Real Time Electronic Acquisition & Monitoring. & Human Machine Interface REAM HMI

Transcription

1 Real Time Electronic Acquisition & Monitoring & Human Machine Interface REAM HMI Copyright MEDCO 2007

2 Table of Contents REAM HMI...1 Table of Contents...2 System Overview...3 System Description...4 Default System Settings...4 Accessing the System...4 Displaying the Data...6 Analogues Display Schematic...7 Counters Display Schematic...7 Real Time Graphs...8 Resetting Fluid Totals...9 SYSTEM MENU Button...9 Calibrate Analogue Channel...11 Reset All Ports...12 Set Analogue Ports Data...12 Set Counter Ports Data...13 Change Units...14 Change Date and Time...14 System Memory...16 Communication...16 Power...17 Sensors...18 Pressure Sensors...18 Electrical Connection for Pressure Sensors...18 Proximity Switch...19 Specifications:...19 Electrical Connection for Proximity Switch:...19 Cable for Proximity Switch to Data Collection Unit:...20 Connectors on Cable for Proximity Switch/Magnetic Pickup:...21 Temperature...21 Wiring Diagram REAM HMI Connectors

3 System Overview The REAM HMI is a user-friendly data acquisition system that reads data from electronic sensors and displays the data. The system records the data on solid state Compact Flash memory and allows remote monitoring of the data. The system is made of two main parts, REAM (Real-time Electronic Acquisition & Monitoring) is a microprocessor based data acquisition board, which collects data from electronic sensors, digitise the readings, and supply the appropriate excitation voltage to the sensors. The HMI (Human Machine Interface) communicates with the REAM board(s) to retrieve, display, and store the data. REAM has 4 analogue channels, 2 counters, and 1 quadrature channel. The number of channels is doubled in the case of a double REAM. The analogue channels accept output signals from sensors with 0-5 vdc, 0-10 vdc, or 4-20 ma. The counters accept pulse signals produced from proximity switches or magnetic pickups. Finally, the quadrature channel accepts quadrature signals (up/down counter). HMI can communicate with up to 4 REAM boards simultaneously in addition to many other controllers or data acquisition modules. The outputs are available on Web Pages, which mean that they can be viewed remotely on a Local Area Network (LAN) or even a Wide Area Network (WAN), provided that proper Internet connections are available. This later feature means that the data can be viewed simultaneously from several terminals. There are many other features in the HMI and these can be tailored to client s request. Some specific features of this system are that it has two REAM boards, providing 8 analogue channels, 4 counters, and 2 quadratures. One of the analogue channels is dedicated to reading temperature using a Type-J Thermocouple. 3

4 System Description The picture below describes the various components of REAM HMI. Menu buttons 8.4 Touch Screen System Menu Button RJ45 Lead Power Switch Analogue channels Counters Thermocouple Type-J Quadrature Default System Settings The default values are: Date and Time: As per the UK date and time. ADC channels (Analogue to Digital Convertors): o Gain: Unity. o Offset: Zero. Pulse counters (frequency channels) and quadrature: K-factor = 1. Rates of counters and quadrature: K-factor = 1. Accessing the System REAM HMI starts by displaying the default web page. To access the other web pages in the REAM HMI use the buttons on the left hand side of the touch screen. The SYSTEM MENU button is used to reset or edit the system settings and calibrating analogue channels. The default web page shows MEDCO s logo and a Welcome message. In addition, the system date and time, the REAM HMI software version, as well as the data stream from the two REAM boards. This page can always be accessed by pressing the first button. 4

5 Default Page The default page can be used to check if communication is actually taking place between the HMI and the REAM boards. All the data here are shown as raw values, i.e. without applying any calibration constants. The first line of data shows the first 4 analogue signals followed by the totals of counters 1 & 2, and the total for the quadrature. The next line shows the rates of the counters, including the quadrature. Third and fourth lines apply to the second REAM board, i.e. analogue channels 5-8, and counters 4 & 5. The HMI communicates with the REAM boards through serial ports. On the HMI panel these are marked PGM PORT and COMMS PORT (RS232). 5

6 Displaying the Data The second button is used to display the data page. This page will display the parameter names, current values, and units. Data Display Note that the parameters have already been assigned to channels. Thus, it is important that the user adheres to this setup. The assignments are as follows: Channel Parameter Channel Parameter Analogue 1 Wellhead Pressure Counter 1 Fluid Total 1 Analogue 2 Pump Pressure Counter 2 Fluid Total 2 Analogue 3 Fluid Density Counter 3 Fluid Total 3 Analogue 4 Not assigned Counter 3 Fluid Total 4 Analogue 5 Not assigned Counter 1 - Rate Flow Rate 1 Analogue 6 Not assigned Counter 2 - Rate Flow Rate 2 Analogue 7 Not assigned Counter 3 - Rate Flow Rate 3 Analogue 8 Temperature Counter 4 - Rate Flow Rate 4 The quadrature channels are not assigned. The end user will not be able to make changes to the assignments in the above table. To make any changes, contact MEDCO. 6

7 Furthermore, the units and the scales are pre-set. The user has a choice of three different UNITS SYSTEMS and their associated scales. The scales (range of values) will apply to the gauges of the schematics and the graph (see below). Further details of the UNITS and SCALES can be found in the SYSTEM MENU section. Analogues Display Schematic A schematic of the analogue signals can be displayed by selecting the third button. The gauges will have scales corresponding to the Units System selected. (see SYSTEM MENU). Analogues Display Schematic Counters Display Schematic A schematic of the totals and flow rates can be displayed by selecting the fourth button. The gauges will have scales corresponding to the Units System selected. (see SYSTEM MENU). 7

8 Counters Display Schematic Real Time Graphs The fifth button will display a real time graph the width of which is fixed to 4 minutes. Real Time Graph 8

9 Resetting Fluid Totals The sixth button will display a page dedicated to resetting fluid totals. The actual value will be shown on the left-hand-side column while the user can enter the new value on the right-hand-side column. Resetting Fluid Totals SYSTEM MENU Button When this button is selected, the user will be prompted to enter a password. The password is which can be easily remembered as the date MEDCO was founded. 9

10 By pressing on the password a popup numeric keyboard will appear which can be used to enter the password. Data Entry Once the correct password has been entered, another screen will appear with some more options. 10

11 Calibrate Analogue Channel The user must supply channel number and two actual (reference) values. The system will provide the raw values then compute the gain and offset. If acceptable, then the user can ACCEPT & SAVE these values to be stored. For counters, see Set Counter Ports Data. Calibrate Analogue Channel Calibration is a procedure of establishing a correlation between the raw values produced by the REAM HMI and the physical values they represent. Most electronic sensors will have a linear response range, thus the calibration procedure is effectively a procedure to establish the straight-line relationship. For a straight-line, two points are required to completely define the line. The physical values (e.g. pressure) will be equivalent to the Y-axis while the raw values will be equivalent to the X-axis. The slope of the line is referred to as the GAIN and the intersection with the Y-axis is referred to as the OFFSET. Actual value (e.g. Pressure) Raw value 11

12 Reset All Ports This will reset all the ports (channels) to have a gain or K-Factor of unity (1) and an offset of zero (0). When this button is used, it will appear pressed for some time while the HMI is resetting. The user should wait for the button to appear un-pressed before issuing other commands. Set Analogue Ports Data The page will display the settings of the analogue channels. The user can make the necessary changes here. Note that if calibrations of analogue channels are done then the gain and offset of analogue channels will change to display the values obtained from the calibration process. Note that you can change the analogue channel type in this page. The channel types are as follows: Type 0 = 0 5 vdc Type 1 = 0 10 vdc Type 2 = 4 20 ma Set Analogue Ports Data It is important to note that the REAM boards have been set for type 2 (4-20 ma). If for any reason a different type of sensor is used producing a voltage output, then the flip switch on the REAM board for the corresponding channel must be moved to the OFF position. 12

13 Set Counter Ports Data For the counters and the quadrature channels, you only need to change the K-factor. If you already know the K-factor, for example from the manufacturer of the sensor, then you can enter the value directly. To get the rate, you use the same K-factor for rate per second or divide the K-factor by 60 to get the rate per minute. For example, if you have a flow meter that produces 54 pulses per gallon, then the K- factor for the Total will be 54. If the flow rate is required in gallons per minute, then the K-factor for the flow rate will be 54/60 = 0.9. If, on the other hand, you do not know the K-factor for your sensor, then you will need to calculate the K-factor using the following procedure: 1. Ensure that the counter channel has a K-factor of unity. 2. Ensure that the channel reading is zero. If necessary, reset the value to zero. 3. Physically, apply a known total. Example: If this is a flow total channel, then pump a known quantity of the fluid. 4. Take note of the channel final reading. This is the number of pulses that your sensor will produce for the physical quantity. The K-factor is thus calculated as (Number of Pulses, i.e. final reading) (Physical quantity). Example: If you pumped 2 barrels of water and your channel reading is 4600, then your K- factor is = 2300 (pulses per barrel) or 54.7 pulses per gallon. 5. Remember, you only need to calculate the K-factor for the total. For rates, you use the same K-factor to get per second or divide the K-factor by 60 to get per minute. Set Counter Ports Data 13

14 Change Units Three unit systems are available. The table below shows the units of measurement and the scales (or range of values) that will be applied for each of the unit systems. The scales (range of values) will only apply to the graph and the display schematics. Parameter type API English API Metric 1 API Metric 2 Pressure Scale psi 0-20,000 kpa 0-150,000 MPa Fluid Density Scale ppg 0-20 g/cc 0-5 kgs/m Temperature Scale deg F -50 to +250 deg C -50 to +150 deg C -50 to +150 Fluid Total Scale bbls 0-1,000 ltrs 0-200,000 m Flow Rate Scale bpm 0-12 ltr/min 0-2,000 m3/min 0-2 Change Date and Time To change the date or time, select this button and a popup window will appear allowing changes to be made. Once the popup window appear, press the enter button to select the DATE, use the left/right scroll buttons to move to the day, month, or year and use the up/down scroll buttons to increase or decrease the value (similarly for time). 14

15 Change Date and Time 15

16 System Memory REAM HMI has a 512 Mbyte CompactFlash memory that is used for storing data. The data storage is done automatically at a once per second sampling rate. There are two log files for storing the data, One Hour Log and One Day Log. The maximum length of time for continuous recording of data is 200 hours (OneHourLogs) and 10 days (OneDayLogs). Communication The user can access the data in REAM HMI using the IP Address of the system. By default, the IP Address is The user can access the pages simply by typing the IP Address in the address bar of a web browser, example in Internet Explorer. For communication with the DART software, use the default html page auto/001/. A local area network has to be present to enable browsing the pages. Two types of RJ45 cable are supplied with the system, one is crossed meaning it connects directly to a computer (laptop), while the other is straight which has to be used with a LAN router. The first page that will appear will have the following hyperlinks: View Data: Will display raw data with raw variable names. This is not meant for end users, it is meant for transmitting data to other devices capable of logging data through TCP/IP, example DART software on a laptop. This page address is auto/001/. View Logs: Will display all the data logs available. By default, OneHour will contain all the files of length one hour and OneDay will contain all those of 16

17 length one day. The files format is Comma Delimited Text (extension CSV) and this can be opened directly by Microsoft Excel. The log files follow a naming convention, which is made up of the year, month, day, and hour. Each OneHour file contains 1 hour worth of data as a maximum, and each OneDay file contains 1 day worth of data as a maximum. The CompactFlash memory can hold anything up to 200 files or the OneHour files (more than a week worth of data recorded from all channels at 1 per second) and 10 OneDay files, again recording data every one second. Remote View: Gives access to the pages described above. The current page being displayed on the HMI is the page that will be shown. Power HMI and REAM boards are operated by 24 vdc power supply. The system comes with an AC to DC converter, which takes VAC and outputs 24 vdc up to a maximum of 4.5 Amp. It is important to take note of the AC voltage setting of the AC/DC converter to match the available AC power. To connect the system directly to a 24 vdc battery, remove the connection to the AC inputs of the AC/DC converter and connect the DC power as per the diagram below. To REAM +24 vdc Ground AC to DC converter 110 or 220 VAC to 24 VDC, 4.5 Amp max Power connector to HMI L N E 1 2 Ground +24 vdc Wiring Diagram for Power 17

18 Sensors Pressure Sensors The pressure sensors supplied are equipped with a WECO union fitting. The sensors have a range of 0-15,000 psi (0-103 MPa) and produce a current output of 4-20 ma. Pressure sensor (Part No ) Electrical Connection for Pressure Sensors A 100 ft (30m) cable is supplied with these sensors. The electrical wiring diagram is shown below. A B C D E F Sensor side A B C Data collection unit side IMPORTANT NOTICE: WIRE COLORS NOT NECESSARILY MATCHING CHECK CABLE CONTINUITY TO CONFIRM 18

19 Connector - data collection unit side Connector sensor side (Part No ) (Part No ) Proximity Switch Proximity Switch Sensor (Part No ) Specifications: Operating voltage: Current rating: Switching frequency: Temperature range: Thread size: vdc 250 ma 800 Hz -25 to 80 o C M12 Electrical Connection for Proximity Switch: The proximity switch comes with a short cable and a 4-way in-line sensor plug connector. Connector for Proximity Switch (Part No ) 19

20 The wiring inside the connector is as shown in the diagram below. 4 Sensor Signal (black wire) Power (brown wire) Common (blue wire) Connector Wiring diagram for proximity switch (Part No ) Cable for Proximity Switch to Data Collection Unit: The wiring of the cable 100 ft (30m) to the data collection unit is as shown in the diagram below: 1 2 Common Power A B 3 4 Signal Used for Magnetic Pickup C D Sensor side Data collection unit side IMPORTANT NOTICE: WIRE COLORS NOT NECESSARILY MATCHING CHECK CABLE CONTINUITY TO CONFIRM (Part No ) 20

21 Connectors on Cable for Proximity Switch/Magnetic Pickup: Connector - sensor side (Part No ) Connector - data collection unit side (Part No ) Temperature A 5m type-j thermocouple is used for measuring temperature. The thermocouple wires are connected to a Module for interpreting the signal and converting the output to a 4-20 ma signal. The blue wire of the thermocouple is connected to pin 5 of the module and the yellow wire to pin 4. 21

22 Wiring Diagram REAM HMI Connectors Black, 0 v comm A B C White, signal Red, +24v supply Analogue channels Black, 0v Red, +12v supply A B D C Blue, mag p/u low level Quadrature channel White, Ch-A A B Blue, Ch-B F Black, 0v White, signal (pulses) Counter channel C D E Red, +24v supply IMPORTANT NOTICE: WIRE COLORS NOT NECESSARILY MATCHING CHECK CABLE CONTINUITY TO CONFIRM