ePIC™ Rod Pump Controller

Intelligent rod pumping control for production optimization.

 ePIC Rod Pump Controller

Access to accurate, timely

Exceptional Intelligence and Well Site Control
information is the key to Proven technology has been expanded and enhanced in the ePIC RPC to
preventing an uninformed, costly
provide the following advanced functions:
decision. Weatherford’s production
optimization division developed
• Well site alarms and system diagnostics
the ePIC rod pump controller
(RPC) to provide improved • Selected pumping system alarms based on host analysis of well
decision making opportunities for
conditions
operators of today’s oilfields.

The RPC is part of a complete • Card area alarms for deep rod part detection and downhole friction
rod pump solution. Weatherford identification
provides the unique combination
of intelligent hardware controllers, • Well site valve checks and CBE determination, available to host
communication systems, analysis systems
advanced desktop analysis,
training and support. • Improved data storage and trending

• Enhanced data-logging function which allows any register to be logged

at user defined intervals..

• Event and time stamped logging of alarms

• Read/modify any numeric parameter, execute command parameters

Additional technology available in the ePIC II version RPC includes:

• Serial variable speed drive (VSD) control interface

• Analog output added for control output to VSD

• Two extended communication ports for Modbus® protocol device

scanning capability

When enabled, the VSD control algorithm closely monitors pump fillage on
every stroke and makes quick decisions to speed up or slow the well down
in order to maintain optimum pump fillage and efficiency.

The controllers, using patented automatic idle time optimization, can

be used to continuously optimize cycle time, even adjusting for power
outages, pump wear, tubing leaks or production kicks. Air balance control
automatically balances pumping units. The peak energy control option
can inhibit well operation during peak periods of higher energy costs. The
power fail recovery method allows wells to pump down high fluid levels
after power failures and the motor restart protection function prevents
motor restart when condensation is present on motor windings.

Modbus is a registered trademark of Modbus-IDA organization.

2 © 2008 Weatherford. All rights reserved.

 ePIC Rod Pump Controller

When a pumping system malfunction or alarm is

detected either by the well site RPC or the host
software, the controller can be configured to respond
in a number of ways–from illuminating a flashing
light on the controller box to shutting the well down.
The RPC clearly defines both the identified fault and
the action taken by the controllers so the operator
can quickly and easily analyze the situation. Time
consuming troubleshooting guesswork is eliminated.

Dynamic Interaction with Analytical Tools

The registers are all available for analytical tools to
read and write. This makes the results of any program
written in the controller available to host-based
analytical programs. The accuracy derived from this
architecture allows for more exact analytical control at
the well site and more exact analysis at the desktop.

The RPC’s gross fluid production calculation includes user-defined pump

efficiency values for both deep and shallow wells as well as using the
calculated downhole pump stroke information from host software analysis
of deep wells.

Simplified Setup and Maintenance

• Improved and expanded well site configuration screens

• New three step load sensor calibration method

• Improved RPC interface access to energy management feature,

communication diagnostics, continuous position sensor diagnostics and
load cell setup and diagnostics

Enhanced Input/Output (I/O) Configuration

The RPCs include programmable I/O for unique analog, meter and
discrete monitoring and control applications. With the ePIC RPC,
operators can fine-tune their wells using operational set points and are
notified of load-based and other alarms immediately.

• Simple new I/O configuration menu

• Improved analog I/O logging method

• Auto-acting I/O functions provide easily configured control capabilities

• Expanded event action options

© 2008 Weatherford. All rights reserved. 3

 ePIC Rod Pump Controller

KiloWatt Hours/Day–Before and After RPC Field-Proven Technology

Weatherford is known worldwide for manufacturing
■ Before POC and supporting reliable, stable and accurate
400
■ POC Installed electronics. The ePIC RPC takes the knowledge
and experience gained from the CAC line of rod
KWH Consumed, KWH/Day

300 pump control products and combines them with

new, innovative features to create a state-of-the-art
RPC. Much of the ePIC technology is included in
200 Weatherford’s product line currently used by over
30,000 wells worldwide.

100
With inventive manufacturing processes based on
years of experience, Weatherford has made this
controller both robust and affordable. It provides the
stability and durability needed for harsh operating
0
Well 1 Well 2 Well 3 Well 4 Well 5 Well 6 Well 7 Well 8 Well 9 Well 10 environments without sacrificing the latest technological
Electrical Use = 14.1% Decrease in KWH improvements for advanced rod pump control.

Open Technology
ePIC RPCs control virtually any rod-pumped lift system, including
ePIC RPC Highlights improved geometry pumping units, long stroke units (Rotaflex) and even
wells using two stage downhole pumps.
• Controller commissioned with
minimal effort
Backwards Compatibility
• Improved gross fluid
calculation The ePIC RPC is fully compatible with all generations of Weatherford RPC
• Advanced integration with host products. This design feature allows the RPC to be installed using existing
surveillance systems register configuration as a base. The configuration can then be expanded
• Robust data-logging and with the new features.
trending capabilities
Software Interfaces
• Valve checks and CBE
determination ePIC RPCs are highly integrated with many industry leading host-based
• Compatible with all monitoring and analysis software packages (i.e. LOWIS™ Software,
Weatherford RPC products Shell Services International, Theta XSPOC™, SOFS, etc.). It also
can be integrated directly to HMI applications such as Wonderware
and Intellution®. With multiple communication protocols available,
Weatherford’s ePIC RPC is easily integrated into any host system.

4 © 2008 Weatherford. All rights reserved.

 ePIC Rod Pump Controller

Advanced Features for Intelligent Control

Control
Feature Benefit
Patented air balance control Automatically optimizes and controls air cylinder pressure on air-balanced units.
Peak energy control functionality Inhibits well operation during peak periods of high energy cost as determined by the operator.
Motor restart protection Prevents motor restart when condensation is present on motor windings
Power fail recovery method Inhibits selected load alarms following a loss of power to allow a well to pump down a high fluid level.
Programmable (auto-acting) I/O Unique monitoring and control applications using analogs, meters, and discretes.
Multiple control methods Point or quadrant, for lower right or upper left hand portions of the surface cards, and reverse pump-off.
Automatic idle time optimization Improved determination of idle time adjusted for inflow based production.
Pump-up delay timer Eliminates immediate pump-off due to incomplete pump fillage following well idle time.
Monitor only mode Monitor dyno cards without regard for control setpoints or speed ranges. Ideal for dyno card generation
with VFD controlled pumping system.
Works with all kinds of wells Companies can standardize on one controller for heavy oil, sand, deviated holes, etc.

Analysis
Feature Benefit
Gross fluid or inferred production calculations Accurate estimates of total fluid production from shallow and deep wells without complex well site
configuration.
Available ESP operating mode Allows the RPC to monitor submersible pump controllers.
System load analysis Host based detection of load cell drift on changing downhole conditions.
Cycle and run time buffers Easy access to historical data at the well site or using the host software.
Dynamometer card buffers Access to event cards (Full, Current, Shutdown, etc.) and several cards stored leading up to the event.
Expanded alarm features Host based alarms (torque, stress, pump efficiency, prime mover size, unbalance, etc.).
New stored card types and associated alarms Card Area Alarm; Excessive Card Areas; and Hi-Hi, Hi, Low-Low, and Low loads.

Alarm
Feature Benefit
Extensive communications debugging capabilities Capable of analyzing data at the well site to diagnose data transmission problems due to faulty radios, etc.

System Configuration
Feature Benefit
Improved well site configuration Simple menu for configuration, data management, system diagnostics, and load cell calibration.
Upgradeable modular hardware design Auxiliary I/O, communications, and local user interface options can be added in the field.
Flexible, expandable I/O Three options available to allow the best match for individual wellsite applications.
Backward compatible parameter structure Prevents incompatibility issues with older eP RPC equipment.
Basic three level password protection scheme Provides security for access to critical RPC setup parameters and well control commands.
Optional enhanced graphic display and keypad Menu driven user interface for configuration and review of system data including dyno cards, valve
checks, and run times.
Available ESP operating mode Allows the RPC to interface to submersible pump controllers.
Local graphic display Provides readily understood messages relating to pump system conditions.
Digital rod load calibration Operator no longer has to manually adjust potentiometers to calibrate the load sensor.
Automatic beam mounted load calibration Simply enter the correct maximum and minimum loads, no complex multi-step program required.
Integrated single package design Simplifies installation with all components in one unit.
Rugged hardware design Manufactured to strict standards to ensure long life and reduced cost of ownership.
Sensor options Position switch, continuous position sensor, polished rod load cell, and beam mounted sensor.

© 2008 Weatherford. All rights reserved. 5

 ePIC Rod Pump Controller

Specifications
ePIC and ePIC II Rod Pump Controller
Enclosure NEMA 4
Weight (lbs./kg) 22 (9.97), approximately
Input voltage range 120/240 VAC or 12 to 24 VDC
Frequency 47 to 63 Hz
Relay output 12 VDC
Operating temperature (°F/°C) -40 to 185 (-40 to 85)
Printed circuit boards Conformally coated to protect against moisture, H2S and salt air
Operator selectable, CAC 8500 native, Modbus RTU or Modbus
Communication protocol
ASCII
ePIC II Rod Pump Controller
Serial ports Host, MMI, display and two extended communication ports
Analog output One
Modbus scanning Two scanners with 8 devices and 32 scan blocks available
Available with automatic configuration for ePAC VSD
VSD interface
Available with manual configuration for other VSDs
Transient Protection
Overvoltage/transient Meets ANSI/IEEE C37.90.1-1989 protection specifications
Samples and stores load and position data at 20 times-per-second
Dynamometer card resolution
for downhole analysis
Analog-to-digital converion Monolithic, successive approximation 12-bit A/D converter

6 © 2008 Weatherford. All rights reserved.

 ePIC Rod Pump Controller

Oilfield Sensor Specifications

Clamp on Beam Load Transducer (Beam Sensor)
Operating temperature (°F/°C) -60 to 212 (-51 to 100)
Temperature effect on zero ±0.19 uV°F
Temperature effect on output ±0.0008% of full scale/°F
Combined accuracy 0.5% to 1.0% full scale
DPS (Dual Position Sensor)
Analog output 0 to 5 Volts
Tilt range ±45° to ±22°
Accuracy 0.1 degree of tilt
Filters Four selectable digital filters
Input voltage 8 to 15 VDC @ 14 mA
Polished Rod Load Cell
Class Quantitative strain gauge
Range (lb./kg) 0 to 30,000 (0 to 13,607) or 0 to 50,000 (0 to 22679)
Maximum error ±0.5% full scale
Operating temperature (°F/°C) -70 to 190 (-55 to 88)

Expansion I/O Boards

Board Number Analog Inputs Digital Inputs Digital Outputs Analog Outputs
1 2 2 2 0
2 4 4 4 0
3 8 4 4* 1
*Can be configured as DI or DO

© 2008 Weatherford. All rights reserved. 7

515 Post Oak Blvd., Suite 600 Weatherford products and services are subject to the Company’s standard terms and conditions, available on request or
at weatherford.com. For more information contact an authorized Weatherford representative. Unless noted otherwise,
Houston, Texas 77027 USA trademarks and service marks herein are the property of Weatherford. Specifications are subject to change without notice.
Tel: 281-348-1000 Weatherford sells its products and services in accordance with the terms and conditions set forth in the applicable contract
between Weatherford and the client.
[email protected]
www.ep-weatherford.com © 2008 Weatherford. All rights reserved. Brochure 5273.00