sps control system for vector vii drives - pn 810520

2011 GE Oil & Gas

SPS CONTROL SYSTEM For VECTOR VII DRIVES

USER MANUAL

GE Oil & Gas Surface Pumping Systems 5500 S.E. 59th Street Oklahoma City, OK 73135 Tel 405-670-1431 www.geoilandgas.com/artificiallift

Part Number 810520 Revision 2.0 November 2, 2011 Software Version 1.0.0

2011 GE Oil & Gas 1

SYSTEM OVERVIEW

This SPS System Controller will provide the following basic SPS functions:

Automated Pump Startup Control The Pump Startup Sequence is automatically controlled based on a limited number of user inputs

I/O Monitoring for System Protection and Control Pump and System Sensors are monitored and may be configured to shutdown the system under abnormal operating conditions

Drive Speed and System Control After the Pump Startup Sequence is complete, the SPS System Controller will control drive speed based on one of several pre-defined control algorithms. A second PID Loop is provided for control of auxiliary equipment such as valves.

STANDARD HARDWARE CONFIGURATION

SPS System Controller Mounted Inside of Drive Enclosure: - Rockwell Automation MicroLogix 1100 Programmable Logic

Controller - 10 Digital Inputs (120 VAC standard, 24 VDC optional) - 6 Digital Outputs (Isolated Relay Contacts 5 to 125 VDC / 5 to

265 VAC) - 8 Analog Inputs (4 to 20 ma standard, 0 to 10 VDC optional) - 2 Analog Outputs (0 to 10 VDC or 4 to 20 ma) - Modbus RTU Communications Port Used For Customer (SCADA)

Interface - Ethernet Communications Port Used as Interface to the Drive - Real Time Clock Provides Date & Time Information for Event

Logging - Removable Memory Module Easy Field Upgrades to System

Program

Graphical Operator Interface Mounted on Drive Enclosure Door - Rockwell Automation PanelView Plus 600 - 5.5 Color Touch Screen Display - NEMA 4X / IP65 Rated - Used for Operator Control, Monitoring, and Machine Set Up - Displayed Values are Scaled and Displayed in Engineering Units

2011 GE Oil & Gas 2

AUTOMATED PUMP STARTUP CONTROL

The following will describe the startup sequence for general SPS applications. These steps are sequential.

- System Start o A Start command is issued either manually using the start push-

button provided on the Graphical Operator Interface or via a customer provided contact closure.

- Charge Pump Operation o Once a Start command is received the Charge Pump Startup

permissives will be checked. After the required Charge Pump Startup permissives are met, the Charge Pump Run Output will be activated to start the Charge Pump.

Charge Pump Startup permissives: Assigned Analog Input point must be = a

specified value for a specified amount of time. Assigned Digital Input point must be in its normal

state o For applications without a Charge Pump the Charge Pump

Startup routine can be disabled

- Main Motor Start Sequence o If the Charge Pump Startup routine is enabled, the Main Motor

Start Sequence will not be executed until the Charge Pump Run Output is active

o Main Motor Start Permissives: Assigned Analog Input point must be = a specified

value for a specified amount of time (generally this input is Suction Pressure and Suction Pressure must be greater than a specified value for a specified amount of time.

Assigned Digital Input point must be in its normal state o Lube Oil Pump Operation

Once the above permissives are met for Main Motor Startup, the Lube Pump Start Output is activated, starting the Lube Oil Pump.

Once Lube Oil Pressure Input point reaches its normal state, the systems waits for 5 seconds and the Main Motor is started

2011 GE Oil & Gas 3

THE FOLLOWING FLOW CHART DEPICTS A TYPICAL SPS SYSTEM STARTUP SEQUENCE.

2011 GE Oil & Gas 4

I/O MONITORING SYSTEM PROTECTION AND CONTROL

Digital Inputs 24 Vdc

- Dedicated Digital Inputs o Start/Stop Inputs

Momentary Pushbuttons or customer supplied contact closure to trigger automatic startup sequence

o Local/Remote Inputs Local Control

Drive Speed is controlled manually through the drive (Not by PLC)

Automated Pump Startup Sequence Control remains active

PLC I/O Monitoring and Protection functions remain active

Remote Control Drive Speed is controlled by PLC Automated Pump Startup Sequence Control is

functional PLC I/O Monitoring and Control is functional

o Lube Pump Pressure Switch Input Shuts down drive on loss of Lube Pressure

- Configurable Digital Inputs o 8 Programmable Inputs are available for application dependent

functions. Typical Inputs include: Excessive Vibration Switch Motor Winding Temperature Switch Bearing Temperature Switch(s) Charge Pump Pressure Switch Charge Pump On / Lube Pump On Tank Level Switches External Fault Emergency Stop

o Each Digital Input is independently configurable: NO or NC Contact Enable (Start) Time Delay Trip Time Delay Maximum Number of Restart Attempts Restart Time Delay

o Alarm Action (Alarm or Shutdown)

2011 GE Oil & Gas 5

Digital (Relay) Outputs

- Charge Pump Run Output - Lube Pump Run Output - Main Motor Run Output - Three additional programmable outputs are available

Analog Inputs (4 to 20 ma standard, 0 to 10 Vdc optional)

- Dedicated Analog Inputs o Suction Pressure o Discharge Pressure

- Configurable Analog Inputs o 6 Additional Programmable Inputs are available for application

dependent functions. Typical Inputs include: Thrust Chamber Temperature Motor Bearing Temperature Mass Flow

- Each Input is independently configurable o High or Low Threshold Limit o Enable (Start) Time Delay o Trip Time Delay o Maximum Number of Restart Attempts o Restart Time Delay o Alarm Action (Bypass or Fault)

Analog Outputs (0 to 10 Vdc standard, 4 to 20 mA optional)

- 2 Programmable Analog Outputs - Typical: Output based on PID Control Algorithm

o Operator Setpoint o Selected Analog Input

2011 GE Oil & Gas 6

SYSTEM SETUP

MAIN MENU

On boot the system will display the Main Menu. The main menu is used to navigate through the system.

If the user is not logged in, the SETUP button will NOT be visible. Access to the Setup Menu can be restricted only to personnel who have access.

To log into the system, or change the password, press the LOG IN button on the screen.

2011 GE Oil & Gas 7

LOG IN

Touch the Password box to open the numeric entry screen and enter the 4 digit password. From the factory the password is zero. Press the Log In button after the 4 digit password is entered. You will now be able to enter your own password. If no password protection is needed, the password can be left at zero.

When the user is logged in the password can then be changed. Press the New Password box to enter a new 4 digit password and press the UPDATE PASSWORD button to change.

Press the BACK button to return to the Main Menu. SETUP MENU

2011 GE Oil & Gas 8

The Setup Menu is used to access the I/O configuration screens. Press the DISCRETE I/O button to access the Digital Inputs and Outputs configuration screens.

2011 GE Oil & Gas 9

DISCRETE I/O MENU

The Digital I/O setup screens are accessed through the Digital Setup screen. Press the DIGIN 1 button to configure Digital Input 1. After the Description is changed in the configuration screen, the button on the Digital Setup screen will change to show the description of the input.

The Digital Outputs are accessed through either of the Outputs Buttons. All the digital outputs are configured on one screen.

Press the BACK button to return to the Setup Menu.

2011 GE Oil & Gas 10

DIGITAL INPUTS SCREEN

Digital inputs 1 thru 4 are user configurable. Digital inputs 0, 5, 6, and 7 are preconfigured for Start Push Button Input, Lube Pressure Switch, Local/Remote Switch and Stop Push Button.

Digital inputs 1 through 4 are each configured in their own screen.

Press the Description box to enter a new description for the input. The description can be up to 16 characters long.

Press the NORMALLY CLOSED/NORMALLY OPEN button to toggle the input operation between a normally closed input and a normally open input.

The Enable Delay is the amount of time after the system has been placed in SEQUENCE START that the system waits to evaluate the input for an Alarm or Shutdown of the system. The enable delay must be set to at least 1 sec to enable the input in the system.

The Trip Delay is the amount of time after the input changes state before it trips the alarm or shuts down the system.


After the main motor has shutdown from this input, the Restart Delay is the amount of time the system will wait before restarting the main motor. This delay is in minutes.

The Max Restarts are the number of restarts the system will automatically allow. After the max restarts have been exceeded the system must be restart by an operator.

Press the ALARM/SHUTDOWN button to toggle between shutdown of the motor and alarm only operation of this input.

DIGITAL OUTPUTS SCREEN

The Charge Pump and Lube Pump are preconfigured and operate with permissives as stated in the Automated Startup flow chart. Outputs 3 and 4 operate with permissives which are evaluated after the system is placed in SEQUENCE START.

Press the >=/


Press the Discrete # box to select a digital input to trigger the digital output.

Select the Seconds box to set the amount of time after the system has been in SEQUENCE START mode before evaluating the trigger input.

ANALOG INPUTS SCREEN

The system has 8 user configurable analog inputs. Select the analog input you want to configure from the Analog Inputs Menu.

Once the description has been changed in the setup screen, the button in the Analog Inputs menu will change to show the description of the input.


ANALOG INPUT CONFIGURATION SCREEN

Press the Description box to enter a new description for the input. The description can be up to 16 characters long. Press the Units box to enter the units for the input.

The Span and Offset are used to set the zero and span for the input. Set the Span to the number equivalent to a 20 mA signal level. Set the Offset to the number equivalent to 4 mA. These numbers can then be adjusted up or down if needed to adjust the signal to match the actual process being measured.

The Lo Limit and Hi Limit are the comparison values for the analog input to trigger a system shutdown or alarm. The limit must be greater than zero to enable the comparison.

The Enable Delay is the amount of time after the system has been placed in SEQUENCE START that the system waits to evaluate the input for an Alarm or Shutdown of the system.

The Trip Delay is the amount of time after the input has exceeded the limit before it trips the alarm or shuts down the system.


After the main motor has shutdown from this input, the Restart Delay is the amount of time the system will wait before restarting the main motor. This delay is in minutes.

The Max Restarts are the number of restarts the system will automatically allow. After the max restarts have been exceeded the system must be restart by an operator.

Press the ALARM/SHUTDOWN button to toggle between shutdown of the motor and alarm only operation of this input.

ANALOG OUTPUT CONFIGURATION SCREEN

The system has two, 0-10 Vdc analog outputs. Analog output 1 is preconfigured for drive speed. The level of the output is copied over Ethernet to the speed reference of the P7 drive. If a different drive is used, the analog output should be wired to the analog input on the drive to control the drive speed.


The outputs can be preset to a defined value by selecting the MANUAL checkbox. The value is set in percent of full scale, 0 being 0 Vdc and 100 being 10 Vdc. Set the desired signal level in the OUTPUT ADJUST box.

To configure an output to be evaluated through the PID loop, an analog input must be defined in the INPUT # box. Set the Setpoint in the SETPOINT box. It must also be set in the 0-100% range.

To set up the PID loop to operate in reverse acting mode, (increasing analog input causes the output to increase), select the REVERSE ACTING box.

Press the TUNE button to access the tuning parameters for the PID loops.

PID TUNING SCREEN

Use the PID tuning screen to change the P, I and D terms of the PID loops. The deadband for the feedback analog input can also be changed from this screen.


PUMP CONTROL SCREEN

The Pump Control screen is used to place the system into and out of SEQUENCE START mode.

Press the START button to enable SEQUENCE START. Digital Input 0 is also dedicated to a remote START pushbutton. Wire a momentary pushbutton into DIGIN 0 to implement a remote start.

Press the STOP button to take the system out of SEQUENCE START mode. Digital input 7 is also dedicated to a remote STOP pushbutton. Wire a momentary pushbutton into DIGIN 7 to implement a remote stop.

When the max restarts for any input has been exceeded, use the RESTART button to reset the system.

When an input has tripped a shutdown of the main motor, the indicator above the buttons will display AWAITING RESTART. A timer will appear above the Reset button displaying the time since shutdown, and the number directly above the Reset button will display the number of shutdowns the system has experienced. The display will also indicate if the max restarts for any input have been exceeded.


RUN SCREEN

The RUN screen is used to monitor the system.

Across the top of the screen is the status of the main motor, the charge pump, and the lube oil pump. The drive output speed is also displayed in Hz.

The analog inputs are displayed in the center of the screen. Only four can be displayed at a time. Press the AIN 1-4 button to toggle between analog inputs 1-4 and 4-8.

The status of the digital inputs and digital outputs are shown below the analog inputs. The description of the inputs is displayed in a green or red box for On and Off status.

The levels of the analog outputs are displayed at the bottom of the screen. The levels are displayed as 0 to 100%.


DIAGNOSTICS SCREEN

The I/O can also be monitored from the Diagnostics screen. Like the Run screen the analog input and output values are displayed, and the status of the digital inputs and outputs are indicated by a red or green pilot indicator.

The digital inputs are displayed from left to right: Start PB, Digin1, Digin2, Digin3, Digin4, Press Switch, Local/Remote and Stop PB.

The digital outputs are displayed from left to right: Charge Pump, Lube Pump, Dout3, Dout4 and Main Motor.


DRIVE STATUS SCREEN

The drive status screen displays the information read from the drive over the Ethernet link. If the RUN indicator displays NO COMMS, the PLC and the Drive are not communicating over the Ethernet link.

The CURRENT FAULT AND PREVIOUS FAULT will display the last two faults in the drives fault cue.


ALARMS SCREEN

The Alarms screen displays alarm messages and diagnostic messages. Press the ALARM/DIAG button to toggle between the alarm messages and the diagnostic messages. Press the up and down arrows to move through the pages of messages.

The system will display the last 500 messages and discard the oldest after reaching 500.


SYSTEM WIRING

The system I/O is wired into the PLC through the terminal block PLC TB. 24 Vdc is available on the power terminal block for loop powered instruments.


Digital inputs are wired in on terminals 1 thru 8. Inputs are 24 Vdc ONLY, DO NOT wire in a 120VAC signal, you will burn out the input. Interposing relays must be used for 120 VAC digital inputs.

Terminal 1 - momentary START PB input. Terminal 2 Digin 1 Terminal 3 Digin 2 Terminal 4 Digin 3 Terminal 5 Digin 4 Terminal 6 Lube Pressure Switch Terminal 7 maintained Local/Remote Switch Terminal 8 momentary STOP PB input

Digital Outputs are wired into terminals 9 thru 20. Outputs are relay contacts. They can be either AC or DC loads. Each output has a common and an output terminal. Relay contacts are rated for 3 amps max. Use interposing relays for any large loads.

Terminal 9 and 10 Charge Pump Terminal 11 and 12 Lube Pump Terminal 13 and 14 Dout 3 Terminal 15 and 16 Dout 4 Terminal 17 and 18 Main Motor Terminal 19 and 20 Not used future expansion


Because of the potentially high current surges that occur when switching inductive load devices, such as motor starters and solenoids, the use of some type of surge suppression to protect and extend the operating life of the controllers output contacts is required. Switching inductive loads without surge suppression can significantly reduce the life expectancy of relay contacts. By adding a suppression device directly across the coil of an inductive device, you prolong the life of the output or relay contacts. You also reduce the effects of voltage transients and electrical noise from radiating into adjacent systems. The following diagram shows an output with a suppression device. We recommend that you locate the suppression device as close as possible to the load device.

If the outputs are dc, we recommend that you use a 1N4004 diode for surge suppression, as shown below. For inductive dc load devices, a diode is suitable. A 1N4004 diode is acceptable for most applications. These surge suppression circuits connect directly across the load device.


Analog inputs are wired into terminals 21 thru 36. Analog input signals are 4 to 20 mA.

Terminal 21 and 22 Analog input 1 Terminal 23 and 24 Analog input 2 Terminal 25 and 26 Analog input 3 Terminal 27 and 28 Analog input 4 Terminal 29 and 30 Analog input 5 Terminal 31 and 32 Analog input 6 Terminal 33 and 34 Analog input 7 Terminal 35 and 36 Analog input 8

The analog outputs are wired into terminals 37 thru 40. Analog output signals are 0-10 Vdc.

Terminal 37 and 38 Analog output 1 Terminal 39 and 40 Analog output 2

sps control system for vector vii drives - pn 810520

Documents