasteners from mounting system to prepare for tower install.
Figure 15 – Fasteners removed on an EUE baseplate
7. Install mounting baseplate on the wellhead.
Figure 13 - Flange mounted baseplate
Figure 14 - EUE mounted baseplate
1. Ensure the baseplate is level with the wellhead, not the ground.
14 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
4.5 Hydraulic Lift Unit Layout
Table 6
Tower Model Dimension ‘A’ (in) Dimension ‘B’ (in)
HL-300DM 323 264
HL-168DM 191 96
HL-168PM 412 96
HL-144DM 167 96
HL-144PM 363 96
HL-96DM 119 96
HL-96PM 267 96
HL-72PM 216 96
1. Total Height Dimension is contingent on the particular Wellhead configuration. 2. Standard minimum setback dimension from tower shall be 30 ft. Setback can be extended further as a special
order.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 15
4.6 Hydraulic Power Unit Install
1. Determine the desired location of the Hydraulic Power Unit (HPU). Consider zoned areas around the wellhead and
piping direction to avoid HPU placement in a zoned area. The standard set-back distance of the HPU from the wellhead
is 30 feet with the HPU’s bulkhead facing the wellhead.
2. Ensure the HPU’s location is level. If not, construct a level base for it.
Figure 16 – Level Base
1. Do not stand under load while it is being installed. 2. Substitution of components may impair Intrinsic Safety 3. Use of derricks or cranes without qualified and certified personnel is illegal and dangerous to workers. 4. Forklift operators should be certified for lifting operations. It is a danger to workers to use uncertified lift
personnel. 5. LOTO electrically or mechanically must be done before work begins of all energy sources. 6. Presence of Toxic gases can cause death or injury. Before Entry, testing is required to check for presence of H2S,
Natural gas and carbon monoxide gas. 7. Confined spaces can cause death or injury. 8. To prevent the use of the OSHA confined space rule, LOTO all doors to be locked open during service, setup, and
maintenance to allow immediate exit. 9. Reversal of LOTO requires that the service man or men look inside the enclosure to be sure no one is trapped
inside the enclosure.
1. Lifting products with an unknown weight or lift method should not be done. 2. Incompetency of installers/users may cause death or injury 3. Hydraulic fluid leaks will impose an environmental issue. Proper cleanup will be required. 4. Use of unauthorized parts can lead to product failure.
1. Pinch points in lifting may cause injury or dismemberment. 2. Swing Doors / Overhead Door closure may cause injury.
16 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
3. Fasten the crane shackles to the designated lifting points on the HPU or use the forklift pockets.
Figure 17 – Lifting points
4. Carefully lift the HPU, keeping jolting to a minimum, and position it in the determined location.
Figure 18 – HPU positioned in determined location
5. Connect the Power Hose and Vent Lines to their respective bulkhead connections.
Figure 19 – Hose connections
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 17
6. Choose the correct Hydraulic Oil ISO grade from Table 7 for the ambient temperature of the application, where the
average temperature is in the center of the applicable range.
Table 71
7. Fill the hydraulic tank up to the required level with filtered hydraulic oil.
Figure 20 – Hydraulic Oil Filled in Tank
1 Oil specifications may vary by brand. Review vendor cut sheets for details.
18 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
4.6.1 Grounding Installation
1. Attach ground wire to the bulkhead at the clamping lug and run to the wellhead.
Figure 21 - Grounding connection on bulkhead
2. Attach grounding wire to the 2” ground clamp on the flow line or next to the wellhead.
Figure 22 – Grounding connection on Wellhead
3. Certified electrician will hook up the electric from there.
1. Only certified electricians are authorized to perform electrical work. 2. Loss of Grounding system can cause ignition in exposed atmospheres. Grounding should be monitored at
installation and maintained by monthly maintenance. 3. Site grounding and proper PPE to be used to neutralize static discharge in zoned area.
1. If the flow line is disconnected, make sure there is a clean grounding when it is reconnected.
Note: 1. Determine which Tower style is being used before proceeding as that will determine which section must be
followed. Once determined, skip to section.
Pedestal Mount Tower Install
Or
Direct Mount Tower Install
Grounding Lug
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 19
4.7 Pedestal Mount Tower Install
1. Check for correct orientation of hydraulic pressure lines to pressure line valve.
2. Fasten the lift slings to the cylinder trunnion at the top of the tower and install a chain tag line to the bottom of the
tower using a forklift or machinery. This will hold the bottom of the tower connection above the ground to keep dirt,
rocks and grime out of the lower connections as the lift system raises the tower.
Figure 23 – Lift Slings
3. Tie a sling onto the Rod Adapter and leave it hanging down through center of the pedestal.
1. Do not stand under load while it is being installed. 2. High pressure leak can cause environmental damage and possible health issues for personnel. 3. Use of derricks or cranes without qualified and certified personnel is illegal and dangerous to workers. 4. Forklift operators should be certified for lifting operations. It is a danger to workers to use uncertified lift
personnel. 5. Wellhead leakage of wells with H2S may cause death.
1. Lifting products of an unknown weight, or with a nonstandard lift method, should not be done. 2. Pinch points in lifting may cause injury or dismemberment. 3. Incompetency of installers/users may cause death or injury. 4. Inadvertent hitting of tower by site vehicles can cause injury or death.
1. It is important to note that a PR (Polished Rod) coupling must be used and correctly torqued on both rod end
connections or failure may result at this joint.
1. Engineering advises the use of Guy Wires on EUE Pedestal Mount applications to increase the tower’s stability. 2. Rod Adapters are available in 1” pin connections for API Polished Rod Couplings.
20 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
4. Install the Electrical control cable to the top of the tower.
Figure 24 – Power cable
5. Install the guy wire cables to the holes provided in the tower plate.
Figure 25 – Guy wire connecting holes
Guy Wire
Connecting Holes
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 21
6. Slowly lift the tower up and position it vertically over the specified wellhead adapter, either the baseplate or flange
adapter.
Figure 26 – Tower positioned vertically over wellhead
7. Use the tag line to turn the tower until the Power Hose and Vent Lines are pointed towards the HPU.
8. Align the bolt holes and lower onto the wellhead interface.
Figure 27 – Tower Bolt Holes alignment
22 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
9. Mate the Tower assembly to the adapter and install the supplied fasteners to specified torque values as per Fastener
Torqueing in section 4.1.
Figure 28 – Tower bolted on wellhead
10. Follow Figure 29 to ensure proper guy wire installation. To calculate the distance of the stakes from the wellhead,
[tan(30) ≈ 0.5774], therefore use [𝑌 = 𝑋 × 0.5774] to find Y.
Figure 29 – Proper Guy Wire Angles
11. Sink each stake at a 45° angle up to their eye.
Figure 30 - Installed Guy Wire stake
1. The height of each tower will be different based upon the wellhead configuration.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 23
12. Install the three supplied Guy Wire Stakes, at 120° apart, around the tower. Recommendation: Install one guy wire in
the direction of the Hydraulic Power Unit (HPU), running parallel with the hydraulic hoses as demonstrated in Figure
31, as to reduce equipment footprint on the well site.
Figure 31 – Guy wire spacing and placement
13. Install Guy Wire cables and tighten until taut.
Figure 32 – Guy wire cables
14. Connect the Power Hose to the Quick Disconnect (QD) fitting on the tower.
Figure 33 – QD Fitting for Power Hose
1. Ensure the yellow guy wire markers are installed on the guy wires.
24 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
15. Using the sling previously attached to the Rod Adapter, pull down the cylinder rod.
16. Thread the Rod Adapter to the polished rod, and correctly tighten to coupling standards for polished rod to sucker rod
grade in use. Hand-tighten first and mark the two rod coupling connections by displacement method. Torque to the
correct tightness. Check by measuring with a supplied rod displacement card.
Figure 34 – Rod Adapter
17. Run the Homerun Cable through the HPU’s bulkhead to the controller.
Figure 35 – Homerun Cable
1. Incorrect tightening of polished rod couplings can cause early failure of the jointed connection.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 25
18. Connect the Vent lines to their respective connections on the Tower Assembly.
Figure 36 – Vent Lines
19. Remove all shackles and slings from the Tower Assembly.
20. Tie down all the hoses and cables together.
Figure 37 – Cables and Hoses
26 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
4.8 Direct Mount Tower Install
1. Check for correct orientation of hydraulic pressure lines to pressure line valve.
2. Fasten the lift slings to the cylinder trunnion at the top of the tower and install a chain
tag line to the bottom of the tower using a forklift or machinery. This will hold the
bottom of the tower connection above the ground to keep dirt, rocks and grime out of
the lower connections as the lift system raises the tower.
Figure 38 – Lift Slings
1. Do not stand under load while it is being installed. 2. High pressure leak can cause environmental damage and possible health issues for personnel. 3. Use of derricks or cranes without qualified and certified personnel is illegal and dangerous to workers. 4. Forklift operators should be certified for lifting operations. It is a danger to workers to use uncertified lift
personnel. 5. Wellhead leakage of wells with H2S may cause death.
1. Lifting products of an unknown weight or with an nonstandard lift method should not be done. 2. Pinch points in lifting may cause injury or dismemberment. 3. Incompetency of installers/users may cause death or injury. 4. Inadvertent hitting of tower by site vehicles can cause injury or death.
1. It is important to note that a PR (Polished Rod) coupling must be used and correctly torqued on both rod end
connections or failure may result at this joint.
1. Rod Adapters are available in 1” pin connections for API Polished Rod Couplings.
Figure 39 – Direct Mount
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 27
3. Install the Electrical control cable to the top of the tower.
Figure 40 – Power cable
4. Slowly lift the tower up and position it vertically over the flange adapter.
5. Use the tag line to turn the tower until the Power Hose and Vent Lines are pointed towards the HPU.
6. Thread the Rod Adapter to the polished rod, and correctly tighten to coupling standards for polished rod to sucker rod
grade in use. Hand-tighten first and mark the two rod coupling connections by displacement method. Torque to the
correct tightness. Check by measuring with a supplied rod displacement card.
Figure 41 – Rod Adapter
1. Incorrect tightening of polished rod couplings can cause early failure of the jointed connection.
28 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
7. Align the bolt holes and lower onto the wellhead interface.
8. Mate the Tower assembly to the adapter and install the supplied fasteners to specified torque values as per Fastener
Torqueing in section 4.1.
9. Connect the Power Hose to the Quick Disconnect (QD) fitting on the tower.
Figure 42 – QD Fitting for Power Hose
10. Run the Homerun Cable through the HPU’s bulkhead to the controller.
Figure 43 – Homerun Cable
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 29
11. Connect the Vent lines to their respective connections on the Tower Assembly.
Figure 44 – Vent Lines
12. Remove all shackles and slings from the Tower Assembly.
13. Tie down all the hoses and cables together.
Figure 45 – Cables and Hoses
Note: 1. Determine which Prime Mover style is being used before proceeding as that will determine which section must
be followed. Once determined, skip to the designated section.
Electric Motor Connection
Or
Natural Gas Engine Connection
30 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
4.9 Electric Motor Connection
1. Ensure the Main Disconnect is in the OFF position.
2. Open the Electric Motor starter panel and layout wiring pattern.
3. Hot connection from the grid is to connect to the Main Disconnect as pointed out in Figure 46.
Figure 46 - Electric Motor control panel showing disconnect
4. Ensure cables are tight and secured before closing the control panel for operation.
1. Only certified electricians are authorized to perform electrical work. 2. Wiring modifications are strictly prohibited. 3. Loss of Ground in Zoned area can lead to explosion and death. Monitoring is required. 4. Death or injury may occur. Changing the speed of the engine up may over pressurize equipment and lead to
failure. 5. Contact with high pressure leaking hydraulic fluid requires immediate medical attention.
1. Severe Burns can occur from electrical arc or discharge. Burn Hazard and Risk apply for any electric motor
application FRC clothing must be used along with other PPE. 2. Hydraulic fluid leaks will impose an environmental issue. Proper cleanup will be required. 3. Health and Environmental exposure items containing Chromium and Cadmium must be disposed of correctly
(Electrical Items etc.).
Note: 1. The delivered control panel may appear different than pictured below.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 31
4.10 Natural Gas Engine Connection
1. Decide whether the unit is to run off well gas, propane/butane, or be tied into both, and whether it is an Enclosed
skid or External skid. Figure 47 displays the possible differences between connecting to the two different variations.
Figure 47 – Natural Gas Fuel Connections for Enclosed Skids (left) and External Skids (right)
2. If well gas will be used, 1.5-inch piping needs to be run from the wellhead, into the side of the supplied Gas
Separator, and then between the separator and labeled HPU connections shown in Figure 47.
3. For propane/butane connection, connect the storage tank directly into its labeled inlet connection on the skid.
4. If the engine’s fuel source is wellhead gas, a gas separation volume tank, functioning with a minimum of 6 ounces of
head pressure, will be required. The volumetric flow demand, created by the engines displacement, must be
supported with the available pressure and piping or the engine may not start or perform properly. The volume tank
associated with the single stage separator helps to overcome momentary pressure fluctuations that might
otherwise affect engine performance.
5. Fuel Line PID, Figure 48, on Next Page
1. Removal of Gas from engine requires LOTO and a locked isolation. Follow LOTO procedures in section 1.4. 2. Check for leaking fuel supply before starting service on the unit. 3. Cleanliness of Natural Gas must be noted. H2S, CO2, etc. should not be present. A clean, dry fuel that has a high
enough BTU rating is required for gas engine application. The presence of H2S , CO2, or other contaminant will be detrimental to the engine and equipment.
4. Supplying a fuel into the wrong port on the engine may result in damage to the equipment or personal injury. 5. Death or injury can occur. Battery acid leaks or explosion can cause breathing problems, dissolving flesh,
blindness and death. 6. Explosion may occur, causing Death or injury.
1. Do not co-mingle fuel lines. All lines are to be independent. 2. Severe Burns can occur. Burn Hazard and Risk apply for any Natural Gas engine as well has exposure to exhaust
heat. FRC clothing must be used along with other PPE. 3. Injury may occur without proper ventilation for fumes, gas, and heat. 4. Health and Environmental exposure items containing Chromium and Cadmium must be disposed of correctly.
(Electrical Items, etc.) 5. Oil leaks will impose an environmental issue. Proper cleanup will be required.
1. The Natural Gas Prime Movers come hooked up to the inside bulkhead “BUTANE/PROPANE” and “WELL BORE
GAS” ports. It is the responsibility of the end user to connect from the bulkhead to the gas separator and well gas, or directly to the propane tank.
2. Review the typical fuel line PID in Figure 48.
32 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
Fig
ure
48
- T
ypic
al f
ue
l in
sta
lla
tio
n (
Gre
yed
po
rtio
ns
are
pro
vid
ed
wit
h u
nit
)
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 33
5. Operation
5.1 Electric Motor
After the electrical lines have been plugged into the starter panel and a certified electrician has signed off on the work, flip
on the main breaker and begin to ramp up the system.
Figure 49 – Electrical Panel
1. Examination of HPU and Cylinder controls should be done before startup of pumping unit to look for sabotage. 2. Death or Injury may occur. All Guards should be in place before startup of unit. 3. Contact with high pressure leaking hydraulic fluid requires immediate medical attention 4. Explosive zoned area - No Smoking. Hot Ignition Sources can cause Ignition. No Flames, Sparks, or Welding.
1. To prevent ignition of flammable or combustible atmospheres, read, understand, and adhere to the
manufacturer’s live maintenance procedures. 2. To prevent ignition of flammable or combustible atmospheres, disconnect power before servicing 3. Use of unauthorized parts can lead to product failure. 4. Death or Injury can occur. Trip and fall hazards exist in HPU due to tanks, coolers, motors, electrical and hydraulic
hoses any of these items along with poor lighting can cause a trip or fall. 5. Steel items have sharp edges that may cause injury.
1. Ensure all Hydraulic line connections are tight. 2. Ensure all hydraulic line ball valves are open. 3. Inspect for evidence of leaks, hydraulic oil or gas. 4. Remove Polished Rod clamp before proceeding. 5. Poor light visibility may cause a tripping hazard in the HPU if the doors and vents are completely shut or day light
hours have expired.
1. Refer Lufkin Well Manager Hydraulic Lift Controller Setup Guide to set the parameters of the well in the HLC.
1. Electricity is a danger if not handled properly. All electrical work should be performed by qualified electricians.
Main Disconnect
34 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
5.2 Natural Gas Engine
Fuel gas is fed to the engine via gas lines running from the wellhead to the gas separator tank on the pumping unit or from
an appropriate pressure tank set for the operation. The engine acquires the required volume of gas from the separator
tank and with the correct pressure from the regulator. Some units are equipped with a flow valve to allow gas to flow to
the engine. Open the gas flow valve to allow the gas to flow to the engine. Open the hydraulic fluid bypass valve to allow
engine start up without the well load allowing it to warm-up.
5.3 Hydraulic System
1. Dual Pump: Loosen the locknut on the pressure compensator valve.
Figure 50 – Pressure Compensator Valve
2. Dual Pump: Rotate the knob clockwise to increase the pressure.
3. Single Pump: Adjust the pressure compensator on the pump.
4. Once the cylinder rod starts moving, close the ball valve on the manifold, and increase the pressure by 500 Psi to
ensure the well load will be lifted. Then open the ball valve to continue operation.
5. Tighten the locknut on the pressure compensator spool.
1. Natural gas is extremely flammable. Verify all connections are tight before opening valves and energizing the
system. 2. Cleanliness of Natural Gas must be noted. H2S, CO2, etc. should not be present. A clean dry fuel that has a high
enough BTU rating is required for gas engine application. The presence of H2S or CO2 will be detrimental to the engine and equipment.
1. Refer to the HLC Setup Guide Page 1-6.
1. Actions 1-2 are for Dual Pump configurations only. 2. Action 3 is for Single Pump configurations only. Refer to the hydraulic pump manufacturer’s manual if adjustment
is needed.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 35
6. Maintenance
Component Schedule Task Action
Daily Maintenance
Tower Inspect the cylinder for damage or leaks. Contact a service representative.
Hydraulic System Inspect for loose hardware, hoses, or fittings. Tighten or replace as necessary.
Inspect for abrasion, pinching, kinking, cracking, or excessive bending and twisting of hydraulic hoses.
Replace damaged hoses as required.
Inspect hydraulic fluid sight glass to ensure the fluid is at a proper level.
Fill or replace and contact a service representative.
Electrical System Inspect for abrasion, pinching, kinking, cracking, or excessive bending of cables.
Replace damaged cables as required.
Engine Inspect oil pressure gauge. Adjust or fill as necessary. 2
Inspect oil level indicator to ensure it is at proper level.
Adjust or fill as necessary.2
Inspect Fuel Lines. Tighten or replace as necessary.
Inspect Scrubber Pot Drain.
2 Item is required maintenance. If not followed, warranty on the HLU is void.
1. Presence of Toxic gases can cause death or injury. Before Entry, testing is required to check for presence of H2S,
Natural gas and carbon monoxide gas. 2. Confined spaces can cause death or injury. 3. To prevent the use of the OSHA confined space rule, LOTO all doors to be locked open during service, setup, and
maintenance to allow immediate exit. 4. Reversal of LOTO requires that the service man or men look inside the enclosure to be sure no one is trapped
inside the enclosure. 5. Failure to perform all necessary safety precautions before beginning work may cause damage to equipment,
personal injury or death. 6. To prevent ignition of flammable or combustible atmospheres, disconnect power before servicing.
1. Only certified OEM parts from factory approved vendors should be used for warranty of equipment, safety of
personnel and environment. 2. Health and Environmental exposure items containing Chromium and Cadmium must be disposed of correctly
(Electrical Items etc…).
1. Never approach a hydraulic unit assuming everything is functioning properly. With time, some components could
work loose and present a potentially dangerous situation. 2. Do not perform any task on the unit until you review the Safety Information in section 1 of this manual. The unit
must be powered down. 3. Always follow the LOTO procedure mentioned in the Safety Information in section 1 of this manual.
4. Gauge Isolators must be the kept closed and shut off when Operators are not present.
36 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
Component Schedule Task Action
Weekly Maintenance
Complete all previously listed inspections
Hydraulic System Inspect gauges to ensure system pressure functions properly.
Refer to Operation Manual if adjustments are needed.
Inspect the suction and return filter indicators for cleanliness.
Clean or replace as required. The suction filter is a screen that will need to be inspected.
Inspect manifold for damage or leaks. Contact a service representative.
Inspect the skid for accumulated liquid. Clean and dry as necessary.
Engine Inspect fluids to ensure they are filled to proper levels.
Replenish fluids as needed.
Inspect the Gas Separator for proper operating pressure.
Adjust as needed.
30 Day Maintenance
Complete all previously listed inspections
Tower Inspect for fluid leakage at the gland seal, fittings, and hoses.
Contact a service representative.
Inspect the tautness of the guy wires, tightness of hardware, and check the cylinder to ensure it is perpendicular to wellhead (using a level).
Adjust or tighten as needed.
Verify the control system is reading the sensor.
Contact a service representative.
Hydraulic System Function test all valves to ensure proper operation.
Contact a service representative.
Function test Hand/Off/Auto switch, Breaker, E-Stop, High/Low hydraulic oil float switch, and Temperature switch to ensure functionality.
Contact a service representative.
Inspect the control panel for accumulation of moisture, dirt, oil, or any damage or noticeable defects.
Contact a service representative.
Inspect hydraulic oil in the system and replace if required.
Inspect and replace oil if required.2
Inspect air breather on tank and replace if required.
Inspect and replace breather if required.2
Inspect heat exchanger. Pressure wash.
Inspect the grounding connection Tighten as needed
Natural Gas Engine3 Change engine oil. Replace oil.2
Change oil filter. Replace filter.2
Inspect the spark plug wire for damage. Replace as needed.
Change engine spark plugs. Replace spark plugs.2
Inspect coolant mix ratio in the radiator. Replenish coolant in radiator.
3 If installed in the system as the Prime Mover.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 37
Component Schedule Task Action
Replenish the engine oil in the reservoir. Replace engine oil.
Inspect the O₂ Sensor to ensure it is functioning properly.
Replace if needed.
Inspect the radiator. Pressure wash.
Electric Motor3 Ensure the grease fittings are properly lubricated.
Fill as needed.
60 Day Maintenance *One Time Maintenance*
Electrical Motor and Starter Panel3 Inspect all high voltage electrical connections and retorque as needed.
To be performed by a certified electrician.
90 Day Maintenance
Complete all previously listed inspections
Natural Gas Engine3 Replace air filter. Replace filter.2
Replace Luber Finer oil filter. Replace filter.2
Replace the housing gasket. Replace gasket.
Replace the spark plug wires. Replace spark plug wires.
Replace the distributor cap and rotor cap. Replace the caps.
Biannual Maintenance
Complete all previously listed inspections
Hydraulic System Replace hydraulic oil return filter. Replace filter.2
Inspect hydraulic oil suction filter. Replace filter if needed.
Yearly Maintenance
Complete all previously listed inspections
Natural Gas Engine3 Recommended replacement of engine coolant.
Replace engine coolant.
Electrical Motor and Starter Panel3 Inspect all high voltage electrical connections and retorque them.
To be performed by a certified electrician.
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 39
7. Troubleshooting
Problem Possible Cause Action
On Startup
Electric Motor not starting An Emergency Stop Button may be engaged
• Disengage all Emergency Stop Buttons and attempt to start the motor
Breakers may be disengaged further up the line
• Look for disengaged breakers and have a certified electrician clear them to be put back into service
• Check if any breaker is under LOTO and ask the responsible party if the system can be put back into service
The starter panel may not have sufficient power
• Have a certified electrician test the starter panel
• Have a certified electrician run sufficient power to the starter panel
Natural Gas Engine not starting An Emergency Stop Button may be engaged
• Disengage all Emergency Stop Buttons and attempt to start the engine
If starter cranks, but engine doesn’t turn over, fuel supply lines may be closed
• Open the fuel supply lines and attempt to start the engine
The 12V battery may be missing or not have enough charge
• Check the voltage on the battery to ensure it is good
• Replace or charge the battery
1. Never approach a hydraulic unit assuming everything is functioning properly. With time, some components could
work loose and present a potentially dangerous situation. 2. Do not perform any task on the unit until you review the Safety Information in section 1 of this manual. The unit
must be powered down. 3. Always follow the LOTO procedure mentioned in the Safety Information in section 1 of this manual. 4. Electrical troubleshooting should always be performed by a certified electrician.
Note: 1. Think before acting. 2. Thoroughly study the symptoms of the problem and ask the following questions:
a. Were there warning signs preceding the trouble? b. Were any repairs or maintenance performed immediately before the symptoms started? c. Is the unit or component still operational and is it safe to continue operation before further testing?
3. Answers to these questions might be obtained by the following: a. Question the owner or operator of the equipment. b. Look for additional symptoms. c. Check the simple things first.
4. Refer to the repair and maintenance records. 5. Always use calibrated instruments. 6. If a new problem transpires, start over from the top of the Troubleshooting section.
40 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
Problem Possible Cause Action
Hydraulic Lift Controller (HLC) not powering on
The fuse on the front panel may be blown in the HLC
• Inspect the fuse to see if it is blown
• Replace the front panel fuse
The fuse inside the control panel may be blown in the HLC
• Inspect the fuse to see if it is blown
• Replace the inside panel fuse
On Electric Motor configurations, the step-down transformer may not have power
• Have a certified electrician test the transformer
• Have a certified electrician run sufficient power to the 12V transformer
On Natural Gas Engine configurations, the 12V backup battery may be missing or not have enough charge
• Check the voltage on the battery to ensure it is good
• Replace or charge the battery
*See “Electric Motor not starting” section
*See “Natural Gas Engine not starting” section
During Operation
Cylinder not moving as desired The spring on the bypass compensator may be broken
• Contact your nearest BHGE Service Office
The system may not be set with sufficient compensator pressure to lift the load
• Verify the prime mover rotates clockwise
• Test the compensator pressure by closing the outlet ball valve and pulling the connector off the bypass valve
• Increase the compensator pressure from the pump to lift the load
There may be trash lodged in the proportional valve
• Close the outlet ball valve and pull the bypass valve to flush the proportional valves
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 41
Problem Possible Cause Action
The downhole pump may be stuck
• Review the dynocard from the HLC panel to see if the load changed drastically before the stroke changed
• Contact your nearest BHGE Service Office
The electronic coil in the directional valve may not be working
• Remove the electric connector off the bypass valve and pull the manual override knob on the directional valve to see if the cylinder begins stroking
• Contact your nearest BHGE Service Office
Cylinder seals are leaking on the Tower
The seals may be worn out due to the service interval
• Review the service time on the seal pack currently installed
• Contact your nearest BHGE Service Office
The cylinder rod may be misaligned to the downhole rods
• Clamp off the polished rod, unthread the polished rod coupling, and review the alignment between the polished rod and cylinder rod
• Contact your nearest BHGE Service Office
The cylinder rod may have scuffs or abrasions causing damage to the seals
• Inspect the cylinder rod for and damage to the surface finish
• Contact your nearest BHGE Service Office
The tower may be misaligned to the wellhead
• Check alignment all the way from the mounting of the tower to the bottom flange on the wellhead to verify alignment
• Contact your nearest BHGE Service Office
The pump is not building pressure The spring on the bypass compensator may be broken
• Contact your nearest BHGE Service Office
The system may not be set with sufficient compensator pressure to lift the load
• Verify the prime mover rotates clockwise
• Test the compensator pressure by closing the outlet ball valve and pulling the connector off the bypass valve
• Increase the compensator pressure from the pump to lift the load
There may be trash lodged in the proportional valve
• Close the outlet ball valve and pull the bypass valve to flush the proportional valves
Pump not venting pressure The bypass valve may not be operating properly
• Have a certified electrician check the voltage on the bypass valve relay
• Pull the manual override knob on the bypass valve to see if the pump vents pressure
• Contact your nearest BHGE Service Office
Pump is generating considerable noise
Suction strainer may be clogged
• Drain the hydraulic reservoir, and inspect/clean the suction strainer
42 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
Problem Possible Cause Action
Fluid level in the hydraulic reservoir may be too low
• Check the fluid level gauge on the reservoir and add fluid as needed
Pump may be damaged • Contact your nearest BHGE Service Office
Irregular dynocard Well may be performing inconsistent
• Compare the live dynocard to Menu-4 to see possible irregularities. *More than one may apply
HLC does not turn off The control relay may be stuck in the ‘ON’ position
• Have a certified electrician check the bottom control relay for functionality
• Replace the bottom control relay
HLC irregularities The input voltage may be incorrect
• Have a certified electrician check the incoming power
Unplanned Shutdown
Unit randomly shutdown An Emergency Stop Button may be engaged
• Disengage all Emergency Stop Buttons
The bypass valve may not be operating properly triggering a ‘Bad Load’ alarm
• Have a certified electrician check the voltage on the bypass valve relay
• Pull the manual override knob on the bypass valve to see if the pump vents pressure
• Contact your nearest BHGE Service Office
ALARM: Bad stroke position The electric connections going to the tower may not be connected properly
• Reconnect all electrical connections going to the tower
The barrier may no longer be working
• Look for signs of electrical backflow on the lines from the tower
• Contact your nearest BHGE Service Office
The Transducer Rod on the tower may not be working
• Manually pull the directional control knob to stroke the unit while watching the dynocard to see if it is recording the movement properly
• Contact your nearest BHGE Service Office
A relay in the HLC may be bad
• Have a certified electrician check the relays
The input parameters may be wrong
• Verify parameters are correct (Skip to the Resetting the HLC section)
• Default the HLC (Skip to the Resetting the HLC section)
ALARM: Bad load Well may be performing inconsistent
• Compare the live dynocard to Menu-4 to see possible irregularities. *More than one may apply
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 43
Problem Possible Cause Action
Pressure transducer may be incorrectly wired
• Remove the yellow cable and make sure it is wired as follows:
o 1 = Red
o 2 = White
o 3 = Green
o 4 = Black and Shield
• Rewire if needed
Pressure transducer connections may be loose
• Check and reconnect all pressure transducer cables and connections
HLC mV value may be incorrect
• Verify value from the Resetting the HLC section
• Replace pressure transducer
44 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
Resetting the HLC
1. Menu 2-5-4: Reset HLC to Default. Press OK.
2. Menu 2-6-1-3: Digital Configuration 10 and 11 to NC.
13 and 14 Disable
3. Menu 2-5-1: Date and Time
4. Menu 2-1-1: HLC Control Parameters: Prime Mover
type, top of stroke pause=00002, min pump
strokes=001, enable kill switch
5. Menu 2-1-1-NEXT: Speed Parameter
© 2018 Baker Hughes, a GE company – All rights reserved. Contents HL-IOM-EN | 45
6. Menu 2-1-2: Load and Position: Set Pressure
Transducer Sensitivity to 10,000mV, Set top=91 and
bottom=25
7. Menu 2-1-3: Downhole settings
8. Menu 2-1-4: Rod taper
46 | HL-IOM-EN Contents © 2018 Baker Hughes, a GE company – All rights reserved.
8. References 1. Occupational Safety and Health Standards. The control of hazardous energy (lockout/tagout). OSHA. [Online] 29
CFR 1910.147.
© 2018 Baker Hughes, a GE company – All rights reserved.
Baker Hughes reserves the right to make changes in specifications and features shown herein, or discontinue the product described at any time
without notice or obligation. Contact your BHGE representative for the most current information. The Baker Hughes logo is a trade mark of Baker
Hughes, a GE company. The GE Monogram is a trademark of the General Electric Company.
OPD-HL-IOM-EN | Revision: C
Office Locations
United States
Broussard, LA
Phone: +1 337 374 1328
Fax: +1 337 837 9387
bhge.com