FIELD MANUAL

Geophysical Research Company, LLC

6540 East Apache Street, Tulsa, Oklahoma 74115-3616 USA
P.O. Box 581570 Tulsa, Oklahoma 74158-1570 USA
E-Mail: sales@grcamerada.com or support@grcamerada.com
Telephone: (1) 918-834-9600 / Fax: (1) 918-838-8846
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NOTICE

This manual is intended for private information only, with the understanding that any other use
of the subject matter, in whole or in part, by reference or otherwise, shall be only with the prior
knowledge and approval of Geophysical Research Company, LLC, and with the further
understanding that this manual is for informational purposes only and that suggestions and
recommendations contained herein shall not be understood or construed as a guarantee or
warranty of any method, product or device.

Federal copyright law protects the publication. No part of this publication may be copied or
distributed, transmitted, transcribed, stored in a retrieval system, or translated into any human or
computer language, in any form or by any means, electronic, magnetic, manual or otherwise, or
disclosed to third parties without the express written permission of Geophysical Research
Company, LLC.

Any questions concerning the content of this manual, equipment operation, field maintenance,
maintenance assistance and operation or maintenance training courses should be directed to:

MODEL:
FORTRESS ESP-3500 Field Manual

Copyright © 2009 by GRC, LLC

All rights reserved worldwide.

Document Number: 006-0190-00

Geophysical Research Company, LLC

6540 East Apache Street, Tulsa, Oklahoma 74115-3616 USA
P.O. Box 581570, Tulsa, Oklahoma 74158-1570 USA
Telephone: (1) 918-834-9600/ Fax: 918-838-8846
Contact GRC by e-mail at: sales@grcamerada.com or support@grcamerada.com
Visit our web page at www.grcamerada.com

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Table of Contents
FORTRESS ESP-3500 Gauge Overview ...................................................................................4
FORTRESS ESP-3500 Specifications .............................................................................4
Surface Components .......................................................................................................5
Before Installation Checks........................................................................................................7
Megger Testing ..........................................................................................................................7
Bench Testing the FORTRESS ESP-3500 using Scout-2200..................................................8
Bench Testing the FORTRESS ESP-3500 using the SPS-3000 ..............................................9
Installing the FORTRESS ESP-3500 to the pump motor assembly .....................................12
Surface Component Installation Procedures ........................................................................14
Installation of the 3-phase Choke...........................................................................................15
Intallation of Fuse Block/Surge Suppressor..........................................................................16
Installation using the Power/Signal Cable and Fuse Block..................................................17
Well Installation Overview.......................................................................................................18
Appendix-Cable Drawings ......................................................................................................19
GRC Authorized Sales/Service Centers.................................................................................22

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FORTRESS ESP-3500 Gauge Overview

The FORTRESS ESP-3500 Module is a combination of the dual GRC capacitance pressure
gauge with a precision choke assembly. The pressure transducers and circuitry are factory
sealed and tested for maintenance free operation and unrivaled dependability. Data is digitally
transmitted to the surface through a motor power cable and interfaced with the GRC Scout-2200
or SPS-3000 to retrieve the downhole data. GRC Memory Tools is the operational software for
the FORTRESS ESP-3500 Module and is user friendly and compatible with Microsoft Windows
98 and later versions.

FORTRESS ESP-3500 Specifications

P/N 90D3520
Transducer Type Capacitance
Intake Pressure Range 5,000 psi
Discharge Pressure Range 5,000 psi
Intake Temperature Range 25°-150°C (77°-302°F)
Motor Temp (Max) 346°C (655° F)
Vibration (X and Y) 10g
Pressure Accuracy ± 25 psi

The FORTRESS ESP-3500 utilizes two capacitance pressure transducers with an internal
temperature sensing circuit and an accelerometer that measures vibration (Figure 1). When the
gauge is powered up, gauge data including serial number and calibration coefficients are
transmitted to the Scout-2200 or SPS-3000. Calibration data is programmed into the
FORTRESS ESP-3500 during the initial calibration and testing of the gauge at the factory. It is
stored indefinitely within the gauge and therefore does not need to be loaded manually before or
during operation.

Figure 1. Overview of the FORTRESS ESP-3500

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Surface Components

The following components are used to provide downhole pressure and temperature data from
an Electric Submersible Pump (ESP) installation.

1. Surface readout device (SPS-3000 or Scout-2200)

2. 3-phase choke (P/N 99B990)
3. Fuse block/surge suppressor (P/N 90C2215 or 90D2210)

The surface readout devices provide power to control the FORTRESS ESP-3500 and convert
signals from the FORTRESS ESP-3500 into usable data.

The SPS-3000 (Figure 2) sends the data, via Modbus, to the VSD or any Modbus master. For
more information on the SPS-3000, refer to the SPS-3000 Operations Manual, number 006-
0189-00.

Figure 2. SPS-3000 Surface Readout Module

The Scout-2200 (Figure 3) will display the data on the built in LCD display or output the data to
a laptop PC and saves the data to internal memory. The Scout-2200 also has available options
to allow Modbus communications as well as single or dual 4-20mA outputs. For more
information on the Scout-2200, refer to the Scout-2200 Operations Manual, number 006-0172-
00.

Figure 3. Scout-2200 Surface Readout Device

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The 3-phase choke isolates the high voltage A/C of the motor circuit from the surface equipment
while allowing the DC power and gauge signals from the FORTRESS ESP-3500 to pass
through. The choke provides a connection to each phase of the A/C motor circuit with a single
neutral lead that carries the gauge signal (Figure 4).

Figure 4. 3-Phase Surface Choke

The fuse block/surge suppressor takes the FORTRESS ESP-3500’s signal from the 3-phase
choke and passes it to the Scout-2200. MOV protection is utilized to keep voltage surges and
spikes from reaching the Scout-2200. A ½ amp user-replaceable fuse is used on the input
where the signal from the 3-phase choke is attached. A single coil choke and capacitor filter any
remaining A/C ripple and noise from the signal before it goes to the Scout-2200 (Figure 5).

Figure 5. Fuse Block/Surge Suppressor

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Before Installation Checks

The interface between the FORTRESS ESP-3500 and a surface readout device (Scout-2200
and SPS-3000) is composed of two parts. The first part is the high-voltage 3-phase choke that
connects to the motor power cable. The second part is the fuse block/surge suppressor
between the choke and the Scout-2200. A visual inspection should check for the following:

• Verify that the wiring on the fuse block assembly and the 3-phase choke are correct and
have not been damaged.
• Verify that the 0.5A high-voltage fuse on the fuse block assembly is not an open circuit.
• Verify that the MOV on the fuse block assembly has not been damaged.

A resistance check on the MOV should give a reading of 2000 Meg ohms. Low resistance or a
broken MOV indicates the MOV must be replaced. Do not operate the unit without the MOVs
in place. Check the three-phase choke with a meter by measuring the resistance between each
of the three phases and the neutral lead that connects to the fuse block. It should measure
around 130 ohms. Because of the high inductance of the choke, a digital meter may not read
correctly. A Triplet VOM should be used to measure the three-phase choke.

Megger Testing Motor and Cable

The motor and cable may be Megger tested if required using the following guidelines:

The output voltage of a Megger will exceed the breakdown voltage of the protective MOV
mounted on the fuse block. The MOV will conduct if a Megger is used, giving incorrect readings.
Disconnect the three phase choke and fuse block from the motor cable before testing. Do not
Megger test the downhole equipment while any of the surface components are
connected to the motor power cable.

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Bench Testing the FORTRESS ESP-3500 using Scout-2200

The FORTRESS ESP-3500 should be tested before installation using the following steps.

1. Make sure the Scout-2200 is powered OFF.

2. Remove the shipping cover from the top of the FORTRESS ESP-3500, extend the white
wire and remove the protective cover from the signal pin.
3. Connect the black clip from the test cable (Figure A1) to the housing of the gauge.
4. Connect the red lead of the test cable to the pin on the white signal wire from the gauge
(Figure 6). If using a Y-Point “Hockey Puck” adapter, insert red clip lead from Scout test
cable into one of the three phase motor connections (Figures 7 and 8).
5. Connect the two white wires to the motor temp RTD that was shipped with the gauge
(Figure 14).
6. Turn on the Scout-2200 and check the display. You should begin to see several
analyzing and SPS SncPhs 3 messages indicating that communication with the
FORTRESS ESP-3500 has begun. Several status messages will follow as
communication is established with the FORTRESS ESP-3500 and data is received. In
approximately 3-5 minutes, you should see “Rcv Hdr 0”, followed by temperature and
pressure readings on the LCD. Temperature and pressure values may vary as the
gauge stabilizes to room temperature. Temperature is needed to calculate pressure so if
the gauge has just been moved from a very hot or cold area then it may take some time
for the readings to stabilize at ambient conditions.
7. When the test is complete, turn off the power and disconnect the FORTRESS ESP-
3500.

ESP Hookup for

Ambient Bench
Test
ESP Gauge

Figure 6. Bench testing the FORTRESS ESP-3500

Figure 7. Y-Point adapter

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Bench Testing the FORTRESS ESP-3500 using the SPS-3000

1. Connect Gauge+ on the SPS-3000 to the white signal pin of the FORTRESS ESP-3500
(Figure 6). If using the Y-Point “Hockey Puck”, connect to one of the motor connection
pins (Figure 8). Connect Gauge- to the gauge housing.

Figure 8. Bench test connection

2. Connect the SPS-3000 to your computer using an RS-485/232 converter P/N 034-0164-
01 (Figure 9).

Figure 9. RS-485/232 Converter

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3. Connect the SPS-3000 to 12-18VDC.

4. Open Memory Tools Software.
5. From the dropdown box select “SPS-3000” (Figure 10).

Figure 10. Tool Selection with Memory Tools Software

6. Click “Real Time” (Figure 11).

Figure 11. Real Time

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7. Click “Start” (Figure 12).

Figure 12. Start Screen

8. Under the OEM/SPS Data tab, you will see data once the FORTRESS ESP-3500 is
acquired. This will take approximately 3-5 minutes (Figure 13).

Figure 13. Data Display

9. Once the data is verified, disconnect the power.

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Installing the FORTRESS ESP-3500 to the pump motor assembly

The FORTRESS ESP-3500 mounts directly to the bottom of the pump motor or to a motor
adapter that matches the bolt pattern on the flange of the ESP gauge. Electrical connection is
made via a single wire or a y-point adapter (hockey puck) depending on the type of motor used.
Common ground is made between the pump and motor housing and the FORTRESS ESP-3500
housing.

1. If using the Y-Point adapter, remove the shipping cap, make the motor RTD connections
and then connect the pump and motor assembly to the FORTRESS ESP-3500. Pay
close attention to the rubber boots of the Y-Point adapter to not fold over the boot.
2. If using the single wire connection, remove the shipping cover over the FORTRESS
ESP-3500 and carefully extend the white signal wire.
3. Remove and discard the protective cover over the connector.
4. Bench test the FORTRESS ESP-3500 as described above. Attach the white signal wire
from the FORTRESS ESP-3500 to the neutral Y-point of the motor winding. There
should be a single lead extending from the motor or adapter.
5. If a socket connector is not already installed on the motor or adapter lead, use P/N 037-
0052-04 and install it on the lead from the Y-point of the motor or adapter. This
connector is comprised of a rubber boot, Teflon sleeve and crimp/solder socket.
6. Slide the narrow end of the rubber over the wire followed by the tapered end of the teflon
sleeve.

Attach the brass end of the socket connector to the wire. A crimping tool such as P/N 093-0189-00
should be used to attach the socket to the wire although a solder connection is acceptable. Insert
the pin from the signal lead from the FORTRESS ESP-3500 into the socket of the motor lead.

7. The socket should seat flat against the Teflon body of the signal pin.
8. Slide the Teflon sleeve over the socket and over the narrow end of the Teflon body of
the signal pin until it butts against the mounting shoulder of the Teflon body of the signal
pin.
9. Slide the rubber boot over the pin/socket connection until it seats over the Teflon sleeve.
The groove inside the rubber boot will fit over the ridge on the Teflon body of the signal
pin.
10. Connect the two white wires coming from the FORTRESS ESP-3500 housing to the
motor temp RTD that was shipped with the gauge (Figure 14).

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Figure 14. Motor RTD Connections

11. Carefully slide the excess wire into the pump motor housing and FORTRESS ESP-3500
housing until the flange of the FORTRESS ESP-3500 meets the flange of the pump
motor.
12. Make sure an appropriate o-ring is installed on the motor or adapter flange and carefully
bolt the FORTRESS ESP-3500 onto the motor or motor adapter. The FORTRESS ESP-
3500 provides a Swagelok connector on the base of the housing for connection to the
discharge pressure line (Figure 15). GRC leaves installation of the discharge pressure
line up to the customer.

Swage fitting for

¼ inch discharge
tubing

Figure 15. Discharge tubing connection

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Surface Component Installation Procedures

GRC’s FORTRESS ESP-3500 will continuously measure temperature, inlet pressure, outlet
pressure, motor temperature, current leakage, and vibration. GRC’s Scout-2200 or SPS-3000
Surface Readout Tools process the data and provide a means to display the data at a well site
and have various options to transfer the data to a remote computer, PLC, etc.

The information in this section details the components and the installation procedures for proper
installation and operation of GRC’s equipment downhole. Any deviation from these procedures
or the use of non-GRC approved components may lead to poor or no data at the surface. See
Figure 20 for a block diagram of the field installation components.

After the FORTRESS ESP-3500 has been mounted to the pump motor, the surface connections
can be made. There are three components of the surface portion of the installation:

1. 3-phase choke (P/N 99B990)

2. Fuse block/surge suppressor (P/N 90D2210 or 90C2215)
3. Interface cable (P/N 90B1750) or power/signal cable (P/N 90C2235)

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Installation of the 3-phase Choke

The 3-phase choke (Figure 16) allows the signal from the FORTRESS ESP-3500 to pass
though while isolating the Scout-2200 or SPS-3000 from the A/C high voltage (Figure 17) of the
motor circuit. Check the choke as described in the “Before Installation Checks” section before
installation. The Choke has three coils with one wire attached to the top of each coil that
connects to each phase of the motor A/C circuit. These are typically labeled A1, B1, and C1 or
X1, X2, and X3. Connect these wires, one from each coil to each phase of the A/C high voltage.

Note: It is recommended that the 3-phase connection wires on the 3-phase choke be
twisted together and kept as short as possible to help cancel unwanted noise.

Figure 16. 3-Phase Choke

Figure 17. Diagram of the 3-Phase Choke to the Motor A/C

A fourth wire, normally at the bottom of the center coil and labeled N, is the neutral point that
passes the FORTRESS ESP-3500 gauge voltage and signal. Connect the neutral wire to the
signal input of the fuse block/surge suppressor. The neutral line from the choke connects to the

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fuse block/surge suppressor at the ½ amp fuse input point (Figures 18 and 19). This will be
terminal 4 (counting left to right) on the terminal strip on the fuse block/surge suppressor panel.

Installation of Fuse Block/Surge Suppressor

The schematic below (Figure 18) and accompanying photo (Figure 19) are the Fuse
Block/Surge Suppressor (P/N 90D2215).

Fuse Block/Surge Suppressor Connections 1 - 8

1. N/C
2. Gauge signal wire to SPS-3000 or Scout-2200
3. N/C
4. To three-phase choke Y-point
5. N/C
6. Gauge ground to SPS-3000 or Scout-2200
7. Dedicated well head ground
8. N/C

Figure 18. Connection Points of the Fuse Block/Surge Suppressor

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Figure 19. Line Surge Suppressor Terminal Strip Connection Points

Installation using the Power/Signal Cable and Fuse Block

1. Securely mount the fuse block in an accessible and safe location (vent box).
2. Take the neutral wire from the 99B990 three phase choke and connect it to terminal 4 on
the fuse block (see previous diagram and photo for location).
3. Take the red and white wires from the 90C2235 power/signal cable and pass them into
the enclosure to the fuse block.
4. Connect the red wire (gauge signal) to position number 2 on the terminal strip of the fuse
block.
5. Connect the black wire (ground) to position 6 or 7 on the terminal strip of the fuse block.
6. Connect the 10-position connector of the 90C2235 cable to the 10-position connector on
the bottom of the Scout-2200 enclosure.
7. Connect the A/C cable to an available 115/230VAC source to complete the installation.

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Well Installation Overview

Figure 20. Field installation overview

This manual is intended to give an overview of the FORTRESS ESP-3500 and instruction on
bench testing procedures using GRC system components. Please contact a GRC Customer
Service Representative if you experience problems with the pre-installation bench test.

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Appendix - Cable Drawings

Figure A1………FORTRESS ESP-3500/Scout-2200 Bench Test Cable, P/N 90C1753

Figure A2……FORTRESS ESP-3500/Scout 2200 Power Signal Cable, P/N 90C2235

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Figure A1. FORTRESS ESP-3500/Scout-2200 Bench Test Cable P/N 90C1753

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Figure A2. FORTRESS ESP-3500/Scout-2200 Power Signal Cable

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trademarks of Geophysical Research Company, LLC. All other Page 22 Document No. 006-0190-00
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