Operators Manual: Artificial Lift

>>>OPERATORS MANUAL
ICI ARTIFICIAL LIFT
ICI
ARTIFICIAL LIFT
1
ICI
TABLE OF CONTENTS
ARTIFICIAL LIFT
1.1) Table of Contents
2 Introduction
3 The Copperhead 10 Series
4 The Golden Rod 20 Series
5 The Golden Rod 30 Series
6 Parts Description
7 How it Works
8 Service Rig Instructions/Wellhead Setup
9 Jack Installation Instructions
10 Jack Installation Instructions (cont.)
11 Operating Instructions
12 Operating Instructions - Startup
13 Operating Instructions - Stroke Length Change
14 Operating Instructions - Stroke Speed Change
15 Maintenance Instructions - Engines
16 Maintenance Instructions - Hydraulics
17 Detailed Parts Assemblies
18 Common Replacement Parts List
19 Specifications
20 Troubleshooting
21 Troubleshooting (cont.)
22 Schematics
ICI - Volume 1
>>>ICI ARTIFICIAL LIFT INC. >>>BOX 21027, LLOYDMINSTER, ALBERTA, T9V 2S1 >>>WWW.ICISOLUTIONS.CA >>>(780) 872-7470
2
ICI
INTRODUCTION
ARTIFICIAL LIFT
ICI designs and manufactures a suite of patented artificial lift technologies designed for the
production of:
(1) Heavy oil

(2) Light-Medium Crude
(3) Natural Gas (dewatering)
(4) Shallow Gas/Coal Bed Methane (dewatering)
(5) Subsurface Bitumen Recovery
ICI's products can be categorized in three main series:
(1) THE COPPERHEAD 10 SERIES:

A rod pumping hydraulic pump jack with a
14,000lb lift capacity designed for the production
of shallow gas/coal bed methane and light
production oil wells. This jack replaces the
conventional "rod and beam" 114's, 80's and
anything below.
(2) THE GOLDEN ROD 20 SERIES:

A rod pumping hydraulic pump jack with a
30,000lb lift capacity designed for the production
of light-medium crude and natural gas
dewatering (lifting fluid off of liquid loaded gas
wells). This jack replaces any conventional "rod
and beam" 456's, 320's, 228's and anything
below. With a high lift capacity and a stroke
length that can be changed from 0" to 120", one
Golden Rod jack can replace a 320-256-120 or a
320-213-86 or a 228-213-86 etc.
(3) THE GOLDEN ROD 30 SERIES:

A tubing pumping hydraulic pump jack with a
40,000lb lift capacity designed for heavy oil and
high sand/debris content wells. This jack
reciprocates the entire tubing string (no sucker
rods) to work a large bore downhole tubing
pump, producing wells with low gravity, highly
viscous oils with very high sand cuts. GR-30 Series CH-10 Series GR-20 Series
Each Series consists of two main components: (1) The Pumpjack and (2) The Powerskid Unit
3
ICI
THE COPPERHEAD - 10 Series
ARTIFICIAL LIFT
The Copperhead 10 Series consists of two main components:

(A) the Pump Jack and, (B) the Powerskid Unit
A) THE PUMP JACK

(12c) Anti-Rotation Bar
(12b) Rod Rotator Bracket

(optional)
Polished Rod Clamp

(not included) (1) Connecting Polished Rod
Rod Rotator
(not included) Rod Rotator Actuator
Anti-Rotation Plate
(11) Top Proximity Switch
(10) Side Rails

(2) Ladder Assembly
(9) Plumb Bob Assembly
(8) Mast Assembly

(3) Cylinder
B) THE POWERSKID UNIT (7) Electrical Cord
(6) Bottom Proximity Switch

(13) Intank Filter
(26) Directional Control Valve (4) Quick Couplers
(25) Valve Subplate
(14) Breather Filter (24) Control Panel
(23) Prime Mover

(15) Hydraulic Tank
(12a) Yoke Stand

(16) Murphy Shutdown
(not shown) (12d) Stuffing Box
(17) Inline Flow Control
(18) Scrubber Assembly

(optional - not shown)
(19) Hydraulic Cooler Assembly

(not shown)
(22) Skid Pan
(20) Hydraulic Pump
(21) Hydraulic Hoses
4
ICI
THE GOLDEN ROD - 20 Series
ARTIFICIAL LIFT
(12c) Anti-Rotation Bar

(optional)
The Golden Rod 20 Series consists of two main components: (12b) Rod Rotator Bracket
(A) the Pump Jack and, (B) the Powerskid Unit (optional)
Polished Rod Clamp

A) THE PUMP JACK (not included)
(1) Connecting Polished Rod
Rod Rotator Rod Rotator Actuator
(not included)
Anti-Rotation
Plate
(10) Side Rails
(8) Mast Assembly

(2) Ladder Assembly
(7) Electrical Cord
(3) Cylinder
B) THE POWERSKID UNIT
(13) Intank Filter

(25) Valve Subplate
(23) Prime Mover

(15) Hydraulic Tank
(5) Pedestal Stand

(not shown)
(18) Scrubber Assembly


(not shown)
(20) Hydraulic Pump (22) Skid Pan
5
ICI
THE GOLDEN ROD - 30 Series
ARTIFICIAL LIFT
The Golden Rod 30 Series consists of two main components:

(A) the Pump Jack and, (B) the Powerskid Unit
(1) Connecting Polished Rod
Polished Rod Clamp
A) THE PUMP JACK (not included)
(10) Side Rails
(8) Mast Assembly

(2) Ladder Assembly
(7) Electrical Cord
(3) Cylinder
B) THE POWERSKID UNIT
(13) Intank Filter

(25) Valve Subplate
(23) Prime Mover

(15) Hydraulic Tank
(5) Pedestal Stand

(not shown)
(12d) Y-Tool Assembly

(18) Scrubber Assembly (optional)

(not shown)
(22) Skid Pan
(20) Hydraulic Pump
6
ICI
PARTS DESCRIPTION
ARTIFICIAL LIFT
Number Item Description ICI Part Number
Common Pump Jack Components (All Series)

Connecting Connects the polished rod downhole to the top of the hydraulic cylinder with a standard rod
1 Polished Rod 4801
coupling
Allows for safe climbing of the pumpjack
2 Ladder Assembly 2800
Cylinder A patented hydraulic cylinder that provides the reciprocating action to work a downhole pump
3 1000
Quick Couplers Allows for a quick means to connect/disconnect the hydraulic lines between the pumpjack and
4 2904
the powerskid unit
Pedestal Stand Used as a means to bolt the pumpjack directly to the wellhead
5 4500
Bottom Proximity Reads the location of a traveling plumb bob to tell the pumpjack when to switch from the
6 2600
Switch downstroke to the upstroke
A detachable 13 meter cord that connects the control panel on the powerskid unit to the
7 Electrical Cord 2250
proximity switches on the pumpjack
A CSA approved Class 1, Div 2 means of housing electrical junctions on the pumpjack
8 Mast Assembly 2200
Plumb Bob Contains a plumb bob that travels with the cylinder triggering the proximity switches
9 Assembly 2300
Side Rails Used on both sides of the pumpjack to house the pumpjack components
10 2020
Top Proximity Reads the location of the traveling plumb bob to tell the pumpjack when to switch from the
11 Switch 2601
upstroke to the downstroke
Unique Pump Jack Components

Yoke Frame A unique stand utilized mostly with the Copperhead series to allow the jack to mount to the top
12a of the flow T. 4591
Rod Rotator An optional component used to mount a common rod rotator
12b Bracket 4000
Anti-Rotation Bar Used with a the Copperhead and Golden Rod 20 Series to ensure the cylinder does not turn with
12c 4006
the rods
Y-Tool Assembly An optional component used in heavy oil applications that provides surface level coil tubing
12d 10200
access to the production string, without the removal of any equipment
12e ICI Stuffing Box An optional heavy duty stuffing box 10100
Common Powerskid Components

In Tank Filter Filters the oil in the hydraulic tank
13 8060
Breather Filter Filters the air that is drawn into the hydraulic tank
14 8050
Hydraulic Tank Houses the hydraulic oil that is used to power the pumpjack
15 6720
Low Oil A low oil shutdown that will shut down the prime mover if the hydraulic oil falls below a pre-set
16 7200
Murphy Shutdown level
Scrubber An optional component on gas engines that allows the engine to run off of casing gas (removes
17 9000
the liquids from casing gas)
Hydraulic Cooler A radiator, controlled by a thermal bypass, used to cool the hydraulic oil
18 6800
In Line Flow A flow control valve that can be used to slow the return of oil from the bottom of the cylinder to
19 3010
Control the tank, thus controlling the downstroke speed
Hydraulic Pump An open loop pump which supplies pressurized hydraulic fluid to the hydraulic system
20 6000
Hydraulic Hoses High pressure hydraulic hoses used to convey fluid from the powerskid unit to the pumpjack
21 6600
Enviro Skid Pan An environmentally friendly skid pan used to house the powerskid unit components
22 7500
Primemover A natural gas, diesel or electric motor used to power the hydraulic pump
23 5000
Control Panel A CSA approved electronic control system used to start, stop and control the pumpjack
24 Assembly 3000
Directional Control A valve that switches between ports, changing the flow of hydraulic fluid
25 Valve 3003
Valve Subplate The connecting ports beneath the directional control valve used to connect the valve to the rest
26 of the hydraulic system 3021
7
ICI
HOW IT WORKS
ARTIFICIAL LIFT
*shown with
Setup: GR-30 Series
1) The downhole pump and rods are run into the well and clamped off on the stuffing box at surface.
2) The pedestal stand is bolted directly to the wellhead.
3) The pumpjack bolts to the pedestal stand.
4) The top of the rod string is connected to the bottom of the connecting rod with a rod box.
5) The top of the connecting rod is attached to the top of the pumpjack with a rod clamp.
Operation:
6) The gas, diesel or electric prime mover powers the hydraulic pump providing fluid power to the hydraulic
valve and the rest of the system.
7) As hydraulic fluid is pumped into the bottom inlet of the pumpjack, it pushes the internal piston in an
upward direction.
8) As the piston extends upwards, it lifts the attached rod string and the plumb bob until the plumb bob comes
into contact with the top proximity switch.
9) When the top switch is triggered, it sends an electronic signal to the hydraulic valve telling it to change
direction. Fluid exits the bottom of the pumpjack and is allowed to flow into the top inlet, allowing the piston
(and rod string) to fall. This starts the downstroke.
9) As the piston moves downwards, so too does the rod string and the plumb bob until the bottom switch is
triggered, again reversing the direction.
10) Repeated up and down motion of the piston between the proximity switches, imparts an up and down
motion on the rod string, creating the reciprocating action necessary to work the downhole pump.
6
8
ICI
WELLHEAD SETUP
ARTIFICIAL LIFT
8.1) Service Rig Instructions The Copperhead 10 Series

The Copperhead Series uses a "Yoke Stand" to bolt the
pumpjack directly to the Flow T, providing a universal means to
bolt to any wellhead. Installation with a pedestal stand is also
4 possible (see below) and this stand can be used to mount the
GR-20 Series.
1 Foot Stickup
1) Install the Radigans and Flow T as usual
Yoke Stand 2) Attach a 2-7/8 EUE nipple between the top of the Flow T and
the Yoke Stand (the threads on the Yoke Stand are 2-7/8. For
2-3/8 wellheads, swedge up to 2-7/8)
3 3) Attach the stuffing box inside of the Yoke Frame
4) Leave one foot polished rod stickup above the top of the
1 stand
Stuffing Box 2 5) Clamp off on the stuffing box
Flow T 2-7/8 Nipple NOTE:
Radigan A) The Yoke Stand must be installed with the service rig, prior
to reassembly of the wellhead.
B) Polished Rod must not exceed 1-1/4" with this series
C) Please report Polished Rod Size and pin to an ICI
representative prior to installation of the pumpjack.
The Golden Rod 20 Series

The Golden Rod 20 Series pedestal stand bolts directly onto the
2 tubing bonnet flange. The standard pedestal stand is 50 inches
in height and will bolt directly to 7-1/16", 2000lb or 3000lb
3 Feet Stickup flanges. Custom stands can be built for specialized wellheads
(i.e. dual completion, composite wellheads, sour gas wellheads,
5000lb wellheads etc.)
1) Turn Radigans in-line with the flow line
Stuffing Box
2) Leave 3 feet of polished rod stickup above the stuffing box
3) Clamp off on the stuffing box
1 NOTE:
A) Please report the size of the tubing bonnet flange to an ICI
representative prior to installation of the pumpjack (i.e.7-1/16,
2000lb)
B) Please report Polished Rod Size and pin to an ICI
The Golden Rod 30 Series

The Golden Rod 30 Series has an optional Y-Tool wellhead
assembly. If utilizing a standard wellhead, see Golden Rod 20
4 instructions above.
3 Feet Stickup 1) Bolt the Y-Tool Assembly directly to the wellhead flange
2) Install the radigan on top of the Y-tool, perpendicular to the
Flow Line
3) install the stuffing box above the radigan
3 4) Leave 3 feet of polished rod stickup above the stuffing box
5) Clamp off on the stuffing box
2 NOTE:
A) Please report the size of the wellhead flange to an ICI
B) Please report Polished Rod Size and pin to an ICI
1
9
ICI
PUMP JACK INSTALLATION
ARTIFICIAL LIFT
Step 1: Prepare Wellhead

1a) To ensure a timely installation at minimal cost, the wellhead
should be prepared prior to ICI's arrival on the lease (See Wellhead
Setup - Page 8).
2a - Long Studs
1b) Thread a Rod Coupling to the Polished Rod Stickup matching the
pin size of the Connecting Rod 2b - "2H" Nuts
Step 2: Install the Stand
Golden Rod Series:

2a) Remove 4 studs from the tubing bonnet flange and replace with
long studs (replace with 10" studs on a standard 2000lb wellhead and
12" studs on a standard 3000lb wellhead).
2b) Secure the wellhead with "2H" nuts on the top and bottom of the
wellhead.
2c) Position the Pedestal Stand on top of the nuts on the tubing
bonnet flange with the long stud protruding through the stand.
2d) Secure the Pedestal Stand with 4 "2H" nuts.
2d - "2H" Nuts
Copperhead Series:
2e) Stand should be installed according to Wellhead Setup instructions
(page 8)
Step 3: Prepare Pump Jack on Ground *Note: Stand illustrated

incorrectly. Horseshoe
should be in-line with
the radigan
3a) Ensure Plumb Bob can move freely within the PVC Pipe (during
shipping, the Plumb Bob is secured to the bottom bracket housing the 2e - Copperhead Setup
PVC pipe. Loosen off the 3/8 bolt.

3b) Insert Connecting Rod in the top of the jack
3c) Assemble Rod Rotator System (optional)
3c.1) Install Rod Rotator Bracket on the top plate of the cylinder
using the provided 1" bolt
3c.2) Position Plumb Bob Bracket so that the Plumb Bob is aligned
with the PVC pipe.
3c.3) Install Anti Rotation Bar into the brackets on the side rail.
p
p !
Warning: Ensure this bar is held tightly in place to
prevent slippage during installation.
p
p
!
Note: At this stage, install Anti Rotation Bar to the height
of the pump jack only. The bar will be moved into its
fully extended position once the pump jack is installed
3d - Polished Rod Clamp
3c.4 - Rod Rotator
3c.1 - Rod Rotator Bracket
3c.4) Position Rod Rotator so that the arm of the Rod Rotator will 3c.3 - Anti Rotation Bar
come into contact with the arm of the Rod Rotator Bracket.
3d) Install Polished Rod Clamp on top of the cylinder
3e) Install Pony Rod or Polished Rod Coupling on the top of the
Connecting Rod.
10
ICI
OPERATING INSTRUCTIONS
ARTIFICIAL LIFT
Step 4: Install Cylinder on Pedestal Stand

4a) Thread 2 Clevis Fasterners and 10ft Slings into the eyeholes on the
top of the Pump Jack. (Cleavis Fasterners should have a minimum lift
4a - Attach Clevis Here
rating of 1 Tonne. The Slings should have a minimum rating of
10,000lbs).
4b) Protect the threads on the bottom of the jack by moving the nuts so
that they are flush with the end of the bolts (A piece of wood can also
be placed underneath the bolts for added protection).
4c) Lift the Pump Jack into place above the Pedestal Stand.
4d) Secure in Place using 4 "2H" nuts.
Step 5: Tighten Connecting Polished Rod
5a) Prevent Polished Rod stickup from turning using a pipe wrench on
the Polished Rod Clamp (Warning: Do not place wrench on the Polished
Rod itself).
5b) Thread Connecting Rod into Rod Coupling on the Polished Rod.
Stickup. Tighten Securely (You may need to loosen the top Polished
Rod Clamp to let the Connecting Rod fall to the Coupling).
5c) Tighten top Polished Rod Clamp.
Step 6: Connect Electrical Cord
6a) Connect 13 Meter Electrical Cord to the bottom of the Control Panel
on the Powerskid Unit (ensure this cord is not beneath hydraulic hoses).
Step 7: Connect Hydraulic Hoses 7a) Quick Couplers
4d) Secure Jack with 4 nuts
7a) Connect Hydraulic Hoses from the Powerskid Unit to the Pump Jack.
Thread Quick Couplers to the line indicator on the coupler (You should
be able to do this by hand. Do not use a wrench).
p
p
!
Note: Ensure quick couplers are free of any dirt/debris to
aviod contamination of the hydraulic system.
Step 8: Remove Bottom Polished Rod Clamp
8a) Start Engine.
8b) On the Control Panel, switch to Manual Mode (Hand/Jog).
8c) Jog up 4" above the stuffing box.
p
Warning: Do not try this in Auto Mode. Be very careful not to
p
! ram the Polished Rod Clamp into the bottom of the cylinder.
8d) Check to ensure top clamp is holding. The bottom clamp should
not slide back down to the stuffing box.
8e) Check alignment of polished rod through center of cylinder. Shim 6a) Connect Electrical Cord
between pedestal stand and the wellhead nuts as necessary to correct

wellhead misalignment.
8f) If no slippage is observed, remove Bottom Polished Rod Clamp.
Step 9: Make Required Adjustments
10a) Extend
9a) Set Stroke Length (detailed on Page 13). Anti Rotation
Bar
9b) Correct Pressure Setting if necessary (detailed on Page 14).
9c) Set Rod Rotator bracket so the Rod Rotator arm is triggered without
passing the arm on the bracket.
Step 10: Extend Anti Rotation Bar 10b) Install
Cotter Pin
10a) Extend Anti Rotation Bar so that the pole is nearly flush with the
bottom bracket.
10b) Install the Cotter Pin through the Anti Rotation bar so that it rests
on the bottom Bracket.
11
ICI
ARTIFICIAL LIFT
11.1) Control of the Pump Jack

The Control Panel is used to control the startup, shutdown and movement of
the Pump Jack. Each Control Panel has 3 main modes of operation:
1) Auto Mode ("Auto")

In Auto mode the unit will cycle automatically
between the proximity switches.
AUTO START
2) Off Mode ("Off")
OFF
In Off Mode the primemover may continue to
run, but the Pump Jack will stop and/or will JOG
not function.
3) Manual Mode ("Hand/Jog")

In Manual Mode the unit will override the HI PRES
proximity switches and high pressure UP
shutdown. JOG
DOWN
p
p
!
Warning: The High Pressure shutdown is
disabled in Manual Mode. Be careful not to
overpressurize the flowline operating the jack
in Manual.
In Auto Mode, press the start button to start the Pump Jack. The Pump Jack will continue its cycle
automatically.
In Manual Mode, the Pump jack can be moved up and down incrementally using the Hand/Jog toggle
switch.
p
p
!
Warning: When the start button is pressed in Auto mode, the Pump Jack will always
travel upwards first. Therefore, always ensure the Plumb Bob is below the Top Proximity
switch before pressing the start button.
If the Plumb Bob is above the Top Proximity switch:
1) Switch to Manual Mode

2) Jog downward until the Plumb Bob is clearly below the Top Proximity Switch
3) Switch to Auto Mode
4) Press the Start Button
12
ICI
ARTIFICIAL LIFT
12.1) Start Up
Step 1) Open Bypass Valve (shown on Page 17)
Step 2) Start Prime Mover
With Electric Prime Movers, switch Breaker in the Starter to "On" and toggle to "Auto". Check motor
rotation (should be right hand or turning clockwise when facing the motor fan). With Gas Prime Movers,
hold in Murphy Switch while pressing the Start Button on the Engine (or while turning the key on some
Step 3) Set RPM (gas, diesel engnes only)

Turn Throttle Control counterclockwise to increase RPM (clockwise if using electronic governer).
p
p
!
Warning: Do not exceed 1800 RPM on the prime mover or you will damage the hydraulic
pump.
Step 4) Circulate Hydraulic Oil (as necessary).
p
p
!
Warning: On all cold startups, circulate system to heat hydraulic oil, prior to activating
the Pump Jack. Sending cold oil to the cylinder will damage the internal seals.
p
p
!
Warning: On all cold startups, destroke the hydraulic pump to start system slowly (i.e. 1
- 2 SPM)
p
p
!
Warning: On all new startups, circulate hydraulic oil to purge air from the system, prior
to activating the Pump Jack. Having air in the hydraulic system will damage the internal
seals.
To circulate hydraulic oil:
a) Join the two hydraulic hoses on the Powerskid Unit together

b) Close By-Pass Valve (shown on Page 17)
c) Switch the Control Panel to Auto Mode and press Auto Start
d) Circulate oil for 15 minutes on new startups and 45 minutes on cold startups.
Step 5) Close By-Pass Valve
Step 6) Ensure Plumb Bob is below the Top Proximity Switch (if not, switch to Manual and jog down).
Step 7) Switch Control Panel to "Auto"
Step 8) Press Start
12.2) Shut down

Step 1) On the Control Panel, switch to Manual Mode and jog down until cylinder is fully retracted
p
p
!
Note: Cylinder should be fully retracted daily to prevent rust buildup. When stopping
the unit for extended periods and during takedown, shipping and storage, always
ensure the cylinder is fully retracted.
Step 2) On the Control Panel, switch to "Off"
Step 3) Open By-Pass Valve
p
p
!
Note: During takedown, shipping or storage of the unit, ensure Quick Couplers are
properly covered to prevent build up of dirt and debris.
13
ICI
ARTIFICIAL LIFT
13.1) Stroke Length Change

Since the Proximity Switches determine when the Pump Jack changes from
the upstroke to the downstroke and vice versa, the distance between the 1
switches determines the surface stroke length. Moving the switches farther q
apart increases the stroke length. Moving them closer together decreases
the stroke length.
Setting the Stroke Length:

1) Determine desired stroke length
2) Loosen 3/8" bolt on the Proximity Switch Bracket (1) and adjust
Proximity Switch by:
A) Moving the Bottom Proximity Switch up or down 120" 86" 64"

B) Moving the Top Proximity Switch up or down
To adjust the Top Proximity Switch position without climbing the ladder,
loosen the bolt holding the PVC pipe and lower the entire pipe.
p
p
!
Warning: Cylinder should never be allowed to bottom out on
the downstroke or top out on the upstroke. Use caution
when moving the proximity switches to the ends of travel.
q
13.2) Stroke Speed Change - Downstroke Speed

The downstroke speed is controlled by the Inline Flow Control Valve (2).
This valve limits the speed at which oil can exit the bottom of the cylinder.
A) To increase the downstroke speed - Turn knob counter-clockwise
B) To decrease the downstroke speed - Turn knob clockwise
p
p
!
Note: Downstroke speed should not exceed 3 Feet per
second or 2 times the up speed (i.e. if the upstroke speed is
10 seconds, the downstroke speed should not exceed 5
seconds). Excessive speed may cavitate the seals.
q
2
q
14
ICI
ARTIFICIAL LIFT
14.1) Stroke Speed Change - Upstroke Speed

The upstroke speed is determined by the flow of oil generated by the hydraulic pump (1) - the greater the
flow, the faster the upstroke speed. The hydraulic flow is controlled by the Maximum Volume Stop (3). Turn
Max Volume Stop out for faster upstroke speed and in for slower upstroke speed.
The hydraulic pressure determines the maximum the system can lift. The Pressure is controlled by the
Pressure Compensator (2) and the Pressure Relief Valve (7).
p
p
!
Warning: Consult an ICI representative PRIOR to making any pressure adjustments.
INCORRECT ADJUSTMENT CAN SEVERELY DAMAGE SURFACE AND DOWNHOLE COMPONENTS.
CALL (780) 872-7470.
To Increase the Pressure:
1) Stop the Cylinder and open Bypass Valve.
2) Disconnect bottom hydraulic line on cylinder.
3) Turn in pressure relief adjustment (7) clockwise to safety stop.
4) Close Bypass. Pressure gauge (8) should read 200 - 300 psi. 2
This is the load sense setting. Switch to Auto and press start.
Pressure will build in the system. Check pressure gauge. This is 3
the current compensator pressure setting.
5) Remove Cap Nut (5) with a 17mm (11/16") wrench.
6) Loosen Lock Nut (6) with a 17mm wrench. 1
7) Using a 3mm allen wrench turn adjustment
screw (4) until desired pressure is attained
(turn clockwise to increase pressure).
8) Retighten lock nut and caps.
Reset Pressure Relief
9) Switch Control Panel to "Off".
10) Open Bypass.
11) Reconnect hydraulic line.
12) Restart the Well.
13) On upstroke, back out Pressure Relief until cracking pressure
(you will hear hydraulic oil bypassing at the Relief Valve). 2
14) Turn Relief Valve 1/2 to 3/4 turn clockwise. Load Sense
15) Tighten lock nut. Pressures are factory pre-set as follows:
The Copperhead 10 Series - 1000 psi

The Golden Rod 20 Series - 1800 psi
The Golden Rod 30 Series - 2100 psi
The Golden Rod 40 Series - 1200 psi 4
5 6 Pressure Compensator
It is strongly recommended that these
pressures are not exceeded without first
9 consulting with an ICI representative!
9 8
If the system does not shift

smoothly after a speed
adjustment change, the Valve
Chokes (9) will need to be
7 readjusted to reduce the shock
7 in the system. Remove
protective caps and thread
adjustments OUT for faster
shifting and IN to slow or
smooth out the shifting.
15
ICI
MAINTENANCE INSTRUCTIONS
ARTIFICIAL LIFT
15.1) Maintenance Instructions - Gas Engines - 3L, 4.3L and 5.7L GM Powertrain Engines
15.1 A) ENGINE OIL RECOMMENDATIONS
1) Use only engine oil that meets GM Standard GM6094M and displays the American Petroleum
Institute (API) Starburst certification mark "FOR GASOLINE ENGINES" on the container and has a low ash
content.
2) DO NOT USE synthetic or diesel motor oils
15.1 B) ENGINE OIL SELECTION
AMBIENT TEMPERATURE ENGINE OIL TYPE

- 18 degrees C (0 degrees F) and above SAE 10W-30
Below -18 degrees C (0 degrees F) SAE 5W-30
15.1 C) COOLING SYSTEM
The coolant should give freezing protection to -32 degrees C and boiling protection to 125 degrees C. Add or
refill the engine cooling system using only a permanent-type coolant. Use a mix of 50% ethylene glycol and
50% clean softened water up to a maximum of 60% ethylene glycol and 40% clean softened water.
Refer to the mixture chart on the container for additional antifreeze protection information. Do not use
alcohol or methanol antifreeze or mix them with the specified coolant.
15.1 D) FUEL SYSTEM
Fuel source lines should have 2.5 oz pressure coming into the engine if running off of propane, and 5 oz
pressure if running off of casing gas. Do not use fuel sources that are > 20 ppm sour.
15.1 E) GAUGE READINGS
1) Oil Pressure Gauge - Oil pressure should be greater than 20 psi.
2) DC Volt/Amperage Gauge - Should read 2 amps or greater depending on battery requirement and no less
than 13.5 VDC
3) Coolant Temperature Gauge - Should read no greater than 220 degrees F
4) Manifold Vacuum Gauge - Engine life is extended if Vacuum Gauge reading is greater than 3 in. Hg.
15.1 F) ENGINE SERVICE SCHEDULE
OPERATION Startup Every Every Every Every As
Daily Weekly
Sequence 100 Hr. 200 Hr. 400 Hr. 750 Hr. Req.
Check engine oil level 1 X
Check coolant level 2 X
Check for fluid leaks 3 X

Change engine oil and filter (1st @ 200hrs.) X
Check battery charge and fluid levels 4 X
inspect and clean radiator exterior X
Clean battery cables X
Check belts and belt tension 5 X
Lubricate throttle, governer and choke linkage X

Inspect and clean air cleaner element X
X
Replace primary air cleaner element
Replace safety air cleaner element X
Replace engine coolant X
Replace fuel filter X

X
Clean, adjust and test spark plugs
Replace PCV holes, tubes and fittings X
X
Replace spark plugs
X
Adjust throttle and governer
X
Check all nuts and bolts for tightness 6
Drain Fuel Gas Scrubber X
16
ICI
MAINTENANCE INSTRUCTIONS
ARTIFICIAL LIFT
16.1) Maintenance Instructions - Hydraulic System

16.1 A) HYDRAULIC OIL RECOMMENDATIONS
1) Use only hydraulic oil desgined for high pressure hydraulic requirements for reciprocating gear,
piston and vane pumps and heavy duty industrial hydraulic systems.
2) Hydraulic oil should meet and exceed the manufacturers requirements for Vickers, Denison,
Cincinnati Milacron, Rexroth and Sundstrand pumps.
16.2 B) TYPICAL PROPERTIES
Density (D1296) @ 15 degrees C, Kg/l 0.870

Viscosity (D445), cSt @ 40 degrees C 35.7
Viscosity (D445), cSt @ 100 degrees C 7.08
Brookfield Viscosity, cp @ -30 degrees C 6550
Brookfield Viscosity, cp @ - 40 degrees C 32200
Viscosity Index 164
Flash Point (D92), degrees C 155
Pour Point (D97), degrees C -48
ASTM Oxidation Test Hours 2000+
Antiwear Additive Present
Foam Test (D892) Pass
Demulsibiity Test (D1401) Pass
Color Clear
OPERATING TEMPERATURE RANGES (degrees C) -10 to 70

Without Warm Up -30 to 70
With Warm Up
16.3 C) HYDRAULIC OIL MAINTENANCE
1) Continually monitor oil filter gauge to ensure

system remains free of contaminants. As needle
moves into the yellow zone, the filter will require
changing.
2) Change Intank Hydraulic Filter every 4320

hours (approximately every 6 months).
3) To maximize equipment lifetime, collect and

test oil samples on a yearly basis. Filter/replace
oil as required.
17
ICI
DETAILED PARTS ASSEMBLIES
ARTIFICIAL LIFT
A) HYDRAULIC VALVE STACK ASSEMBLY
q 12 Volt Coils
q
Chokes
Directional Control Hydraulic Valve

q
q
Pressure Relief Valve

q
Valve Subplate
B) COOLER ASSEMBLY
By-pass Valve
q
Thermal By-pass
q
Temperature Switch
q
Hydraulic Cooler
q
Temperature Control Relay
C) CONTROL PANEL ASSEMBLY
q
Presco Terminals
SSRU-2 Relay
q
Barrier
q
Control Panel Fuse
D) HYDRAULIC PUMP ASSEMBLY

q
Load Sense Control

q
Pressure Compensator
q
Speed Control
18
ICI
REPLACEMENT PARTS LIST
ARTIFICIAL LIFT
17.1) Common Replacement Parts
Category ICI # Item Description
Mast Assembly 2200 Mast Assembly CSA Approved Class 1 Div 2 Junction Box and Conduit
13m Cord 2250 13m Electrical Cord 13m Cord with Control Panel Connection
Plumb Bob Assembly 2300 Complete Plumb Bob Assembly Including plumb bob, airplane wire, bracket
Switching Assembly 2600 Proximity Switches CSA Proximity Switch
Switching Assembly 2620 Conduit Adaptors CSA Adapter
Jack Fittings and Hoses 2906 Female Quick Coupler #16 Parker Connect under Pressure Couplings Wing Nut
Control Panel Assembly 3002 SSRU-2 Relay Relay for Control Box
Control Panel Assembly 3003 Directional Control Valve - lg Directional Control Valve, NS25 Pilot Operated
Control Panel Assembly 3004 Directional Control Valve - sm Directional Control valve
Control Panel Assembly 3010 In-Line Flow Control - lg Inline Flow Control Valve - lg
Control Panel Assembly 3011 In-Line Flow Control - sm Inline Flow Control Valve - sm
Control Panel Assembly 3020 Valve Subplate - lg Subplate Steel, D08, w Sun T-3A Relief cavity
Control Panel Assembly 3021 Valve Subplate - sm DD07SPRVS12S SUBPLATE
Control Panel Assembly 3005 Relief Cartridge Relief Valve Cartridge
Rod Rotator System 4000 Complete Rod Rotator Brackets Complete Rod Rotator Bracket
Regen Kit 4700 Regen Kit Assembly Regen Circuit for Increased SPM
Hydraulic System 6700 36 W Hydraulic Oil 36W Hydraulic Oil

Contamination Kit 7500 Hydraulic Oil Contamination Kit Hydraulic Oil Contamination Kit
Hydraulic Cooler 6801 12V Hydraulic Cooler ASA 0176 12VDC; 0.22kW; 26 bar (370psi)
Hydraulic Cooler 6802 460V Hydraulic Cooler ASA 0176 460VDC; 0.25kW; 26 bar (370psi)
Hydraulic Cooler 6803 Thermal Bypass Valve Parker , #16 NPT Inlet, Bypass Valve
Hydraulic Cooler 6804 Temperature Switch 12V Relay & Sensor for 12V Cooler
Hydraulic Cooler 6805 Temperature Switch 460V ASA ILLZTH6065 TEMP SWITCH
Engine Add ons 7020 Battery Utility Battery
Engine Add ons 7021 Battery Box w/ Lid Box for Battery
Filters & Gaskets
Filter 3.0 8010 Engine Oil Filter for 3.0L Engine Oil Filter for 3.0L
Filter 4.3 8020 Engine Oil Filter for 4.3.L Engine Oil Filter for 4.3L
Filter 5.7 8030 Engine Oil Filter for 5.7L Engine Oil Filter for 5.7L
Filter Cummins 8040 Engine Oil Filter forCummins Engine Oil Filter for Cummins
Oil Pan Gasket 8041 Gasket for Cummins Oil Pan Gasket for Cummins Oil Pan
Filter Breather 8050 Breather Filter Hydraulic Tank Breather Filter
INTANK FILTER 8060 Intank Filter, Complete Assembly, FILTER ASSEMBLY
Filter Intank Element 8061 Intank Filter Element Hydraulic Intank Filter
Intank Filter Gasket 8062 Intank Filter Gasket Gasket for Intank Filter
Intank Filter O-ring 8063 Intank Filter O-Ring AS-251 NBR 90 O-RING
Clogging Indicator 8064 Clogging Indicator Pressure Gauge Clogging Indicator 0-30 psi
Filter Luberfiner 8070 Luberfiner Filter Luberfiner Filter
Natural Gas Scrubber 9000 Natural Gas Scrubber Complete Scrubber
Household Regulator 9010 Household Regulator 1" NPT, 1/4" 6-8" w/c MAX IN 175psi, OUT 25
Fisher Regulator 9020 Fisher Regulator 1" 627 Fisher Regulator, 5-20 psi
POP Valve 9030 1" E/1 Taylor - T-8200 Pop Valve for Scrubber
5000 psi pressure gage 9040 2-1/2" faced - 5000# pressure gauge 5000# pressure gauge
Stuffing Box 10100 1-1/4" Stuffing Box 1-1/4" Stuffing Box
Stuffing Box Packing 10110 Packing for stuffing box PACKING-STUFFING BOX-FLD-SL
19
ICI
SPECIFICATIONS
ARTIFICIAL LIFT
19.1) UNIT SPECIFICATIONS
***
Model CH-10 Series GR-20 Series * GR-30 Series
Variable Stroke Length 0-64" 0-120" 0-144" 0-120"
Shipping Weight 600 lbs 1,050 lbs 1,200 lbs 1,280 lbs
Vertical Unit Height 7' 11'9" 13'9" 11'9"
Typical Lift 14,000 lbs 20,000 lbs 20,000 lbs 40,000 lbs
Maximum Lift 18,000 lbs 30,000 lbs 30,000 lbs 40,000 lbs
Prime Mover Power Source Propane/Natural Gas/Electric Propane/Natural Gas/Electric Propane/Natural Gas/Electric
Installation Equipment Required 1-Tonne Picker 1-Tonne Picker 1-Tonne Picker
Installation Times
Vertical Well 1-3 hours 1-3 hours 1-3 hours

Slant Well 2-4 hours 2-4 hours 2-4 hours
**
Maximum Strokes Per Minute 5 5.5 6 4
Maximum Strokes Per Minute 7.5 8 7 n/a

with Regen Kit ****
* ICI has also manufactured custom 36" and 86" units
** 6 SPM requires a 140cc hydraulic pump
*** ICI has also manufactured a GR-40 Series capable of a 65,000 lb lift
**** An "Intensifier Unit" can also be used to increase SPM
20
ICI
TROUBLE SHOOTING
ARTIFICIAL LIFT
Problem 1: Engine is running. Pumpjack seems to be stuck in the upstroke or downstroke
Probable Cause Solution

1) Pumpjack missed the switch 1) Identify Cause
A) Alternator or battery is failing A) Test voltage of alternator. Alternator should run at 14.2V. At least
13.5V is required to ensure proper switching. Alternatively, boost the
battery and if the jack functions normally when the battery is boosted,
then the alternator or battery needs replacing. Check voltage on battery
with the engine off to isolate the battery as the problem (if voltage is under
12V, replace the battery).
B) 13 meter cord damaged or disconnected B) Check to ensure 13 meter cord is connected and not damaged. If a
military style connector is used and may have been recently
detached/reattached, remove and check to ensure pins have not been
damaged. Check to ensure hydraulic hoses are not rubbing on electrical
cord.
C) Proximity Switch is loose C) Ensure Proximity Switch is tight to the PVC pipe.
D) If no other cause is identified, the Solid State Relay may have failed and
D) Solid State Relay in Control Panel is failing
needs to be replaced.
2) Plumb Bob is caught 2) Check to ensure Plumb Bob can move freely within the PVC pipe. The
Proximity Switch brackets may have been overtightened on a recent stroke
length change (trapping the Plumb Bob in the tube).
3) Hydraulic Pump pressure not properly set or the 3) Jog the cylinder downwards to the bottom proximity switch. Press start in
well has become heavier Auto Mode and watch the cylinder. If the cylinder moves upwards, slows and
stops, the pump pressure may need adjustment. Call and ICI representative
to walk you though this process (adjustments detailed on Page 14).
4) Pressure Relief needs adjustment 4) See Stroke Speed Change Section (Page 14). Pressure relief is typically set
by finding "cracking pressure", then turning the allen screw in by 1/2 to 3/4 of
a turn.
5) Presco Triggered (if Presco is attached to the 5) Check to see if the Presco was triggered. Alleviate pressure concern prior to
panel and not the engine) restarting.
Problem 2: In heavy oil application, the Pumpjack seems to be stuck in the upstroke

1) Pumpjack missed the switch 1) See Above.
2) Downhole Problems (i.e. Well is sanded in) 2) Switch to Manual Mode on the Control Panel and jog the cylinder down. If
the poiished rod separates from the top of the cylinder, or the cylinder will not
travel to the bottom switch, downhole problems are likely. On the upstroke,
check to see if the speed of the cylinder changes. If the jack slows towards
the top of the stroke, or does not reach the top switch, downhole problems are
likely.
3) The well is heavier (the pump is compensating) 3) Increase the compensating pressure on the pump. WARNING: SLIGHT
PRESSURE CHANGES CAN SIGNIFICANTLY INCREASE LIFT AND CAUSE
DAMAGE TO SURFACE OR DOWNHOLE EQUIPMENT. Call and ICI representative
to walk you through this process (adjustments detailed on Page 14).
21
ICI
TROUBLE SHOOTING
ARTIFICIAL LIFT
Problem 3: Hydraulic Cooler runs constantly in cold weather or not at all

1) Hydraulic oil is hot 1) Check temperature of hydraulic oil (temperature gauge on the hydraulic
tank). If temperature is above 140 degrees Fahenheit, the cooler should be
running. If the Powerskid Unit is in an enclosure, ensure proper ventilation.
Also ensure that the cooler has a fresh source of air and is free from
obstructions and debris.
2) Cooler Relay is not properly set 2) Ensure Cooler Relay is set to 3 (140 degrees Fahrenheit)
3) Cooler Relay is damaged 3) Check Cooler Relay by switching the relay to 1. The cooler should kick in.
Move the setting up sequentally (2, 3, 4, 5, 6) and note where it stops
running. If cooler does not kick in, cooler relay is likely damaged and needs
replacing.
Problem 4: Engine is running. Pumpjack will not respond either in Manual or Auto Mode

1) Bypass Valve is open 1) Close the bypass valve to enable supply of oil to the cylinder
2) No power supply to the panel 2)Trace back power supply to the battery (you can test power supply to the
panel by placing a metal object across the Presco connections on the side of
the panel. If Presco light illuminates, then there is power to the panel).
Ensure electrical cable is tightly secured to the Pumpjack and the control
panel. Remove electrical cord at both connection points to ensure pins are not
damaged.
3) Quick coupler is not fully engaged 3) Thread together coupler (hand tighten only) until the end of the female
wing coupler reaches the marked line on the male coupler.
4) Control Panel fuse is blown 4) Check and repace fuse if damaged.
Problem 5: Engine is shutdown

1) An engine shutdown switch was triggered 1) Identify which switch was triggered and alleviate problem
A) Presco switch was triggered (only applicable if A) Check flowline pressure and alleviate problem before restarting
Presco is wired to the engine)
B) Low hydraulic oil switch B) Check hydraulic oil level in the clear tube above the Murphy switch. Fill
as required.
C) Engine temperature switch C) Check for signs of the engine overheating (i.e. coolant spill). Check
coolant levels and fill as required.
D) Hydraulic oil temperature shutdown D) Check to ensure hydraulic cooler is working and is free of
debris/obstruction. Where the powerskid unit is in an enclosure, ensure
adaquate ventilation. Ideal hydraulic temperature is between 140F and
160F. Check temperature gauge on the hydraulic tank to ensure
termperature is in this range.
E) Low engine oil level E) Check oil level. See if engine will turn over. Cummins engines have a
low engine oil level that may be triggered.
2) Power problem 2) Trace back power source from the Control Panel. Check the fuse on the
back of the Murphy Tattle-Tale switch on the engine. Replace fuse if necessary
(14 Amp).
3) Battery or Alternator has failed 3) Test voltage (see above). Replace failed component.
4) If electronic carburetor, engine may have gone 4) Weight of the well has changed. Reset electronic carburetor or take the
down on overspeed. load off the engine by slowing down the hydraulic pump.
5) Fuel gas problems (if running off of casing gas) 5) There may not be enough BTU's in the casing gas. Check for ice plugs in
the regulator on the scrubber. Also check for signs of oil in the scrubber.
Ensure scrubber has fuel pressure when engine is under demand (needs at
least 5 oz pressure).
pp
!
Warning: NEVER RUN THE PUMPJACK WITH COLD HYDRAULIC OIL. When restarting after an engine shutdown in
cold weather, you must circulate the system to heat the hydraulic oil PRIOR to activating the PumpJack (see
Circulating Instructions - Page 12).
22
ICI
SCHEMATICS
ARTIFICIAL LIFT
23.1) Electrical Schematics (Hydraulic Schematics Available Upon Request)

480V
1 FUSE
120V
AUTO HAND
TEMP
M2
100 Amp .63-1 Amp

OFF LEVEL TEMP O/L
HAND AUTO
3 A1 A2 V1 V2
M1
2
REMOTE
SHUTDOWN
M1 M2
12Vdc Power Supply
HYDRAULIC
CONTROL PANEL
+ -
25 - 50 HP 1/3 HP
HOA ON/OFF
DRIVE MOTOR COOLING FAN
Hydraulic System
480V Motor Schematics
30/08/05 DWG: 200 REV:1
START
AUTO START
1
1
10 OFF
2 6 2 SO
2 (supply out)
JOG
2 SI
3 3 (supply in)
+V
5 4 4
JOG UP OUT 2
8 7 5 5
9 OFF
5
INP 2 SOLID
6 6
JOG DOWN STATE
INP 1 RELAY
7 7 SSRU-1/2
OUT 1
9
5 8 8 8
8 0V COM
10
3 9 9 9
9 AUX
2 10 10 10
LIGHT
1 10 11 11
(light)
HIGH PRES.
10 12 HP
12
RTN SIG (switch)
Safe
F1 Haz.
5 AMP
SIG
9
Weidmuller
Non-Incendive Barrier
12
4 9
V1-1
A D
HPS PS-1
A D V1-2
High Pressure B C B C
Switch V COMM
PS-2
12VDC SUPPLY ICI SOLUTIONS
Lloydminster Alberta 780-872-7470
TITLE CYCLE CONTROL

DWG # P2S2001
ICI
ARTIFICIAL LIFT
Legal Disclaimer
This manual is intended to give our customers basic information regarding the design, installation and
operation of ICI hydraulic jacks and powerskid units. It is not intended to be a complete source of
information on these matters. The customer is responsible for using this information in a correct and
safe manner. It is recommended that all customers contact an ICI representative for assistance prior to
installing, adjusting or operating the equipment.
The operation of any ICI product beyond the parameters outlined in this manual without factory approval
may be damaging to the equipment and/or personnel in which case ICI Artificial Lift Inc. and its affiliates
cannot accept any responsibility whatsoever and disclaims all liability thereof.
Warranty
ICI Artificial Lift Inc. (ICI) warrants that its products shall, for the period of the Warranty Term, be free
of any defect in material and workmanship and that it will perform in accordance with specifications. The
Warranty Term shall be a three (3) months from the date of purchase of ICI products unless otherwise
stated in writing.
The sole obligation of this warranty shall be to either repair, or at ICI's option replace, the product, at no
charge. Proof of purchase must be supplied for warranty repair.
There are no warranties except as stated. There are no warranties expressed or implied, including, but
not limited to, the implied warranties of merchantability and of fitness for a particular purpose. In no
event shall ICI be liable for consequential, incidental, or special damages, including, but not limited to,
loss of production, profits or goodwill.
Products which have been subject to abuse, misuse, vandalism, accident, alteration, neglect,
modifications, improper installation, unauthorized repair, or usage not in accordance with product
specifications and instructions will not be covered by warranty.
Only hardware manufactured by ICI is covered by the standard warranty. Additional item such as
pumps and controls, if defective, may be repaired or replaced at ICI's discretion.
Thank you for choosing ICI ARTIFICIAL LIFT.
For additional information on our technologies
please contact us at:
(780) 872-7470
ICI
ARTIFICIAL LIFT

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>>>OPERATORS MANUAL

ICI ARTIFICIAL LIFT

1.1) Table of Contents

3 The Copperhead 10 Series

4 The Golden Rod 20 Series

5 The Golden Rod 30 Series

8 Service Rig Instructions/Wellhead Setup

9 Jack Installation Instructions

10 Jack Installation Instructions (cont.)

12 Operating Instructions - Startup

13 Operating Instructions - Stroke Length Change

14 Operating Instructions - Stroke Speed Change

15 Maintenance Instructions - Engines

16 Maintenance Instructions - Hydraulics

17 Detailed Parts Assemblies

18 Common Replacement Parts List

(1) Heavy oil

ICI's products can be categorized in three main series:

(1) THE COPPERHEAD 10 SERIES:

(2) THE GOLDEN ROD 20 SERIES:

(3) THE GOLDEN ROD 30 SERIES:

The Copperhead 10 Series consists of two main components:

A) THE PUMP JACK

(12b) Rod Rotator Bracket

Polished Rod Clamp

(11) Top Proximity Switch

(10) Side Rails

(9) Plumb Bob Assembly

(8) Mast Assembly

B) THE POWERSKID UNIT (7) Electrical Cord

(6) Bottom Proximity Switch

(23) Prime Mover

(12a) Yoke Stand

(17) Inline Flow Control

(18) Scrubber Assembly

(19) Hydraulic Cooler Assembly

(21) Hydraulic Hoses

(12c) Anti-Rotation Bar

Polished Rod Clamp

(11) Top Proximity Switch

(10) Side Rails

(9) Plumb Bob Assembly

(8) Mast Assembly

(7) Electrical Cord

(13) Intank Filter

(23) Prime Mover

(5) Pedestal Stand

(17) Inline Flow Control

(18) Scrubber Assembly

(19) Hydraulic Cooler Assembly

(21) Hydraulic Hoses

The Golden Rod 30 Series consists of two main components:

(11) Top Proximity Switch

(10) Side Rails

(9) Plumb Bob Assembly

(8) Mast Assembly

(7) Electrical Cord

(13) Intank Filter