ACE RELIANCE SENSOR OPERATIONS MANUAL

ACE Reliance Sensor Operations Manual

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Table of Contents

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

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1. Product Description

ACE Reliance is a downhole sensor designed to be deployed in non-ESP wells (GasLift, PCP, Rod Lift, Hydraulic
Lift, naturally flowing wells …).
ACE Reliance sensor consists of two main components - a downhole instrument and a surface read-out unit. The
downhole instrument is a completely sealed, welded device. The instrument electronics are not exposed to
damaging well fluid caused by leaking threads, seals, O-rings or drain/fill valves. Power to downhole sensor and
communication is provided by a TEC cable.
Figure 1
Downhole instrument (10 K PSI models)

Figure 2
Downhole instrument (1K PSI model)

The surface readout (SRU) provides optically isolated RS-485 and RS-232 Modbus ports for remote
connections to virtually all wired SCADA control systems. The premium SRU2i readout includes all the features

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of the SRU then adds a higher resolution display, Ethernet, USB, analog outputs and relays plus built in data-
logging that will record unlimited readings from the downhole device to removable SD memory cards. The SRU2i
also includes insulation monitoring. The SRU3i adds direct Wi-Fi local connection plus direct connection to Baker
Hughes VSD’s. The SRU's operates from nominal 120 VAC50/60Hzline voltage. ACE Optix is a battery
powered, solar power capable version.
Figure 3
Surface read-out unit (SRU)

2. Product Specifications
Table 1
Downhole tool specifications
Reliance 1k Reliance 10K Reliance 10K HT
Pressure Range 0-1,000 psi 0-10,000 psi 0-10,000
Pressure Accuracy 0.2% 0.2% 0.2%
Pressure Resolution (0.01 to 1 0.0305 psi 0.305 psi 0.305 psi
PSI depending on readout)
Transducer Type Silicon Strain Gauge Silicon Strain Gauge Silicon Strain Gauge
Data sampling frequency 11 sec 11 sec 1.4 sec

Temperature Range 32 - 257 deg °F (0– 32-257 °F (0–125 °C) 32-302 °F (0–150 °C)
125 deg °C)
Diameter 0.75” 0.82” 0.82”
Length 17” 17” 17”
Weight 1.34 lbs ( 610 g) 1.5 lbs ( 680g) 1.5 lbs ( 680g)
Material SS316L SS Duplex 2205 SS Duplex 2205
Thread at the pressure port at 1/8"-27 NPT 1/8"-27 NPT 1/8"-27 NPT
the bottom of the sensor
TEC cable recommended 1/8" TEC 316 1/4" TEC 2205 Duplex 1/4" TEC 2205 Duplex
AWG 16 AWG 16

Table 2
Surface Readout Unit Specifications

SRU2i Srus2i-DC ACE Optix

Power Required 115VAC +/-15% 50/60Hz 10-28 VDC 1A 10-32 VDC 0.25
or A
Display Type 8 digit Alpha Numeric 8 digit Alpha Status LED
LED
Modbus RS-485 ( isolated) 3 wire standard 3 wire standard 3 wire standard
Modbus RS-232 3 wire, no handshaking 3 wire standard
required
USB Modbus ( isolated) Standard USB “B” Standard USB-A

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Ethernet Modbus ( Standard CAT5E 8 Pin

Isolated) connector
WiFi Interface Standard
worldwide,
license fee 802.11
b/g/n
Analog Outputs ( isolated) 4x 0-20 mA User 4x 0-20 mA User
configurable ( SRU2 configurable ( SRU2
sources power) sources power)
Relay Outputs (Isolated) 2x Form C User 2x Form C User
configurable 240VAC / 8 configurable 240VAC
Amps / 8 Amps
SD data logger Up to 32 GB ( SDHC Up to 32 GB Internal
mode supported) ( SDHC mode
supported)
Internal memory 32 GB 32 GB 32GB
GPS Internal +
External port
Operating Temperature 0 deg F – 158 deg F ( -18 0 deg F – 158 deg F ( - 0 deg F – 158 deg
deg C – 50 deg C) 18 deg C – 50 deg C) F ( -18 deg C –
50 deg C)
Dimensions 9.50” x 5.75” x 1.75” 9.50” x 5.75” x 1.75” 5.25”x1”x3.3”
Weight 2 lbs 2 lbs 2lbs
UL Certification Conforms to UL Std. 610- Conforms to UL Std. N/A
10-1 610-10-1
CSA Certification Certified to CAN/CSA N/A N/A
Std. C22.2 # 61010-1

3 Installation tools and materials

Wrench 9/16” (slim version; Proto J3430)
Wrench 5/8”
Wrench 1/2”
Wrench 3/4”
Wrench 11/16”
Petroleum jelly (lip balm)
Pins (included with the instrument)
ACE Downhole strip gauge Dual Seal ¼” (for 10,000 PSI sensors)
ACE Downhole strip gauge ¼” (for 1,000 PSI senso model)
Crimp tool
Vise grips
Tube cutter

Figure 4. Dual Seal ¼” TEC strip Gauge V1.4 (provided with the sensor). This strip gauge is to be used for installing
10 kPSI sensor model

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Figure 5. 1 ¼” TEC Strip Gauge. This strip gauge is to be used for installing 1 kPSI sensor model

WARNING: Ensure an appropriate strip gauge is used for 1,000 PSI and for 10,000 PSI sensor models. Using a wrong strip gauge will lead to
incorrectly stripped TEC cable which may cause a sensor failure.

Figure 6. Crimp tool

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Figure 7. Crimp tool (cont.)

Figure 8. Wire cutters

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Figure 9. Vise grips

Figure 10. Tube cutter

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Figure 11. Tube cutter

4.TEC cable preparation

4.1 Use ACE Dual Seal cable strip gauge to measure and mark the cut-off length (fig 12)

Figure 12. Measuring and marking the TEC tube cut-off length

4.2 Use tube cutter to make a groove in the tube (fig 13)

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Figure 13

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

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Figure 15

4.4 Use the cable cutter to remove a length of the Teflon insulation as per dimensions of the ACE cable strip gauge
(fig 16)

Figure 16. TEC cable stripping dimensions as per the ACE Downhole strip gauge

4.5 Insert the end of the TEC cable wire into the pin (fig 15).

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Figure 4

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

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4.7 Use the dual seal ¼” strip gauge to doublecheck the dimensions of the terminated end of the TEC cable
Figure 19. Dual Seal ¼” strip gauge

5. 10 kPSI Sensor Model Installation

5.1 Unscrew the cover from the head of the sensor

Figure 20 The top

cover

Figure 21. The top cover is unscrewed

5.2 Remove the nuts from the cover and from the top of the sensors
Figure 22. The nuts are unscrewed

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Figure 23. Each nut contains a cone and a ferrule

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

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Figure 24. The ferrule and the cones must point toward the stripped end of the TEC cable

5.3. Insert the TEC cable into the head of the sensor

Figure 25. TEC cable inserted into the head of the sensor

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

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Figure 26. Correct location of the compressed assembly of the ferrule and the cone

5.5 If you observe that the compressed ferrule the cone is situated on the stainless-steel tubing of the TEC cable it
means the cable was stripped correctly. Insert the cable into the heads of the sensor. Tighten the nut finger
tight and then apply 1 ¼” turns with a 9/16” wrench.
WARNING: DO NOT OVERTIGHTEN AS IT CAN DEFORM THE CONE

Figure 27

5.6 You can use a Swagelok gap inspection gage (p/n: MS-IG-400) to ensure the nut is tightened properly.

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Figure 28. Swagelok gap inspection gauge

5.7 Apply petroleum jelly (lip balm) on the thread (fig. 26) at the top of the sensor and screw the top cover
finger tight, after which tighten it using a ¾” and a 11/16” wrenches (fig. 27)
Figure 29 Insert a ¾” wrench into the grove Apply petroleum Use a 11/16” wrench here to
and tighten up the cover jelly (lip balm) hold the sensor in place

Figure 30. The top cover is installed

5.8 Tighten the nut finger tight and then apply 1 ¼” turns with a 9/16” wrench.
WARNING: DO NOT OVERTIGHTEN AS IT CAN DEFORM THE CONE

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Figure 31. The sensor is fully assembled

6. 1kPSI Sensor Model Installation

The installation procedure of the 1kPSI sensor model is similar to the one of the 10kPSI one. One difference is that
the 1kPSI model features fewer components (the 1K model does not have the top cover). The other difference is
that another ACE TEC strip gauge must be used to measure TEC cut-off distance.

Figure 32
Components that are not present in the 1kPSI sensor model are crossed out

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Figure 33
1kPSI sensor model and the TEC cable are ready to be connected

WARNING: The ACE ¼” Gauge Strip must be used to cut TEC cable for the 1kPSI model. If ACE Dual Seal TEC Strip
Gauge is used, this may cause to well fluid leak into the sensor and a failure. Please see the pictures of the two
types of ACE TEC strip gauges at the beginning of this manual.

6. Sensor and cable Integrity testing

During pressure testing in the shop, after the sensor and cable have been mated and been under pressure for
some time, use Fluke 1507 Insulation tester at the 1000V setting to verify 11 GOhm insulation resistance;
anything below that indicates a fluid transgression at some point (or insulation breakdown in the cable on the
spool).

Figure 34

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8. Surface Read-Out Unit Set-up

8.1. Connect a surface cable (from a junction box) and the DC power cable to the ACE Optix SRU.
Figure 35
Power and single wire connections for ACE Optix

DC power cable Signal cable input

input (from a junction
box)

Ground wire Signal wire

8.2 ACE Downhole offers a GPS receiver. If AC mounted in a metallic container it’s possible the internal GPS will
not receive a signal, in this case the ACE Optix external GPS receiver may be plugged into the front of the ACE
Optix case as shown in the figure 36 below.

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Figure 36
GPS antenna connected to ACE Optix SRU

GPS antenna
connection

8.3 Power up the ACE Optix SRU. It will take a couple of minutes for the SRU to initialize. During initialization all
LEDs will be blinking. Once initialized without errors, green light only will stay on as shown in the picture 37
below.

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Figure 37
ACE Optix SRU initialized (green light is on)

8.4. ACE SRU configuration software should be used to set-up ACE Optix SRU. The software can be downloaded at
acedownhole.com.
Figure 38
SRU 2/SRU3/ ADCM Configuration and Setup Program on acedownhole.com

Run ACE SRU configuration program on your PC. You have two options in your Optix SRU to connect to your PC:
via RS 232, RS485 serial ports or via USB port. The example below uses USB port for connection. Chise COM3 and

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clock OK. If the PC Serial /IP Comm Status shows “NO RESPONSE” go back to the USB Config menu, select COM4
and press “OK”. The PC Serial/ IP Comm Status should now show “OK”

Figure 39
No communication, a wrong serial port is selected in the USB Cfg menu.

Figure 40
The correct port # is selected and the PC Serial /IP Comm Status is “OK”

Go to the “downhole parameters” section of the program an select the right Tool Type and PSI range. Tool type
defines the number of channels and the model. If your sensor provides a single pressure and a single
temperature reading and it is a fast data sampling rate (1 sec.) Reliance X sensor you need to select 2F in the

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drop-down menu. If you have a single pressure, single temperature sensor with a standard sampling rate, you
need to select 2 in the drop-down menu. To configure your SRU Optix for SCADA communication go to Comms
menu in the top right hand side corner. In the Comms menu you are able to assign Modbus ID (MD ID), select a
Modbus Baud rate that fits your field communication system (most common- 38,400) and MB Gap ( delay which
you want your SRU Optix to respond to commands from SCADA. Once configuration is complete, press the “Send
Config” button to push these settings into the SRU Optix.

Figure 41
The correct port # is selected and the PC Serial /IP Comm Status is “OK”

8.5. Please see the appendix of the ACE ESP Operations Manual at www.acedownhole.com for Modbus Maps.

9. Accessing downhole sensor data wirelessly from your device

9.1 On your cell phone or a tablet go to “Settings > WiFi” and connect to the ACE OPTIX WiFi network. The last
four letters in the WiFI network (2CDO shown below) are the last 4 letters of the ACE Optix device MAC address,
so will be different for all ACE Optix devices, allowing them to be identified if several are running close together.

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Figure 42
Connection to the OPTX 2CDO network

9.2. Open a web browser on your device and type 1.2.3.4 in the web address tab. It will take a few seconds for the
browser to display Opix SRU status screen. Once ACE Optix SRU has initialized, you will be taken to a set up
menu (figure 39). This menu maybe useful in case a Reliance downhole sensor is pulled out the new Reliance
sensor of a different model is installed. A field service specialist can change Optix settings to work with a different
sensor model without the need to connect PC and use ACE RTU Config Program. Select ACE Reliance pressure
rating-10,000 PSI. For ACE Reliance 302°F (150°C) pick Wireline SlimX-2F. “2F” means number of channels –
Pressure and Temperature and fast updates. Once settings are configured, press the “save” button to save the
selections. Then press “exit”. Note if the sensor fails to connect change the settings to Slim - 2 as the sensor is
probably a lower pressure or an earlier lower data sampling rate version.

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Figure 43
SRU Optix set-up menu

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Figure 44
Main sensor status screen on the cell phone

9.3 To download a data log file, click on “Log File Download”. As the message to confirm download shows up,
select the day to download (defaults to today) then download (fig. 45)

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Figure 45
Downloading log files

9.4. Once the log file is downloaded you can find it and access it in the top right hand side corner of the web
browser fig. 46

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Figure 46
Accessing downloaded log files

9.5. Log file appears. You can view it and send it as a text file attachment via text message or e-mail. The log file
will contain GPS coordinates of the well site. It will also assign date and the time stamp to each pressure and
temperature reading. Please note when ACE Optix SRU is paired with the 150°C (302°C) Ace Reliance sensor the
system provides a fast data rate of 1.4 seconds. While you will have such data granularity in SCADA system, for
the purpose of the log file an average value of measurements will be populated in a log file every 10 seconds.
Such design allows for a +10 years’ worth of downhole data to be stored in the ACE Optix SRU.

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Figure 47. A log file

9.6 Check for SD and GPS staus. If both SDstaus and GPSStatus lights are green, it means that GPS
coordiantes and time are locked and the data logging is initiated ( Fig. 44). If GPS staus light is red, it means that the
GPS signal is not locked and the data logging isn’t initiated ( Fig 45). If the SRU Optix is in the metal container it
might be blocking the signal. . In this case connect the GPS antenna extenion. If the GPSstatus light is green but the
SD status is red it means that the SD card is damaged or missing (Fig.48)

Figure 48
No GPS signal resulting in no SD data logging

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Figure 49
Damaged or missing SD card (SD status light is red)

Figure 50
Both SD status and the GPS status are good

10 Sensor and Cable Integrity Monitoring During Run in Hole

10.1 ACE Spooler overview

The ACE Spooler allows continuous monitoring of an ACE Reliance downhole sensor and the connecting TEC cable
in real time during installation. The unit can be mounted inside the rotating cable spool and is electrically
connected to the end of the cable inside the spool. The Spooler provides electrically limited power to the
downhole sensor via the TEC cable, decodes the sensors transducer readings and monitors the TEC cable
condition. The Spooler establishes a local WiFi network, so readings may be monitored continuously by any
personnel within range using standard cell phones, laptop computers, handheld tablets etc. Multiple personnel
may all monitor the system at the same time, anywhere within range of the WiFi signal.

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Any fault conditions from the cable, sensor or interconnect during installation will be apparent within seconds to
everyone monitoring the system. The unit is battery powered and will typically operate for 15 hours on the field
replaceable, rechargeable batteries. A spare set of batteries and charger is provided, so the device may be up and
running again within a minute or two of the batteries being changed.

Figure 51
ACE Spooler

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Figure 52
TEC cable connection to Spooler

The TEC cable housing is

placed in the diamond
shaped groove on the The bare end of TEC
top of the vise cable is inserted into
a special grove

Tighten up the
bolt to secure
TEC cable in place

Tighten up the nut

with Allen Key to
secure the TEC cable
in the vise.

9.2 ACE Spooler set-up

The ACE Spooler set-up is identical to ACE Optix SRU set-up. Data viewing is also the same as for ACE Optix RTU.
(please refer to the SRU Optix instructions in this manual).

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Figure 53
Spooler set-up screen

9.3. Spooler log file

The start of a typical file will be as follows. The first line will be the GPS coordinates when the Spooler was first
turned on. After that each line will have the date, time and the channel readings, in the example below the Spooler.
readings are stored every 10 seconds. The data is stored on an SD card inside the Spooler2, to extend card life the
data is actually written to the card approximately every 3 minutes.

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Figure 54
Example Spooler log file

36° 42.73047' N 95° 56.05790' W

05/23/19,09:16:58,72.53,2.20,0.00,0.00,0.00,0.000

05/23/19,09:17:08,72.53,2.20,0.00,0.00,0.00,0.000

05/23/19,09:17:18,72.87,1.84,0.00,0.00,0.00,0.000

05/23/19,09:17:29,72.87,1.84,0.00,0.00,0.00,0.000

05/23/19,09:17:39,72.87,1.33,0.00,0.00,0.00,0.000

05/23/19,09:17:49,72.87,1.03,0.00,0.00,0.00,0.000

05/23/19,09:17:59,72.87,0.98,0.00,0.00,0.00,0.000

05/23/19,09:18:08,73.21,1.37,0.00,0.00,0.00,0.000

05/23/19,09:18:20,73.21,1.37,0.00,0.00,0.00,0.000

05/23/19 09:18:30,73.21,1.04,0.00,0.00,0.00,0.000

Error Conditions:

9.4 Error Conditions

The Spooler is able to identify and display three main causes of errors. If the audible beeper is enabled,
these will also cause the alarm to sound. Fig. 55

The first error is caused by an open circuit in the

system. It may be between the Spooler and the end of the
cable, or the cable may be cut either at the surface or
downhole. Turn off the Spooler before trying to locate the
problem.

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Fig. 56

A short circuit again indicates a problem somewhere in the

system which may be at the surface or downhole. Turn off the
Spooler before trying to locate the problem.
Fig. 57

If ‘Cannot decode sensor data’ screen is displayed it indicates that data is being received from the sensor,
however the Spooler cannot decode the data. This may happen briefly as the system is powered up, it may be
caused by intermittent contact somewhere, or if the Spooler is not configured correctly to match the attached
sensor. Verify the Spooler configuration matches the sensor on the Setup screen.

Always ensure all users connected to the Spooler network ensure they are monitoring the main status
screen by clicking ‘Done’ after making changes on the status screen. If different users are both changing items on
the setup screen the Spooler settings may flip back and forth between different users’ settings, so disrupting
good sensor readings.

9.3. Spooler battery recommendations

Li-ion batteries have become very popular in recent years. They are widely available and sold under many
different brands. The most popular application is for operating electronic cigarette ‘vaporizers’ so many Li-ion
batteries are sold for that purpose. Vaporizers however require very large currents, often 10 Amps or more and
typically run for a short time so most Li-ion batteries are designed for that purpose. Batteries designed for
vaporizers need to have very high output current capability, but generally have a limited capacity (mAh).

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The Spooler is just the opposite, as it draws a very low, limited current (0.1 Amp normally, 0.25 Amp
maximum) and its desirable for the Spooler to operate as long as possible without changing the batteries. So
although the Spooler will operate with ‘vape’ batteries in an emergency, it is not recommended as the run time
will be limited. For the best run time and long-term performance Panasonic NCR18650B 3400mAh Flat top
batteries are recommended. These cells, which are provided with the Spooler, typically give a run time of
approximately 12-16 hours when fully charged. Note there are two versions of this battery, one with a ‘button’
top, the other with a flat top, either will work but the flat top is preferable as its less likely to short if mishandled.
Typically the Panasonic cells have a lifetime of at least 500 charge/discharge cycles, which would be well over a
year if used every day.

There are many fakes and mislabeled batteries for sale, one recommended source for genuine
replacement Panasonic cells is www.imrbatteries.com

Battery Lifetime:

If properly cared for these batteries will typically last for over 500 charge / discharge cycles. There are a
few conditions that will help to preserve the long battery life. The most important is to not allow the cells to
become fully discharged, as this rapidly reduces each cells lifetime. Once the battery low warning appears on the
WiFi device display screen the Spooler should be turned off and batteries exchanged with charged ones; then the
removed ones charged. Do not leave the Spooler turned on with depleted batteries since as this may
permanently damage the batteries. When fully charged each cell has an output Voltage of approximately
4.15Volts, for a total of 16.6 Volts. Once the total gets down around 12.5 Volts (each cell ~ 3.12 Volts) the low
battery warning will appear. Although the Spooler will continue to operate when the supply Voltage is as low as 7
Volts DC by this time the batteries may be permanently damaged, so batteries should be exchanged as soon as
they become low.

Charging Notes:

The charger supplied with the Spooler will operate from standard 120 VAC or from 12 VDC (car cigarette
charger adapter) power, it will charge at the same rate when powered from either source. Typically, with cells
that have been removed when the “Replace Batteries” warning first appears it will take approximately 3-4 hours
to fully charge them. Cells completely discharged may take 5 hours or longer to charge. The charger will start
charging at a high rate and slowly reduce the charge current as the cells fill, this increases cell life. Each cell is
individually charged and monitored, so it is safe to mix cells of various states of charge in the charger. The state
of each cell may be monitored, and the charger is also capable of testing the battery condition and capacity,
consult the manual supplied with the charger for further details. Do not attempt to quick charge at an
accelerated rate using a charger or power supply not designed for these cells.

Power Consumption:

The run time before the batteries need exchanging may be up to 15 hours with fully charged ones.
However, the battery run time will vary depending on many factors, such as age of batteries, the ambient
temperature, sensor / cable state (shorted cable causes more power consumption, open circuit less power) and
WiFi activity.

The WiFi communication back and forth to the Spooler actually consumes more power than the
connected sensor does. So as more users connect to the Spooler power consumption increases resulting in

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shorter battery run times. Although users are able to refresh their device screens as quickly as they wish the
Spooler defaults to updating each device every 10 seconds (unless prompted by a user request), since faster rates
increase power consumption.

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