Interface Manual Chemical Injection System

Transcription

1 1 Interface Manual Chemical Injection System SignalFire Numbers: CIJ-xLine (Local Modbus control) CIJ-xLine-Wireless (SignalFire radio) SignalFire Chemical Injection Controller Module The SignalFire Chemical Injection System (CIS) consists of the following: - SignalFire chemical injection controller in NEMA enclosure - Pre-assembled calibration and monitoring unit. Includes solenoid valve, calibration tube, and pressure sensor

2 2 SignalFire Chemical Injection System Diagram

3 Specifications 3 Power VDC (25mA average at 12V no outputs energized) Operating Temperature -40 C to +80 C Analog Inputs 0-10V max, 0-24mA max DC Output Drivers 12/24VDC, 12A max Pressure Sensor 1-5V interface, 0 to 48 H2O Solenoid Valve 12VDC Coil Radio Frequency MHz ISM band, FHSS radio, SMA connector

4 4 Connections and Components The Chemical Injection System provides screw terminals and terminal blocks for connections to the pump motor, solenoid valve, and pressure sensor. Power must be provided through the fused (15A) terminal block (10-30VDC, 12VDC nominal). The controller is designed to run standard 12VDC injection pumps that are controlled in an on/off manner. The antenna port is a standard SMA connector. Connect this port to a suitable 900MHz antenna. Installation The calibration and monitoring unit must be installed between the output of the tank and the input of the chemical injection pump. It must be installed so that the solenoid valve end is connected to the tank. All fittings are ½ NPT and a union is included to make installation easy. Care must be taken to ensure that the calibration tube is vertical to ensure accurate results. Mount the NEMA enclosure containing the chemical injection controller in a suitable location. Connect the solenoid valve, pressure sensor, and injection pump per the wiring diagram on the following page. Connect power to the system.

5 Wiring TERMINALS 5 12V TERMINALS FUSE - - Valve Motor + + VALVE 2 LED BATTERY VALVE+ BATTERY VALVE 1 LED RS232 CONFIG PORT VALVE+ PUMP 2 LED PUMP+ BATTERY Pressure Sensor 12V Valve 1 Valve 2 Chemical Injection Controller SIGNALFIRE wireless telemetry P Sensor IN Signal Power Ground STATUS LED PUMP+ BATTERY PUMP 1 LED TX LED RX LED Pump 1 Pump 2 ANALOG OUT DIG IN AUX OUTPUTS MODBUS RS485 POWER INPUT OUT2 BAT OUT1 BAT DIN2 DIN1 AO2 AO1 AIN2 AIN1 B A B A VDC Wiring Diagram for Single Well System

6 Status LEDs 6 The Chemical Injection System module has a green status LED which blinks indicating the module is running. If a radio is installed, the status LED also indicates the signal strength between the module and the gateway. In addition there are TX/RX LEDs to indicate radio messages to/from the module. The status LED will blink once a second if it is not connected to a gateway. If the module is connected to a gateway, it will blink a link quality code every 3 seconds. 3 Blinks = Strong Signal 2 Blinks = Good Signal 1 Blink = Weak Signal Each output driver also has a green LED which turns on while the relay is energized.

7 Operation The Chemical Injection System will do the following: - Report tank level - Automatically energize injection pump for configured/set amount of time - Slave chemical dosing rate to well production rate in automatic mode - Auto-calibrate the pump and report the calibration results - Report system parameters via a wireless link to the gateway or over a local RS485 Modbus connection - Real time clock for setting and measuring dosing amount over a contract 24-hour period - Automatic pump shut off on low fluid level ( < 2 in tank) 7 All configuration items may be set locally into the controller via RS485 Modbus RTU or over the wireless link from a PLC (or Totalflow, CygNet, etc.) for maximum flexibility.

8 8 Configuration Basic Configuration For the system to operate some basic configuration must be done at installation time. All configuration is done using the SignalFire ToolKit For accurate tank level measurements and calculated fluid volume pumped it is important to enter the specific gravity of the chemical being used. In addition if the pressure sensor is located above or below the bottom of the tank enter a sensor physical offset. For example of the sensor is located 6 below the bottom of the tank you would enter an offset of -6. A sensor mounted above the bottom of the tank would have a positive offset. The default pressure range of 0 to 48 is correct for the pressure sensor provided. The calibration tube diameter is 0.555, this is also pre-configured. The Modbus Slave ID must be configured to a unique address for use either with the SignalFire radio or for local Modbus control. In addition if the SignalFire radio is used the Radio Network and Radio Network Group must be set to match the SignalFire Gateway s settings.

9 The Chemical Injection System has 4 operational modes, listed below. Disabled The pump will be forced off and the valve will remain open (not energized). The system will ignore any commands to control the pump or the valve. 9 Manual In Manual Mode the pump and valve may be controlled either through the Toolkit (via a local connection) or remotely (via Modbus coil writes) through the gateway. This is the only mode that allows manual control. Calibrations can be initiated by the Toolkit or a Modbus coil write from the gateway only. Timed In timed mode, the pump will run based on the configured pump-on-time and pump-interval. In addition, automatic calibration will run if the calibration interval is a non-zero value. The pump-ontime range is 1 to 15 seconds and the pump-interval range is 30 to 180 seconds. Automatic In automatic mode, the pump-on-time and the pump-interval are automatically calculated based on the configured production rate, dosing PPM, and pump constant. Automatic calibration will run if the calibration interval is a non-zero value. In addition to properly configuring the level and sight tube ID parameters, automatic mode also requires the production rate and dosing PPM to be configured. At least one manual calibration must be performed so the Chemical Injection System has a valid calculated pump constant. In automatic mode the valid pumping times range from 2 seconds every 3 minutes to 15 seconds every 30 seconds. These are automatically calculated based on the pump calibration constant, the PPM dosing rate and the production rate. The pump time will automatically adjust if any of these three parameters change.

10 10 Calibration The automatic calibration takes place in the normal pumping schedule, that is, it does not pump chemical solely for the purpose of calibration. When the calibration interval is hit the system will close the solenoid valve for its normal pump on time and measure the volume pumped from the sight tube. The valve will then be opened until the next pump-on-time. This will repeat for the configured calibration run cycles. The calibration run cycles should be configured between 4 and 10 so that a large enough sample size is averaged for accurate calibration (the default is 5). Since the calibration is done in the normal pumping schedule it is possible to run the calibration often (once an hour) so that any voltage swing in the batteries due to solar charging/discharging is accounted for.

11 Error Status The status of the Chemical Injection System will be reported in register This register contains a bit masked set of error bits defined below. More than one error can occur at a 11 time. For example if a calibration fails the 0x01 bit will be set in addition to the reason the calibration failed. Bit Position Error Description 0x01 Latest calibration failed 0x02 Fluid in sight tube dropped below 2 during calibration 0x04 Failed to move > 2 of fluid in sight tube during calibration 0x08 Calibration configuration error, sight tube or calibration run cycles invalid 0x10 Low tank error. Tank level is < 2. Injection stopped 0x20 Over dosing error. Automatic calculated dose rate > 50% 0x40 Under dosing error. Automatic calculated dose rate < 1sec/3minutes 0x80 Configuration error. Parameter out of range. 0x100 Pump not calibrated. Calibration must be run for automatic mode operation

12 12 Modbus Register Mapping Register Address Coils (0xxxx) Register Number Description Data Type Pump energize Used in manual mode only Coil Valve energize Used in manual mode only Coil Aux. energize Used in any mode Coil Force Calibration Used in any mode Coil 05 Function Codes Operation Mode. 0 = disabled, 1 = manual, 2 = timed, 3 = auto Int 03, 04, 06, Pump on time (seconds) used in timed mode Int 03, 04, 06, Pump on interval (seconds) used in timed mode Int 03, 04, 06, Production Rate (barrels/hour) used in auto mode Int 03, 04, 06, Dosing Amount (PPM) used in auto mode Int 03, 04, 06, Error Status Bits (0 = no errors, 1 = calibration failed) Int 03, Calculated Automatic Pump on time (seconds 10) Int 03, Calculated Automatic Pump on interval (seconds 10) Int 03, Hours since last calibration Int 03, Internal temperature ( C) Int 03, Analog Input Value (μa) Int 03, Analog Input Value (mv) Int 03, Depth of fluid (inches) (high word) Float 03, Depth of fluid (inches) (low word) Float 03, Analog Input Scaled Reading (in. H 20) (high word) Float 03, Analog Input Scaled Reading (in. H 20) (low word) Float 03, Volume of fluid in tank (quarts) (high word) (Not Implemented) Float 03, Volume of fluid in tank (quarts) (low word) (Not Implemented) Float 03, Amount pumped this contract period (quarts) (high word) Float 03, Amount pumped this contract period (quarts) (low word) Float 03, Amount pumped previous contract period (quarts) (high word) Float 03, Amount pumped previous contract period (quarts) (low word) Float 03, Pump Relay state (1 = energized, 0 = de-energized) Int 03, Valve Relay state (1 = energized, 0 = de-energized) Int 03, Aux. Relay state (1 = energized, 0 = de-energized) Int 03, Pump Calibration Status (0 = not in cal, 1 = cal in process) Int 03, Auto-calibration interval (0 = disabled, hours) Int 03, 04, 06, Calibration run cycles (0 = disabled) (4 to 10 is valid) Int 03, 04, 06, Current Month (1-12) Int 03, 04, 06, Current Day (1-31) Int 03, 04, 06, Current Year (0 99, 0 = 2000) Int 03, 04, 06, Current Day of Week (0-6, 0 = Sunday) Int 03, 04, 06, Current Hour (0 23) Int 03, 04, 06, Current Minute (0 59) Int 03, 04, 06, Current Second (0 59) Int 03, 04, 06, 16

13 Start of Contract Period, Hour (0 23) Int 03, 04, 06, Start of Contract Period, Minute (0 59) Int 03, 04, 06, Asset ID Register 1 Int 03, 04, 06, Asset ID Register 2 Int 03, 04, 06, Asset ID Register 3 Int 03, 04, 06, Asset ID Register 4 Int 03, 04, 06, Asset ID Register 5 Int 03, 04, 06, Asset ID Register 6 Int 03, 04, 06, Asset ID Register 7 Int 03, 04, 06, Asset ID Register 8 Int 03, 04, 06, Calculated Pump Constant (quarts/hour 100) Int 03, Specific gravity ( 100) Int 03, 04, 06, Sight Tube diameter (ID in inches 1000) Int 03, 04, 06, Analog Input Scale Low ( 100) Int 03, 04, 06, Analog Input Scale High ( 100) Int 03, 04, 06, Sensor Physical Offset (inches 100) Signed Int 03, 04, 06, Calculated Pump Constant (quarts/hour) Float 03, Specific gravity Float 03, 04, Sight Tube diameter (ID in inches) Float 03, 04, Analog Input Scale Low (signed int, ex. 0 psi) Float 03, 04, Analog Input Scale High (signed int, 30 psi) Float 03, 04, Sensor Physical Offset (inches) (-36 to +36) Float 03, 04, Major revision number for the mainboard Int 03, Minor revision number for the mainboard Int 03, Major revision number for the radio Int 03, Minor revision number for the radio Int 03, High 16 bits of SFTS node address Int 03, Low 16 bits of SFTS node address (the radio ID) Int 03, Slave ID readback Int 03, Received signal strength of last packet from the slave Signed Int 03, Supply voltage of the CI controller, in millivolts Int 03, Minutes until the slave will time out, unless new data is received Int 03, Number of registers cached for this slave device Int 03, Remote device type Int 03, 04