Sam Pcp Manual v1.00

SAM Well Manager™ Progressing Cavity Pump

User Manual

Lufkin Automation 11375 W. Sam Houston Parkway South, Suite 800Houston, Texas 77031 Tel: 281.495.1100 Fax: 281.495.6333 www.lufkinautomation.com

PCP Flow & Measurement Control Variable Speed Pump Control Historical Data Display

SAM Well Manager™

Progressing Cavity Pump User Manual

INSTRUCTIONS FOR

INSTALLATION AND OPERATION OF THE

SAM WELL MANAGER PROGRESSING CAVITY PUMP

CONTROLLER AND ANALYSIS SYSTEM

Lufkin Automation 11375 W. Sam Houston Parkway South, Suite 800 Houston, Texas 77031 Tel: 281.495.1100 Fax: 281.495.6333 www.lufkinautomation.com

IMPORTANT

READ THIS NOTICE BEFORE USING THIS PRODUCT

Information in this document is subject to change without notice and does not represent a commitment on the part of LUFKIN AUTOMATION.

No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose other than the purchaser's personal use without the written permission of LUFKIN AUTOMATION.

SAM Well Manager™ is a trademark of Lufkin Automation, Inc.

All other trademarks are the property of their respective owners and are used for explanation purposes only with no intent to infringe.

Copyright © 2008 Lufkin Automation, Inc. All rights reserved.

Part No. 099.5028

Limited Warranty

Lufkin Automation warrants the Product it manufactures, including all parts and components thereof to be free from defects in material and workmanship. Lufkin Automation will, at its option, either repair or replace such a Product, subject to the conditions of this Limited Warranty. This Limited Warranty commences on the date of shipment of the Product and shall remain in effect for a period of one year except for shop repairs and service repair exchange (SRE) items, which carry a 90-day warranty.

This Limited Warranty does not apply if failure is caused or contributed by any of the following: (1) improper handing, storage or installation (2) abuse, (3) unsuitable application of the product, (4) lack of reasonable and necessary maintenance, (5) repairs made or attempted by other than Lufkin Automation, (6) neglect or accident, (7) damage by wind, freezing, lightning, Act of God or other cause or (8) damage in transit or during installation. This Limited Warranty applies only to Products that have been installed and maintained in strict accordance with the Lufkin Automation installation procedure and to Products that have been connected to the supply voltage marked on the Product. The Limited Warranty does not apply to any Product on which the serial number has been altered, effaced or removed.

IMPLIED WARRANTIES, WHEN APPLICABLE, SHALL COMMENCE UPON THE SAME DATE AS THE EXPRESS WARRANTY PROVIDED ABOVE, AND SHALL EXTEND ONLY FOR THE DURATION OF THE EXPRESS WARRANTY. SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. THE ONLY REMEDY PROVIDED TO YOU UNDER AN APPLICABLE IMPLIED WARRANTY AND THE EXPRESS WARRANTY SHALL BE THE REMEDY PROVIDED UNDER THE EXPRESS WARRANTY, SUBJECT TO THE TERMS AND CONDITIONS CONTAINED THEREIN, LUFKIN AUTOMATION SHALL NOT BE LIABLE FOR INCIDENTAL AND CONSEQUENTIAL LOSS AND DAMAGES UNDER THE EXPRESS WARRANTY AND APPLICABLE IMPLIED WARRANTY, OR CLAIMS FOR NEGLIEGENCE, EXCEPT TO THE EXTENT THAT THIS LIMITATION IS FOUND TO BE UNENFORCEABLE UNDER APPLICABLE STATE LAW. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

Lufkin Automation will repair or replace, at its option, any Product which is found to be defective in material or workmanship. The Limited Warranty does not cover the labor costs of repair or replacement of the unit or part unless done at our factory. If you elect to ship the part or Product to Lufkin Automation, authorization to return the Product to the factory must first be obtained from Lufkin Automation and shipping instructions received from Lufkin Automation must be followed. Lufkin Automation is not responsible for the cost of removal of the Product or its components, damage due to removal or any other expenses incurred in shipping the Product or parts to or from the factory or for the installation of the repaired or replacement unit. The owner must bear these expenses and should insure the shipment against loss or damage in transit.

This Limited Warranty gives the owner specific legal rights and the owner may also have other rights, which vary from State to State. Lufkin Automation does not authorize any person to create for it, any other obligations of liability in connection with its Product.

Issue Date: 1/18/08 Revision 1.00

Revision Record

SAM Well Manager™ — Progressing Cavity Pump User Manual

Date Revision No. Section Description 1/18/08 1.00 All sections First release

Issue Date: 1/19/08 Revision 1.00

Safety Procedures • Park vehicles upwind of the wellhead. Stand upwind when installing or dismantling

equipment.

WARNING: Injection fluid lines operate at high pressure. If breaking loose flange connections or opening valves, use all proper energy isolation procedures and wear proper personal protection equipment.

WARNING: Hydrogen sulfide gas (H2S) may be present in high concentrations in

injection fluids and around injection wellheads. Be sure to have proper H2S detection equipment on your person and practice all recommended safety precautions when working around injection wellheads.

• Before leaving the location, return all wellhead equipment to their normal operating positions.

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Table of Contents

Section 1: Introduction to this Manual 1.1 Manual Overview........................................................................... 1-1 1.2 How to Use this Manual................................................................. 1-2

1.2.1 Entering Data and Executing Commands ......................... 1-2 1.2.2 Displayed Messages.......................................................... 1-3 1.2.3 Section Levels ................................................................... 1-3 1.2.4 Procedural Steps................................................................ 1-3 1.2.5 Shorthand Method for Interface Menu Selection.............. 1-3 1.2.6 Notes ................................................................................. 1-4

1.3 Technical Support .......................................................................... 1-4

Section 2: Description of the SAM Progressing Cavity Pump Controller System 2.1 SAM PCP Controller...................................................................... 2-1 2.2 12 Volt Power Supplies.................................................................. 2-4 2.3 Terminal Blocks ............................................................................. 2-4 2.4 Controller Operator Interface ......................................................... 2-4

2.4.1 Operator Interface Keypad................................................ 2-5 2.4.2 LCD Graphics Display...................................................... 2-5 2.4.3 Menu Option Selection ..................................................... 2-8 2.4.4 Control Parameter Programming ...................................... 2-8

2.5 Modbus Master Feature.................................................................. 2-8

Section 3: Technical Specifications 3.1 Enclosure........................................................................................ 3-1 3.2 Internal Component Layout ........................................................... 3-2 3.3 Environmental Operating Range.................................................... 3-2 3.4 120-VAC System ........................................................................... 3-3 3.5 Brownout/Blackout Protection....................................................... 3-3 3.6 Microprocessor and Memory ......................................................... 3-3 3.7 Serial Communications .................................................................. 3-3

Section 4: Parts Lists 4.1 SAM PCP Controllers .................................................................... 4-1 4.2 Spare Parts...................................................................................... 4-1

WCooper1

Typewritten Text


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4.3 SAM PCP Optional Hardware ....................................................... 4-2 4.4 SAM PCP Optional Hardware ....................................................... 4-2 4.5 Operator Interface Systems ............................................................ 4-2 4.6 Documentation ............................................................................... 4-2 4.7 How to Order Parts......................................................................... 4-3

Section 5: System Installation and Wiring 5.1 Overview of the System Installation .............................................. 5-2 5.2 PCP Controller System Installation................................................ 5-2

5.2.1 Installing the Mounting Post or Pedestal and Ground Rod....................................................................... 5-4

5.2.2 Installing the Stepdown Transformer................................ 5-5 5.2.3 Mounting the Controller.................................................... 5-6 5.2.4 Installing Flow Rate Meters and Process Variable

Transmitters ...................................................................... 5-6 5.2.5 Installing the Rod RPM Hall-Effect Transducer............... 5-7

5.3 PCP Controller System Wiring ...................................................... 5-8 5.3.1 Wiring Specifications and Recommended Tools............ 5-10 5.3.2 Grounding the System..................................................... 5-12 5.3.3 Wiring the Stepdown Transformer.................................. 5-14 5.3.4 Wiring the Polished Rod Hall-Effect Transducer ........... 5-16 5.3.5 Wiring the Motor Control Relay..................................... 5-17

5.4 Performing Power-Up Voltage Checks........................................ 5-18

Section 6: Hardware Configuration 6.1 Overview of the Hardware Configuration...................................... 6-1 6.2 Battery Disconnect Jumper Pins .................................................... 6-2 6.3 4–20 MA Transmitters ................................................................... 6-3 6.4 Radio Communications Port .......................................................... 6-4 6.5 RS-485 Communication Expansion Board .................................... 6-6 6.6 Turbine Meter Board...................................................................... 6-9 6.7 VSD Configuration ...................................................................... 6-10

Section 7: PCP Parameter Programming 7.1 Overview of PCP Parameter Programming.................................... 7-1 7.2 Configuring Control Parameters .................................................... 7-3 7.3 Configuring Parameter Violations ............................................... 7-13 7.4 Configuring End Devices ............................................................. 7-19 7.5 Configuring Production and Motor Information.......................... 7-23 7.6 Configuring Special Features ....................................................... 7-25

Section 8: SAM Controller Programming 8.1 Overview of SAM PCP Controller Parameter Programming ........ 8-2 8.2 RTU Level Menu ........................................................................... 8-4 8.3 Setting the Controller Date and Time ............................................ 8-5 8.4 Communication Parameters Configuration.................................... 8-7

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8.4.1 Configuring Communication Parameters.......................... 8-8 8.4.2 Configuring Modbus Transmission Mode ...................... 8-12

8.5 Modbus Master and Slave Device Configuration ........................ 8-14 8.5.1 Configuring Slave Device Parameters ............................ 8-15 8.5.2 Writing Register Values to Registers and the Slave

Device ............................................................................. 8-22 8.5.3 Specifying a Polling Routine Rate .................................. 8-24 8.5.4 Configuring the Communication Expansion Port ........... 8-26

8.6 Changing Passwords .................................................................... 8-28 8.7 Resetting Parameters to Factory-Default Values ......................... 8-30 8.8 Configuring the Default Screen.................................................... 8-31 8.9 Setting Gauge Off Time and Peak Energy Management ............. 8-33 8.10 Auxiliary I/O Configuration......................................................... 8-36

8.10.1 Configuring Auxiliary Analog Inputs ............................. 8-37 8.10.2 Configuring Auxiliary Analog Outputs .......................... 8-41 8.10.3 Configuring Auxiliary Digital Inputs and Outputs ......... 8-45 8.10.4 Configuring Auxiliary Accumulators ............................. 8-48

8.11 Logic Expressions ........................................................................ 8-53 8.11.1 Programming a Logic Expression................................... 8-54 8.11.2 Programming a Logic Expression Action....................... 8-62 8.11.3 Clearing the Logic Expression State............................... 8-65 8.11.4 Enabling and Disabling Logic Expressions .................... 8-67

8.12 AGA 3 Parameter Configuration.................................................. 8-68 8.12.1 Configuring AGA 3 Parameters...................................... 8-70 8.12.2 Configuring NX-19 Design Parameters .......................... 8-73 8.12.3 Configuring Temperature and Pressure .......................... 8-75 8.12.4 Enabling and Disabling AGA 3 Calculations ................. 8-78

8.13 Custody Transfer .......................................................................... 8-79 8.14 Register Configuration ................................................................. 8-79

8.14.1 Configuring a Register Alarm......................................... 8-80 8.14.2 Configuring a Register Log............................................. 8-83 8.14.3 Configuring Register Calculations.................................. 8-88

8.15 Configuring and Enabling/Disabling HOA.................................. 8-94 8.16 Configuring Alarm (Coil) Tracking ............................................. 8-97 8.17 Configuring VSD Parameters....................................................... 8-99

Section 9: Status Screens 9.1 Overview of the Status Screens...................................................... 9-2 9.2 Displaying the Status of PCP Parameters ...................................... 9-2

9.2.1 Current PCP Operating Status........................................... 9-2 9.3 Displaying the Status of SAM PCP Controller Parameters ........... 9-7 9.4 Auxiliary Functions........................................................................ 9-8

9.4.1 Auxiliary Input Status Screens.......................................... 9-9 9.4.2 Displaying AUX Analog Input Status ............................ 9-10 9.4.3 Displaying AUX Analog Output Status.......................... 9-11 9.4.4 Displaying Digital Input Status....................................... 9-12


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9.4.5 Displaying AUX Accumulator Status............................. 9-14 9.4.6 Displaying AUX I/O Boards Status ................................ 9-15 9.4.7 Displaying AGA 3 Status................................................ 9-16 9.4.8 Displaying Logic Expression Status ............................... 9-19

9.5 Register Functions........................................................................ 9-20 9.5.1 Displaying Register Digital Output Status...................... 9-21 9.5.2 Displaying Register Calculations Status ......................... 9-22

9.6 Displaying Alarm/Alert Status ..................................................... 9-23 9.7 Displaying Alarm Tracking Status............................................... 9-24 9.8 Displaying the Status for a Modbus Master Slave Device........... 9-26 9.9 VSD Diagnostics .......................................................................... 9-28

Section 10: Historical Data 10.1 Overview of the Historical Data Features .................................... 10-2 10.2 Plotting Data Menu ...................................................................... 10-4 10.3 PCP Data ...................................................................................... 10-5

10.3.1 Starting Period................................................................. 10-6 10.3.2 Normal Operation Period ................................................ 10-7 10.3.3 Power Off Delay Period .................................................. 10-7 10.3.4 Stopping Period............................................................... 10-7

10.4 60 Day Historical Data................................................................. 10-7 10.4.1 60 Day Peak Speed Measured......................................... 10-8 10.4.2 60 Day Peak Speed Output ............................................. 10-8 10.4.3 60 Day Peak Torque........................................................ 10-8 10.4.4 60 Day Daily Production................................................. 10-8 10.4.5 60 Day Pump Efficiency ................................................. 10-8

10.5 SAM Data..................................................................................... 10-9 10.5.1 Register Log.................................................................... 10-9 10.5.2 60 Day Alarm Tracking ................................................ 10-10

10.6 AGA 3 Data................................................................................ 10-11 10.6.1 24 Hour AGA 3 Gas Flow ............................................ 10-11 10.6.2 60 Day AGA 3 Gas Flow.............................................. 10-12

10.7 Events ......................................................................................... 10-13 10.7.1 Event Log...................................................................... 10-13 10.7.2 Alarm Log ..................................................................... 10-14

Section 11: System Starting and Stopping

Section 12: Reset Malfunctions

Section 13: Firmware Versions

Section 14: System Tools 14.1 Overview of the System Tools ..................................................... 14-1 14.2 Maintenance Log.......................................................................... 14-2 14.3 Main Board I/O Diagnostics ........................................................ 14-3

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14.3.1 Main Board I/O Status .................................................... 14-4 14.3.2 Main Board Manual DIO Diagnostics ............................ 14-5

14.4 Communication Diagnostics ........................................................ 14-6 14.4.1 RX/TX Messages ............................................................ 14-7 14.4.2 MB Register Map Check................................................. 14-8

14.5 Keypad ......................................................................................... 14-9

Section 15: Quick Programming Using the Quick Start Feature 15.1 PCP Quick Start ........................................................................... 15-1

15.1.1 Quick Start Programming Processes............................... 15-2 15.1.2 Methods for Navigating the Quick Start Programming

Screens ............................................................................ 15-2 15.2 Starting the Quick Start Process................................................... 15-3 15.3 Resetting Parameters to Factory-Default Values ......................... 15-3 15.4 Using the Quick Start Feature ...................................................... 15-4

Section 16: Sam Flash Upgrade Utility Software 16.1 Software Overview....................................................................... 16-2 16.2 Sam Flash Upgrade Utility Screen ............................................... 16-2

16.2.1 File To Upload Section ................................................... 16-3 16.2.2 Comm Parameters Section .............................................. 16-5 16.2.3 Status Section.................................................................. 16-7 16.2.4 Message Window Section............................................... 16-7 16.2.5 Command Buttons........................................................... 16-8

16.3 Installing the Software on a Laptop Computer ............................ 16-9 16.4 Specifying Communications Between the Controller and

Laptop......................................................................................... 16-10 16.4.1 Specifying the Communication Baud Rate in the

SAM PCP Controller .................................................... 16-11 16.4.2 Specifying Communication Parameters in the

Laptop Computer .......................................................... 16-12 16.5 Connecting the Controller to the Laptop Computer................... 16-13 16.6 Establishing Communications Between the Controller and

Laptop Computer........................................................................ 16-14 16.7 Saving the Controller Configuration to a File............................ 16-14 16.8 Uploading a Saved Configuration File into the SAM PCP

Controller ................................................................................... 16-16 16.9 Upgrading Application Firmware .............................................. 16-18 16.10 Disconnecting Communications Between the Controller

and Laptop Computer................................................................. 16-20

Appendix A: Well State List A.1 Overview of Well States ............................................................... A-2 A.2 Normal Operation Well States ...................................................... A-2 A.3 Downtime and Malfunction Well States ....................................... A-4


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A.3.1 Violation Conditions and Types ...................................... A-4 A.3.2 Violation Run Well States................................................ A-5 A.3.3 Violation Downtime Well States ..................................... A-5 A.3.4 Malfunction Run Well States ........................................... A-6 A.3.5 Malfunction Shutdown Well States ................................. A-6 A.3.6 Logic Expression Violation Well States .......................... A-6 A.3.7 Malfunction - Drive Fault ................................................ A-7 A.3.8 Miscellaneous Downtime States ...................................... A-7

A.4 HOA Well States ........................................................................... A-8 A.5 Quick-Start Well States................................................................. A-8 A.6 Timed Mode Well States............................................................... A-8 A.7 Host Mode Well States.................................................................. A-9 A.8 Monitor Mode Well States .......................................................... A-10 A.9 Speed Control Well States........................................................... A-10 A.10 Sand Blowout Well States........................................................... A-10 A.11 Power Fail Lockout ..................................................................... A-10 A.12 Error Well States ......................................................................... A-11

Appendix B: AGA 3 Definitions B.1 AGA 3 Formulas ............................................................................B-2

B.1.1 AGA-3 1992 Tap Type Factors Method ...........................B-2 B.1.2 Pressure Measured at Upstream Tap Pf1 ...........................B-4 B.1.3 Orifice Flow Constant C’ ..................................................B-4 B.1.4 Numeric Conversion Factor — Fn ....................................B-5 B.1.5 Velocity Approach Factor — Ev ......................................B-5 B.1.6 Orifice Calculation Factor — Fc .......................................B-6 B.1.7 Reynolds Number — ReD .................................................B-7 B.1.8 Orifice Slope Factor – Fsl ..................................................B-8 B.1.9 Expansion Factor – Y........................................................B-8 B.1.10 Pressure Base Factor — Fpb ..............................................B-9 B.1.11 Temperature Base Factor — Ftb........................................B-9 B.1.12 Flowing Temperature Factor — Ftf ...................................B-9 B.1.13 Real Gas Relative Density (Specific Gravity)

Factor — Fgr ....................................................................B-10 B.1.14 Supercompressibility Factor — Fpv.................................B-10 B.1.15 AGA-3 1985 Formula — Pipe Taps ...............................B-11

B.2 Orifice Flow Constant — C’ ........................................................B-12 B.2.1 Basic Orifice Factor — Fb...............................................B-12 B.2.2 Reynolds Number Factor — Fr .......................................B-13 B.2.3 Pressure Base Factor — Fpb ............................................B-15 B.2.4 Temperature Base Factor — Ftb......................................B-15 B.2.5 Flowing Temperature Factor — Ftf .................................B-15 B.2.6 Real Gas Relative Density (Specific Gravity)

Factor – Fgr ......................................................................B-16 B.2.7 Supercompressibility Factor — Fpv.................................B-16

B.3 NX-19 Formulas...........................................................................B-16

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Issue Date: 1/18/08 Revision 1.00 xiii

B.3.1 Adjusted Pressure And Temperature Calculations .........B-17 B.3.2 Pressure and Temperature Correlation Parameters.........B-19 B.3.3 NX-19 Natural Gas Regions and E Equations ................B-19 B.3.4 Flowing Compressibility — Zf .......................................B-21 B.3.5 Base Compressibility — Zb............................................B-21

B.4 Calibration Factors .......................................................................B-21 B.4.1 Orifice Thermal Expansion Factor — Fa ........................B-22 B.4.2 Water Manometer Correction Factor — Fam .................B-22 B.4.3 Local Gravitational Correction Factor For U-Tube

Manonmeters — Fwl........................................................B-23 B.4.4 Water Manometer Temperature Correction

Factor — Fwt....................................................................B-24 B.4.5 Local Gravitational Correction Factor For Weight

Standards — Fpwl.............................................................B-24 B.4.6 Correction for Gas Column in Mercury Manometer

Instruments – Fhgm...........................................................B-25 B.4.7 Mercury Manometer Temperature Factor — Fhgt ...........B-26

Index

Section 1

Introduction to this Manual

This section explains the topics covered in this manual and how to use this manual.

The topics covered in this section include:

1.1 Manual Overview........................................................................... 1-1 1.2 How to Use this Manual................................................................. 1-2

1.2.1 Entering Data and Executing Commands............................ 1-2 1.2.2 Displayed Messages ............................................................ 1-3 1.2.3 Section Levels ..................................................................... 1-3 1.2.4 Procedural Steps .................................................................. 1-3 1.2.5 Shorthand Method for Interface Menu Selection ................ 1-3 1.2.6 Notes.................................................................................... 1-4

1.3 Technical Support .......................................................................... 1-4

The Lufkin Automation SAM Well Manager™ for PCP Control can perform a wide range of operations. Every attempt is made to provide enough information and explain each procedure clearly so that you can easily and quickly learn how to operate this controller. Please take the time to understand how this manual is organized, and how to use this manual before reading how to install and operate the controller.

1.1 Manual Overview The SAM Well Manager™ — Progressing Cavity Pump User Manual is designed to provide you with information about the SAM PCP Controller hardware specifications, installation procedures, and system operations. All information in this manual falls into three categories.

Issue Date: 1/18/08 Revision 1.00 1-1


Category One introduces you to this manual and to the SAM PCP Controller. A breakdown of the topics covered is:

• Typographical conventions used

• How to obtain technical support when needed

• Description of SAM PCP Controller system

• Description of the SAM PCP Controller system components

• Technical specifications

• Parts lists

Category Two explains how to install the SAM PCP Controller and its components, how to program the SAM PCP Controller, and how to use the SAM PCP Controller analysis capabilities. A breakdown of the topics covered is:

• Installing and Wiring the SAM PCP Controller system

• Programming and operating the SAM PCP Controller

Category Three provides you with an index for quick and easy access to specific information you need.

Other hardware and software components may be used in conjunction with the SAM PCP Controller. Refer to the components’ respective manuals for specific information about these products.

1.2 How to Use this Manual This section explains the typographical conventions used throughout this manual. Typographical conventions are used to represent keyboard functions and to highlight important operations.

1.2.1 Entering Data and Executing Commands All keys used to execute commands are presented in bold type, preceded by the word “press”, and are surrounded with the less-than symbol (<) and the greater-than symbol (>). For example, if you are instructed to press the ENTER key, it is explained to you as:

Press <ENTER>.

1-2 Revision 1.00 Issue Date: 1/18/08

Section 1: Introduction to this Manual

1.2.2 Displayed Messages All messages that are displayed on the optional LED graphics display are represented in bold, uppercase type:

ALARM ALERT

1.2.3 Section Levels Each chapter has up to three section levels. The three section level headings are presented as:

X.X First Level X.X.X Second Level

Third Level

1.2.4 Procedural Steps A procedure that must be followed in a specific order is numbered similar to the following:

1. Perform step one first.

2. Perform step two second.

3. Perform step three third.

1.2.5 Shorthand Method for Interface Menu Selection A shorthand access method for selecting menu options using the SAM PCP Controller interface is provided throughout this manual to quickly explain the procedure required to get to your desired operation.

To the right of many paragraphs, you will find a box displaying “SAM” (shorthand access method) and below it numbers separated with a forward slash (/). For example, the box to the right of this paragraph represents the following:

SAM 3/3/1

1. From the MAIN Menu screen, select option 3. CONFIGURATION.

2. From the Configuration Menu screen, select option 3. SAM CONFIGURATION.

3. From the SAM Configuration Menu screen, select option 1 RTU LEVEL.




1.2.6 Notes Notes draw your attention to important messages within this manual. For example:

Note: If another screen is displayed, press <MENU> to instantly return to the Main Menu screen.

1.3 Technical Support Assistance is available when needed from Lufkin Automation Technical Support Services at (281) 495-1100, Monday through Friday, between 8:00 A.M. and 5:00 P.M., Central Time. You can also e-mail us at [email protected].

To help us answer your question as quickly as possible, please have all information that applies to your problem readily available. Write down or print out any onscreen messages you get when the problem occurs, and have your manual with you when you call.

Issue Date 1/18/08 Revision 1.00 2-1

Section 2

Description of the SAM Progressing Cavity Pump Controller System

This section describes the major components making up the SAM PCP Controller.


2.1 SAM PCP Controller...................................................................... 2-1 2.2 12 Volt Power Supplies.................................................................. 2-4 2.3 Terminal Blocks ............................................................................. 2-4 2.4 Controller Operator Interface ......................................................... 2-4

2.4.1 Operator Interface Keypad .................................................. 2-5 2.4.2 LCD Graphics Display ........................................................ 2-5 2.4.3 Menu Option Selection........................................................ 2-8 2.4.4 Control Parameter Programming......................................... 2-8

2.5 Modbus Master Feature.................................................................. 2-8

Note: Technical specifications for the SAM PCP Controller are provided in section 3, “Technical Specifications.”

2.1 SAM PCP Controller Lufkin Automation’s SAM Progressing Cavity Pump (PCP) Controller complements the field-proven electronics hardware of the SAM Well Manager™ Rod Pump Control unit with new application firmware for monitoring and controlling the PCP activity at the wellhead.


2-2 Revision 1.00 Issue Date 1/18/08

The SAM PCP Controller is a pre-programmed device mounted at the wellsite that gathers, processes, stores, and analyzes data obtained from transmitters and meters. The data collected from these input devices is used to monitor and control pump operation to maximize fluid production efficiency and protect the pump.

Primary Speed Control Algorithm The SAM PCP Controller works in conjunction with a variable speed drive (VSD) to optimize fluid production while protecting the pump. The patented control algorithm varies the speed of the pump in steps while measuring the amount of fluid production from the pump. As long as sufficient fluid is available at the pump intake to completely fill the pump cavities, a linear relationship occurs between fluid production and pump speed.

The SAM PCP Controller begins an operating cycle at a user-defined startup speed. The surface fluid production rate at that speed is measured over a user-defined sampling period after a programmed settling time. The SAM PCP Controller then increases the pump speed by a step and measures the fluid production rate at this new speed. The controller continues to increase the pump speed in user-defined steps, measures production rate at each step after the settling time, and then establishes a speed/rate relationship.

At a point when a step increase in speed does not produce the proportional step increase in fluid production rate, the SAM PCP Controller starts to slow the speed by steps until a reduction in fluid production rate is measured. The control algorithm continues to test the optimum production rate by repeating the speed increase/decrease sequence.

Secondary Control Algorithms The SAM PCP Controller also has secondary control algorithms that monitor the following:

• Torque signal from the variable speed drive

• Polished rod RPM as indicated by a Hall-Effect transducer sensing a magnet mounted on the polished rod

• Low/high fluid rate limits

Section 2: Description of the SAM Progressing Cavity Pump Controller System


All secondary control features slow the pump when one or more of these set point limits is violated. If the monitored variable continues to be in an alarm condition when a programmed minimum speed is reached, the SAM PCP Controller will stop the pump to prevent damage to the pumping equipment.

Production Measurement Options Production measurement options supported by the SAM PCP Controller include the following:

• An accumulator for dry contact inputs pulses

• An analog input from a flow meter

• A differential pressure signal from a wedge meter run

Historical Records Historical records of the previous 1,500 one-minute samples are maintained for process variables that include:

• Production rate

• Speed output to the VSD

• Actual measured speed of the polished rod

• Torque signals from the VSD

• Pump efficiency

A 60-day record of production totals for the day is also stored in the SAM PCP Controller.

Historical data can be displayed graphically in a format easy to understand on the LCD display that is included as part of the SAM PCP Controller, or it can be displayed on a portable laptop computer.

Communication Protocol The SAM PCP Controller uses Modbus-based communications protocol, and also offers the advantages of the Extended Lufkin Automation Modbus (ELAM) protocol for SCADA software packages that goes beyond the limitations of conventional Modbus.



All of the configuration, status, and historical data available at the local keypad interface are also available via data telemetry link to SCADA software.

Common Hardware Platform The SAM PCP Controller operates on the Lufkin Automation SAM Well Manager hardware platform. Using this common platform reduces the number of spare parts that must be kept on hand, simplifies training, and provides you with a single source for rod pump, injection well, and progressing cavity pump automation.

2.2 12 Volt Power Supplies The standard SAM PCP Controller system is powered by 85 – 264 VAC, 50/60 Hz prmary power.

A 12-VDC power supply is included to provide the DC voltage required by the electronics.

2.3 Terminal Blocks Terminal blocks are provided for field termination of all transmitter leads, including individual shield termination points. The terminal blocks are front-access compression-clip type. The field leads do not require crimp lugs.

2.4 Controller Operator Interface Several parameters need to be defined to program the SAM PCP Controller. Programming is done through the local operator interface, which consists of a full-function LCD graphics display and 20-key keypad. This operator interface is menu driven. It allows you at the wellsite to program and calibrate the SAM PCP Controller, and access and display current and historical data instead of using the SamScreen Terminal emulator program that runs on a laptop computer.



2.4.1 Operator Interface Keypad The 20-key operator interface keypad (Figure 2-1) is mounted in the SAM PCP Controller enclosure. It is the quickest and easiest way to program the SAM PCP Controller. It allows you at the wellsite to program and calibrate the controller and access and display current and historical data without using a laptop computer. The keypad is not absolutely required for programming and calibration, because programming can also be done using the SamScreen Terminal emulator interface program installed in your laptop computer.

Figure 2-1. Operator Interface Keypad

Below is a description about each key’s function on the keypad.

Key Function 1 — 0 Selects an option from a menu screen or enters new data in fields

on the programming screens.

↑ ↓ ← → Changes set point position or cursor location in the direction specified by the arrow key. Also scrolls available options in several programming screen fields.

ENTER Confirms a correct entry when changing programming data. When this key is pressed, data is updated.

EDIT Selects the edit mode so that programming changes can be made. Edit mode is selected on a per-field basis.

NEXT Selects the next screen for display. In some cases, <NEXT> is used to execute a control function. In those cases, screen prompts are provided.

EXIT Displays the previously displayed menu. Cancels any changes made on the current screen if <ENTER> is not pressed.

MENU Displays the Main Menu screen. DELETE Voids an incorrect numerical entry if <ENTER> is not pressed.

2.4.2 LCD Graphics Display The SAM PCP Controller user interface is menu-driven. All menus and screens are displayed in the LCD graphics display.



The Main Menu screen (Figure 2-2) is the first screen that appears after the SAM PCP Controller is turned on and the initialization process is completed. This screen also appears any time after <MENU> is pressed on the operator interface keypad.

Figure 2-2. Main Menu Screen

Note: The PCP Status screen (Figure 8-1) automatically appears when a key is not pressed for eight minutes.

The menu map (Figure 2-3) shows all programming options available through the SAM PCP Controller operator interface.



Figure 2-3. SAM PCP Controller Menu Map



2.4.3 Menu Option Selection Two methods are available for selecting an option when a menu screen displays.

• Press the number key on the keypad that represents the desired option shown on the LCD display.

• Press <↑> and <↓> to highlight the desired option shown on the LCD display and then press <ENTER>.

2.4.4 Control Parameter Programming Control parameters are edited (programmed) on a data field basis. To program a parameter, press <↑> or <↓> to highlight the desired parameter field, press <EDIT>, and then do one of the following:

• When the parameter is a numerical entry, use the number keys to enter the desired value. When the data field displays the desired number, press <ENTER> to complete the programming step.

• When the data field requires a text entry, press <↑> and <↓> to scroll through the available options. After the data field displays the correct entry, press <ENTER> to complete the programming step.

After all parameters are correctly programmed on the screen, you can do either of the following to exit from the screen:

• Return to the Main Menu screen by pressing <MENU>.

• Return up one level in the menu tree by pressing <EXIT>. For example, if you are working with the Clock Calendar Configuration screen, pressing <EXIT> returns you to the RTU Level Menu screen.

2.5 Modbus Master Feature The SAM PCP Controller can read and store data from other Modbus RTUs on location. This data is stored in the SAM PCP Controller Modbus register map, and can be read on the local LCD and/or with host SCADA software. This feature allows a single on-location radio in the SAM PCP Controller to read data from and write data to any of up to 10 Modbus-protocol RTUs at the wellsite.



Slave RTUs must be compatible with the Modbus RTU protocol and have an RS-485 communication port available. An optional RS-485 expansion communication board must be added to the SAM PCP Controller, and a two-wire or four-wire RS-485 data cable network must be installed to connect the SAM PCP Controller master with each slave device.

The Modbus Master feature can be programmed to poll and collect data from a maximum of 10 slave devices. Up to 125 data registers can be read from each configured slave device. Data is polled automatically at a programmable interval.

The SAM PCP Controller can also be configured to write data to the slave devices. Desired values can be programmed for up to 25 registers in each slave device. The write function requires a manual command to execute.

The SAM PCP control algorithm uses the Modbus Master feature to read data from and write commands to compatible models of variable speed drives.


Section 3

Technical Specifications

This section lists the specifications for the SAM PCP Controller and the transducers available for use with it.


3.1 Enclosure........................................................................................ 3-1 3.2 Internal Component Layout ........................................................... 3-2 3.3 Environmental Operating Range.................................................... 3-3 3.4 120-VAC System ........................................................................... 3-3 3.5 Brownout/Blackout Protection....................................................... 3-3 3.6 Microprocessor and Memory ......................................................... 3-3 3.7 Serial Communications .................................................................. 3-4

3.1 Enclosure Enclosure Type:

NEMA4X fiberglass enclosure, hinged door with pad lockable hasp.

Height: 15.49 inch (39.34 cm) Width: 13.86 inch (35.20 cm) Depth: 8.34 inch (21.18 cm) Weight: Approximately 22 lbs. (10 kg), including controller, operator

interface, and data radio



3.2 Internal Component Layout The SAM PCP Controller is modular in design with surface-mount components on all circuit board assemblies. SAM PCP Controller units include the following “modules” or components:

• A motherboard, including the CPU and all memory devices plus eight discrete input/output points and two pulse inputs, is mounted on the backside of a hinged front panel. The motherboard includes two communication port connections.

• An expansion board with isolated power and signal lines plugs onto the motherboard. This module includes amplifiers and analog-to-digital conversion circuitry for analog inputs that may also be used as discrete inputs. Two analog outputs are included, one of which is used as a speed control signal to the VFD/VSD.

• A 320 × 240 liquid crystal display (LCD) is mounted on the backside of the hinged front panel underneath the motherboard. The LCD is connected to the motherboard by a 20-pin header. The LCD can be read from the front of the hinged panel through a panel cutout.

• A 20-key membrane keypad with an integral contrast adjust potentiometer is mounted on the front of the hinged front panel and connects to the motherboard with a ribbon cable.

• Back panel space is provided for mounting a radio or other data transmission device. Power supply terminals (12.0 VDC) and mounting hole patterns for popular radios are included. Optional signal cables connect the RJ12 radio port on the motherboard to the radio.

• An optional Turbine Meter board (P/N 060.0221) is available and must be used if production is to be measured using a direct connection to a turbine meter pick-up.

3.3 Environmental Operating Range Operating Temperature:

Circuit Boards: -40° to +140° F (-40° to +60° C) LCD: -4o to +140o F ( -20o to +60o C)

Humidity: 95% non-condensing

Section 3: Technical Specifications


3.4 120-VAC System Primary power to the switching power supply:

85 to 264 VAC, 50/60 Hz.

Power supply: 13.8 VDC output, rated for 42 Watts continuous.

3.5 Brownout/Blackout Protection A watchdog circuit initiates an orderly shutdown of the microprocessor and memory circuits if the DC input voltage level to the motherboard falls below approximately 10.5 VDC. Automatic lockout features protect memory read/write circuits when a power loss is detected. When proper voltage is re-applied, the SAM PCP Controller system automatically re-initializes.

3.6 Microprocessor and Memory • Coldfire XCF/MCF5307 microprocessor operated at 33 MHz.

• 512 Kbytes of battery-backed SRAM. The lithium batteries used will provide data retention for approximately one year without operating power.

• 4 megabytes of SDRAM for use as general operating memory.

• Standard SAM PCP Controller units include 4 megabytes of Flash ROM. Flash ROM can be expanded up to 32 megabytes.

3.7 Serial Communications The SAM PCP Controller motherboard has two RS-232 ports. Only one of the two ports can be active at a particular time. The default active driver is connected to an RJ12 connector designated as the radio port. The second driver is connected to a DB-9 connector designated as the laptop port. When a laptop computer is plugged in, and SAM PCP Controller interrogation software raises the DTR line, the second driver becomes the active driver and any activity on the RJ12 radio port is ignored.

The two serial ports on the motherboard are separately programmable for a baud rate of 300, 1200, 2400, 4800, 9600, 19200, 38400, or 115200 baud.



The RJ12 radio port has programmable time delays for key up and key down.

Communication protocol is Modbus RTU with a data format of 8 data bits, no parity, and two stop bits. Extended Lufkin Automation Modbus (ELAM) protocol is used for RTU addresses of 248 and above. ELAM supports up to 2,295 RTUs on the same communication channel, allows much larger data block sizes to be transmitted, and has a multiple instruction read/write capability. Ask your Lufkin Automation representative for more information about the ELAM protocol.


Section 4

Parts Lists

This section provides parts lists that have all the SAM PCP Controller components available. It also describes how you can order these parts from Lufkin Automation.


4.1 SAM PCP Controllers .................................................................... 4-1 4.2 Spare Parts...................................................................................... 4-1 4.3 SAM PCP Optional Hardware ....................................................... 4-2 4.4 SAM PCP Optional Hardware ....................................................... 4-2 4.5 Operator Interface Systems ............................................................ 4-2 4.6 Documentation ............................................................................... 4-2 4.7 How to Order Parts......................................................................... 4-3

4.1 SAM PCP Controllers Part Description Part No. SAM PCP Stand-alone Controller with LCD/Keypad and window 060.5400 SAM PCP Stand-alone Controller with LCD/Keypad and no window 060.5401

4.2 Spare Parts Part Description Part No. Mother Board 520.5400 LCD Assembly 530.5010BOperator Interface Keypad 184.5000AVSD Expansion Board 520.5003AFuse, 11/2 Amp, 250 Volt 181.0018 Mini Jumper 151.0122



Part Description Part No. Terminal Block, 2 Terminal 153.0094 Terminal Block, 3 Terminal 153.0317 Terminal Block, 4 Terminal 153.0318

4.3 SAM PCP Optional Hardware Part Description Part No. RS-485 Communication Expansion Board 520.5012 Turbine Meter Board 060.0221 75 VA capacity stepdown transformer 161.7513 Electro-mechanical octal-based 12 VDC relay with panel-mount socket and voltage transient suppression diode

530.4454

Panel-mount electro-mechanical relay with a 12 VDC coil and SPDT output contacts rated to switch up to 600 VAC

840.0050

24 V Option for PCP Stand alone controller 530.4457 Ground lug 151.0285 PD Fluid Meter — Floco 062.2500 2" Wedge Meter 062.2264 RPM Sensor Kit 530.4550

4.4 SAM PCP Optional Hardware Part Description Part No. Pad Mount for 10-30 HP 291.1030APad Mount for 40-50 HP 291.4050APad Mount for 60-100 HP 291.6000A

4.5 Operator Interface Systems Part Description Part No. SamScreen Terminal software 090.7050 Lufkin Automation Sam Flash Upgrade Utility software 090.7040 Pocket SAM 020.3955APocket SAM connection cable (required) 510.1002

4.6 Documentation Part Description Part No. SAM Well Manager™ — Progressing Cavity Pump User Manual 099.5028 SAM Well Manager™ — Rod Pump Control User Manual 099.5000

Section 4: Parts Lists


4.7 How to Order Parts Call your local Lufkin Automation representative or contact the factory in Houston, Texas directly at 281.495.1100.


Section 5

System Installation and Wiring

This section briefly describes key points you should follow when mounting and wiring the components making up the PCP control system. Following these guidelines for the SAM PCP Controller and its accompanying devices is crucial for obtaining optimum performance.


5.1 Overview of the System Installation .............................................. 5-2 5.2 PCP Controller System Installation................................................ 5-2

5.2.1 Installing the Mounting Post or Pedestal and Ground Rod ..................................................................................... 5-4

5.2.2 Installing the Stepdown Transformer................................. 5-5 5.2.3 Mounting the Controller..................................................... 5-6 5.2.4 Installing Flow Rate Meters and Process Variable

Transmitters........................................................................ 5-6 5.2.5 Installing the Rod RPM Hall-Effect Transducer................ 5-7

5.3 PCP Controller System Wiring ...................................................... 5-8 5.3.1 Wiring Specifications and Recommended Tools ............. 5-10 5.3.2 Grounding the System...................................................... 5-12 5.3.3 Wiring the Stepdown Transformer................................... 5-14 5.3.4 Wiring the Polished Rod Hall-Effect Transducer ............ 5-16 5.3.5 Wiring the Motor Control Relay ...................................... 5-17

5.4 Performing Power-Up Voltage Checks........................................ 5-18



5.1 Overview of the System Installation The topics covered in this section do not provide step-by-step procedures for mounting and wiring. Only key points that serve as installation guidelines are discussed.

The PCP control system should be installed by skilled personnel that have experience mounting and wiring PCP well systems. If you need help locating skilled personnel, contact your Lufkin Automation representative.

When selecting a site for installing the SAM PCP Controller, keep the following conditions in mind:

• Mount the SAM PCP Controller in a location near the VSD panel so that it is easily accessible to the operator.

• Keep the transducer signal wires and ground conductors as short as possible to reduce signal attenuation and extraneous noise that can affect the operation of the control system.

• Mount the VSD so that the power leads from VSD to the motor are no longer than 30 feet.

• If the SAM PCP Controller has a radio, keep in mind the radio signal path from the well to the base radio location. The Yagi antenna for the SAM PCP Controller should have an unobstructed line of sight with the base radio location.

• If possible, orient the SAM PCP Controller so that the LCD display is not subject to prolonged direct sunlight. In the northern hemisphere this would indicate that the window for LCD viewing should face to the north. This practice will optimize the performance of the LCD.

5.2 PCP Controller System Installation A typical PCP controller installation includes the following:

• SAM PCP Controller

• Variable speed drive

• Mounting post or stand

• Stepdown transformer

• Ground rod

Section 5: System Installation and Wiring


• Telemetry system (optional)

• Production measurement transducer

• Rod speed (RPM) transducer

Figure 5-1 shows an example of a typical SAM PCP Controller installation interfaced with a VSD.

Figure 5-1. Typical SAM PCP Controller Installation Interfaced with a VSD



Note: The system should only be installed by a qualified technician who has experience working with the motor control box and its high-voltage circuits.

5.2.1 Installing the Mounting Post or Pedestal and Ground Rod

DANGER: Be very careful of power cables buried around the motor control box. Striking them will cause serious injury or death.

Make sure that the mounting post structure can support at least 40 pounds if only the controller will be installed and 75 pounds if a radio and antenna system will be included.

Variable speed drives may weigh up to 450 pounds in the larger horsepower ratings. Make sure that the mounting post or pedestal for the VSD will support the weight.

Tools Required • Shovel or posthole digger

• Ground rod driver

• Level

• Lifting equipment, such as a crane or fork truck for VSD installation

Installation Procedure Follow the steps below to properly install the mounting post and ground rod.

1. Plan to place the mounting post for the SAM PCP Controller near the VSD so that it is convenient for electrical hookup.

2. Use a shovel or posthole digger to dig a hole at least two feet deep, with 30 inches being a preferred depth. An appropriately sized concrete pad may be required for the VSD pedestal. Consult the VSD manufacturer.

3. Place the mounting post in the hole and position it facing outward so that it is accessible to the monitor.

4. Pour concrete in the hole.



5. Use a level to verify that the mounting post is positioned upright.

6. Allow sufficient time for the concrete to cure.

7. Drive a ten-foot copper grounding rod into the earth within two feet of the VSD enclosure.

The mounting post and ground rod are now installed.

5.2.2 Installing the Stepdown Transformer The SAM PCP Controller requires primary input power in the range of 85 VAC to 264 VAC. Power available at most wellsites is higher voltage, and therefore, a stepdown transformer may be required. If a transformer is required, Lufkin Automation suggests you use one with a secondary voltage of 115 VAC.

Lufkin Automation offers a 75-VA capacity stepdown transformer (Part No. 161.7513). If your installation requires a stepdown transformer, and if you purchased a power transformer from another manufacturer, use that manufacturer’s mounting instructions. If you purchased the stepdown transformer from Lufkin Automation, follow the steps below.

Tools Required • Voltmeter

• Four #8 self-tapping screws

• Drill

Installation Procedure Follow the steps below to properly install the stepdown transformer.

1. Turn off all power at the main power supply.

2. Lock out the master disconnect so that no one can turn on the power without your knowledge.

3. Open the VSD panel.

4. Measure the incoming power legs with a voltmeter to verify that the power is off.

5. Select an appropriate empty space on the back panel of the VSD.



6. Use four #8 self-tapping screws to mount the stepdown transformer. Drill holes if necessary.

The stepdown transformer is now installed.

5.2.3 Mounting the Controller Mount the SAM PCP Controller on a mounting post. For information about installing a mounting post see “Installing the Mounting Post or Pedestal and Ground Rod” on page 5-4.

If the SAM PCP Controller is to be included in a radio data telemetry network, a “tilt-up” antenna mounting mast can be attached to the same mounting post. The antenna mast design should allow mast/antenna rotation to facilitate antenna alignment so that maximum signal strength reception is possible.

5.2.4 Installing Flow Rate Meters and Process Variable Transmitters

Select and plumb the flow-rate metering equipment and process variable transmitters according to the recommendations of the manufacturers.

A bypass capability for the flow meter is usually included so that it can be serviced without shutting down the well.

Figure 5-1 is a typical installation showing the location of process variable monitoring devices. Contact your Lufkin Automation representative if you need help selecting pressure transmitters, flow-rate metering devices, etc.

Note: The SAM PCP Controller is designed for use with low-power 1 to 5–VDC transmitters. Therefore, the transmitter power provided by the SAM PCP Controller is 12 VDC. If 4 to 20–MA transmitters are used, adding an optional 24-VDC power converter to the SAM PCP Controller may be necessary. Check the transmitter load limitations to determine the voltage required for the 250-Ohm termination resistor that the SAM PCP Controller provides. If the selected flow transducer is a turbine meter , an additional turbine meter board may be required (Part No. 520.5016). If the turbine meter assembly already includes a signal conditioning/pulse output module, the Lufkin Automation turbine meter board will probably not be required.



5.2.5 Installing the Rod RPM Hall-Effect Transducer The magnet assembly must be mounted on the polished rod and the Hall-Effect transducer probe must be mounted so that the magnet passes within about 1/4 inch of the probe tip when it passes the probe. This mounting method will work for most installations. The installation technician may need to be innovative at some locations. Contact your Lufkin Automation representative if you have problems. Extra “T” brackets are available if needed.

Tools Required • Socket set or wrench set

• Screwdriver

Parts Required • Transducer assembly with motor bracket and “T” bracket

• Magnet assembly

• Hose clamp

Installation Procedure Follow the steps below to properly install the Rod RPM Hall-Effect transducer.

1. Turn off the main power switch to the motor.

2. Use the proper lock out and tag procedures. Ensure that the rods have quit turning and that the potential for back spin is eliminated.

3. Attach the magnet (mounted in holder) to the polished rod with a stainless steel hose clamp. Cut off excess hose clamp after it is tightened. See Figure 5-2.



Figure 5-2. Motor Transducer Assembly Diagram Showing “T” Bracket Linkage

4. Install the RPM transducer bracket on a drive head housing bolt. Select a housing bolt that will easily allow the transducer to align with the magnet.

5. Assemble and adjust the “T” bracket linkage so that the magnet passes approximately 1/4 inch from the transducer.

6. Tighten all bracket connections.

The motor Rod RPM Hall-Effect transducer is now installed.

5.3 PCP Controller System Wiring This section provides information about terminal wiring, terminal strips, shielded cables, conduit use, and system wiring order. Since the PCP well system should be installed and wired by skilled personnel, step-by-step wiring procedures are not described here.

Figure 5-3 illustrates a typical field-wiring diagram that can assist you to wire the system correctly.



Figure 5-3. Typical Field Wiring Diagram



5.3.1 Wiring Specifications and Recommended Tools This subsection covers the recommended wiring specifications to follow for power wiring, system grounding, and shielding the SAM PCP Controller system. A list of the minimum tools recommended for effectively wiring the system is also provided.

Recommended Wiring Specifications Local codes and/or company standard procedures will dictate if and where conduit or EMT must be used to protect the cable and or personnel. The table below lists the recommended wire types that should be used.

Note: Special considerations should be taken for the type of wire used in hazardous or highly corrosive environments.

Signal Type Minimum Wire Size

Number of Conductors

Shield Comments

Power 16 AWG 2 No Separate from signal wires

Earth Ground #2 Stranded Green

1 No Keep short as possible

Hardwire Communications

22 AWG 2 No Twisted pair

Hardwire with Repeater

22 AWG 4 No Twisted pair

Modem-to-Radio Communications

18—20 AWG 4 Preferred —

Shielding The shield of each cable must be connected at only the controller end. The transducer end of the shield should be left unconnected; otherwise a ground loop could form that can cause erroneous signals to develop. All shield leads should be terminated in the SAM PCP Controller at the hinge mounting screw on the lower right-hand edge of the front panel on which the motherboard is mounted. This point is recognizable by the factory-installed green wire that connects the front panel to the system ground.



Recommended Tools To help make your wiring tasks easier, you should have, at the very minimum, the following tools:

• Wire cutters

• Wire strippers

• Small flat-bladed (slotted) screw driver

• Voltage/ohmmeter (VOM)

• Slip joint or water pump pliers

Wiring Terminals and Terminal Strips All field-wiring terminals are located on one of the SAM PCP Controller circuit boards mounted on the front panel assembly. See Figure 5-3.

The terminal strips on the SAM PCP Controller motherboard are a pressure-clip type for the Hall-Effect transducer, the production meter, and the VSD output wiring. To insert a wire, press in the orange tab with a small screwdriver (or your thumbnail), insert the wire, and then release the orange tab. Terminals work best with leads that are not “tinned” with solder. You will probably want to clip off the “tinned” ends of the Hall-Effect cable and strip back the insulation to expose the stranded wire. Terminal blocks are a plug-in type so that they can be removed for wire insertion and then plugged back in. Observe the “half moon” design that keys the terminal block for proper insertion.

Terminal strips for transmitter inputs and the motor drive output are also a pressure-clip type. Strip the insulation on the wire to expose about 1/4 inch of conductor. Press the orange tab with a small screwdriver, insert the wire, and then release the orange tab. Pull slightly on the wire lead to ensure that the wire is firmly gripped by the spring clip in the terminal block.

Shielded Cables Shielded cables must be used for the signal leads from the pressure and temperature transmitters. Shields should be terminated only at the hinge mounting screw on the lower right-hand edge of the front panel on which the motherboard is mounted. This point is recognizable by the factory-installed green wire that connects the front panel to the system ground.



Conduit Local codes and customer standards dictate whether conduit is used for cable and wire protection. Conduit is not absolutely necessary for preventing serious electrical shock because system power to transmitters is typically 12 VDC maximum. However, conduit may be useful for protecting wiring cable from damage caused by rodents gnawing on the insulation.

System Wiring When wiring the system, the components should be wired in the order recommended below.

1. Wire the end devices and the process variables to their respective terminals on the SAM PCP Controller.

2. Wire signal leads for control and monitoring to their respective terminals in the VSD and in the SAM PCP Controller. Consult your VSD supplier for information regarding input and out put wiring to the VSD.

3. Wire the SAM PCP Controller primary power (85 VAC to 264 VAC) source leads to terminals L1 (hot) and L2 (neutral) on the SAM PCP Controller back panel. Do not make a connection to the GND terminal at this time.

4. Wire power leads to the VSD and from the VSD to the motor. Lufkin Automation strongly suggests that these high-voltage leads be run in conduit to protect personnel from possible shock.

System Configuration Before you begin configuring and programming the SAM PCP Controller, make sure the controller hardware is configured properly for your system. For information about hardware configuration, see section 6, “Hardware Configuration.”

5.3.2 Grounding the System DANGER: Be very careful of power cables that are buried around the

wellhead area and the VSD cabinet. Striking them could cause serious injury or death.



Proper earth grounding of the SAM PCP Controller is critical to minimize transient voltage that can damage the control system electronics. Refer to Figure 5-1 for a visual of the grounding described below. Ask your Lufkin Automation representative for a copy of Technical Bulletin TB-07-1019, Recommended Grounding Practices for SAM for additional information.

For the PCP application, Lufkin Automation recommends that you use the wellhead as the system ground electrode. The ground bus in the VSD should be connected to the wellhead, and all other parts of the system should in turn be connected to the VSD ground bus. If your VSD does not have a ground bus, obtain one and install it according to manufacturer’s instructions.

The VSD ground bus should be connected to the wellhead with an uninterrupted length of stranded #2 AWG green ground wire. This wire should be terminated at the VSD ground bus with an approved irreversible crimp connector and to the wellhead with an approved pipe ground clamp rated for #2 wire. The connection to the wellhead should be cleaned down to bare metal before you install the clamp, and it must be sufficiently coated afterward to prevent any corrosion. Note from Figure 5-1 that the ground lead from the wellhead to the VSD ground bus should be connected “in line” to the ground rod adjacent to the VSD.

The ground bus in the VSD should be connected to the ground post on the lower left corner of the SAM PCP Controller with an uninterrupted length of stranded #2 AWG green ground wire. Terminations at each end should use approved irreversible crimp connectors.

The ground bus in the VSD should be connected to the motor chassis with an uninterrupted length of stranded #2 AWG green ground wire. Terminations at each end should use approved irreversible crimp connectors.

The primary power service ground lead should be terminated on the VSD ground bus.

All signal cable shields should be terminated at the ground lug provided on SAM PCP Controller’s front door hinge. This bonds the shield directly to the ground conductor.

If the above procedure is followed, it will no longer be necessary to route a green wire to the “GND” terminal of TB-1 on the SAM PCP Controller back panel. The connection to earth ground will have previously been established and any additional paths to ground could create ground loops.

The system is now grounded.



5.3.3 Wiring the Stepdown Transformer The SAM PCP Controller requires primary power in the range of 85 to 264 VAC. In most cases, a stepdown transformer must be installed in the starter panel to convert 460 VAC to 115 VAC.

Two subsections are devoted to wiring the stepdown transformer to the motor starter panel and the SAM PCP Controller. Other components, such as the motor control relay, have sections that explain how they are wired to the motor control circuit.

Refer to the suggested control panel wiring diagram in Figure 5-4 when wiring the stepdown transformer. Many types of motor starter panels are used with varied control wiring methods and control voltages. The suggested method in Figure 5-4 will obviously not work in every situation, but the general idea should provide a qualified electrician with enough information to figure out the best way to wire a particular control panel.

Figure 5-4. Power and Control Relay Wiring Diagram

Wiring the Stepdown Transformer to the Motor Starter Panel Follow the steps below to wire the stepdown transformer to the motor starter panel.



1. Install the stepdown transformer. For instruction to install it, see “Installing the Stepdown Transformer” on page 5-5.

2. Determine the input side of the transformer by looking at the markings on the ends of the transformer.

3. MAKE SURE THE POWER IS OFF TO THE MOTOR STARTER PANEL. Use a voltmeter to check that no power is coming to the motor starter panel.

4. Cut two lengths of 18-to-12 gauge single-conductor wire that will reach from the transformer to the 460-VAC power source.

Note: A 460 VAC power source is assumed. Other jumper arrangements on the transformer are available. See the diagram on the transformer.

5. Strip off approximately 1/4 inch of the insulation from the end of the wires and crimp a spade lug on one end of the wire.

6. Loosen a screw on the input side of the transformer and insert the wire under it. Tighten the screw.

7. Route the single conductor wires to the 460-VAC power source and strip off approximately one inch of insulation from the end of the wire.

8. Connect the two wires to the incoming 460-VAC power source at L1 and L2.

Note: Some local codes require you to install fuses. The SAM PCP Controller has fusing for internal protection, but the 115-VAC power lines and the stepdown transformer are not protected from a short-circuit condition. Therefore, Lufkin Automation recommends that you install fuses in the VSD cabinet on the primary/high voltage side of the transformer.

The stepdown transformer is now wired to the motor starter panel.

Wiring the Stepdown Transformer to the SAM PCP Controller Connect the SAM PCP Controller to the 115-VAC stepdown transformer located in the motor starter panel. Lufkin Automation recommends that you use, as a minimum, 16 gauge wire.

The wires should be connected to the AC power terminals on the SAM PCP Controller as follows (see Figure 5-5):



Figure 5-5. Stepdown Transformer to SAM PCP Controller Wiring Diagram

• 115 VAC to terminal 1 — “LIN”.

• 115 VAC Neutral to terminal 3 — “NEU”

The stepdown transformer is now wired to the SAM PCP Controller.

5.3.4 Wiring the Polished Rod Hall-Effect Transducer The polished rod Hall-Effect transducer cable is a molded assembly that is pre-wired at the sensor end. The only field wiring necessary is to connect the leads at the SAM PCP Controller. Use the following procedures to route and wire the cable from the Hall-Effect transducer to the SAM PCP Controller. Consult the wiring diagram in Figure 5-6.

Figure 5-6. Hall-Effect Transducer to SAM PCP Controller Wiring Diagram

1. Strip off the outer insulation and remove the stress relief material so that only the insulated wire is left.

2. Strip back the insulation about 1/4 inch from the end of the red, white, and green wires on each cable.



3. Insert the wires in the appropriate terminal in TB4. Consult Figure 5-6.

4. Terminate the cable shield lead on the hinge mounting screw on the lower right hand edge of the front panel on which the motherboard is mounted. This point is recognizable by the factory-installed green wire that connects the front panel to the system ground.

The polished rod Hall-Effect transducer is now wired.

5.3.5 Wiring the Motor Control Relay The motor control relay is energized when the SAM PCP Controller issues a Start command to the VSD and is de-energized when the SAM PCP decides to Stop the pump. The relay is labeled “Motor Control Relay” in Figure 5-4.

Follow the steps below to wire the motor control relay.

1. Connect one side of the motor control relay coil to terminal block TB5 and terminal 3 on the SAM PCP Controller logic board. The other side of the relay coil connects to the +12-DC terminal on the back panel of the SAM PCP Controller. The motor control relay has a set of normally open contacts that are wired to the Run Enable input of the VSD. The motor control relay provides a contact closure that enables the VSD to run the motor.

2. The SAM PCP Controller should be wired as follows for the electro-mechanical relay option (see Figure 5-7):

Figure 5-7. Electro-Mechanical Motor Control Relay Wiring to SAM PCP Controller

• Connect terminal 2 on the octal socket to terminal strip TB5, terminal 3 on the SAM PCP Controller motherboard.



• Connect terminal 7 of the octal socket to one of the “+12V” terminals provided on the SAM PCP Controller back panel located in the upper left.

Note: Terminal numbers on the relay will vary depending on the type of relay used. Use the generic “coil” and “normally open” designations if terminal numbers do not agree with Figure 5-7.

3. Wire the control relay output contacts to the run enable input terminals on the VSD.

The motor control relay is now wired.

5.4 Performing Power-Up Voltage Checks

WARNING: Power-up voltage checks should only be performed by a qualified technician who has experience working with the motor control box and its high-voltage circuits.

Use this procedure to make sure that the SAM PCP Controller is receiving proper voltage from the motor control box and that the proper voltage is provided to the SAM PCP Controller.

Tools Required • AC/DC voltmeter

SAM PCP Controller Follow the steps below to make sure that the proper voltage is connected to the SAM PCP Controller.

1. Make sure the SAM PCP Controller power switch is off, put the HOA switch in the Off position, and then turn on the main power switch to the motor control panel.

2. Use an AC voltmeter to check for 110-120 VAC between the terminals labeled LIN and NEU on terminal strip on the lower right corner of the SAM PCP Controller panel.

• If the voltage is correct, go to step 3.



• If the voltage is not correct, check the wiring to the stepdown transformer and the fuses associated with the transformer.

3. Leave the H-O-A switch switched off and the main power switch to the motor switched on, and the turn on the SAM PCP Controller. The power on/off switch is located on the front cover.

4. Turn the H-O-A switch to the position wired for control by the SAM PCP Controller. The unit should start.

5. If a Hall-Effect transducer is used to measure rod speed, observe the RPM light on the left edge of the SAM PCP Controller motherboard. The RPM light should be blinking on and off rapidly as the magnet on the polished rod passes the Hall-Effect sensor.

Wiring is now complete for the PCP control system and you are ready to program the SAM PCP Controller.

VSD Consult manufacturers user manual for recommended check procedures for the VSD.


Section 6

Hardware Configuration

You must ensure that the SAM PCP Controller hardware is configured properly in order to obtain accurate input data and have pump control.


6.1 Overview of the Hardware Configuration...................................... 6-1 6.2 Battery Disconnect Jumper Pins .................................................... 6-2 6.3 4–20 MA Transmitters ................................................................... 6-3 6.4 Radio Communications Port .......................................................... 6-5 6.5 RS-485 Communication Expansion Board .................................... 6-6 6.6 Turbine Meter Board.................................................................... 6-10 6.7 VSD Configuration ...................................................................... 6-11

6.1 Overview of the Hardware Configuration

The following items pertaining to hardware configuration must be checked to ensure that the SAM PCP Controller is properly configured for the meter run inputs and valve control actuation:

• Battery disconnect jumper is on both pins

• 4-20 MA transmitters are configured



6.2 Battery Disconnect Jumper Pins Many of the parameters programmed for PCP control are stored in RAM on the SAM PCP Controller microprocessor circuit board (motherboard). This memory is supported during power outages by a lithium battery located near the top of the motherboard. Battery disconnect jumper pins are located next to the battery. A jumper is installed at the factory to connect the two pins to place the battery in service. It is recommended that you ensure that the shorting jumper is on both pins so that the battery is included in the circuit. Failure to include the battery will cause the SAM PCP Controller to loose programming when the power switch is turned off.

Figure 6-1. Mother Board Showing Lithium Battery, Battery Jumper Pins, and Radio Communication Port

To check the jumper configuration, locate the motherboard with the SAM VSD expansion board assembly on the back of the hinged front panel. Look downward from the top between the expansion board and the motherboard. The green battery should be easy to notice. The battery jumper is just above the end of the battery nearest the door hinge.

Lithium battery

Battery jumper pins

Radio Comm Port

Section 6: Hardware Configuration


If the jumper is not connecting the two pins, you need to temporarily unplug the expansion board to move the jumper so that the two pins are connected.

6.3 4–20 MA Transmitters The SAM VSD expansion board (Part No. 520.5003A) used with the SAM PCP Controller is shipped with all eight inputs configured as voltage inputs. Termination resistor jumpers are provided and mounted on only one of the two pins. To change the inputs to be used for current input, move the jumpers to the right to connect the two pins and place the 250-Ohm termination resistor in the input circuit. See Figure 6-2 to locate the termination resistor jumpers.

Figure 6-2. I/O Expansion Board Showing Termination Resistor Jumpers, Quick Connect Terminal for Earth Ground, and Ground Wire

A 16-pin header designated as JP1 is located on the upper left edge of the installed expansion board to the right of the terminal block for connecting the analog inputs.

The jumper pins are not numbered. To identify the proper jumper for a given input, read the resistor designation located to the left of the JP1 header and use the table below to reference it.

Quick connect terminal

Termination resistor jumpers



Analog Input Termination Resistor AI 1 R2 AI 2 R3 AI 3 R4 AI 4 R5 AI 5 R6 AI 6 R7 AI 7 R8 AI 8 R9

The I/O expansion board includes a 1/4-inch quick connect terminal for an earth ground (chassis ground). A green ground wire is included with this board, and it is imperative that the ground wire be connected to the hinge screw on the front panel. See Figure 6-2.

6.4 Radio Communications Port The communications port on the motherboard (see Figure 6-1 on page 6-2) is most commonly connected with MDS Transnet or Freewave board-level radios. The port connector is labeled RJ 12. The signals are RS-232 and support Modbus RTU slave protocol.

Below is the pin-out configuration for RJ 12. When the motherboard is mounted vertically in the SAM PCP Controller, Pin 1 is located at the bottom of the connector.

Pin Out Function 1 CD (input — not used) 2 TXD (output) 3 RXD (input) 4 Ground 5 RTS (output) 6 CTS (input — not used)

The wiring diagram in Figure 6-3 shows how the radio should be wired to the radio communication port (RJ 12) on the motherboard.



Figure 6-3. PCP Radio Comm Port Wiring Diagram

Radio Transmission Cable If you need to construct a radio transmission cable to connect an MDS radio to the SAM PCP Controller, see Figure 6-4 for the proper wire-to-plug configuration.

Figure 6-4. MDS Radio Transmission Cable Configuration

Baud Rate The radio communications port can support data communication rates from 300 to 115,200 baud. The software controls baud rate on a slave-device basis. For information about configuring baud rate, see “Communication Port Configuration” in section 8, “SAM Controller Programming.”



6.5 RS-485 Communication Expansion Board

The optional RS-485 communication expansion board (Part No. 520.5012) (see Figure 6-5) is designed to piggyback mount on either of the I/O expansion boards (Part Nos. 520.5002 and 520.5003A). When installing the RS-485 board on the I/O expansion board, make sure the connectors are configured as follows:

• JP1 on RS-485 expansion board to JP2 on I/O expansion board

• JP2 on RS-485 expansion board to JP3 on I/O expansion board

The field connection terminal block for the RS-485 communication expansion board should be placed to the left edge and over the terminal block of the I/O expansion board.

Figure 6-5. RS-485 Communication Expansion Board

The RS-485 communication expansion board provides an interface for the SAM PCP Controller to the Modbus Master data network.

Terminal Block Connector The RS-485 expansion board has a five-position terminal block connector used for the data network wiring. The board is properly installed when the terminal block is on the left edge of the SAM PCP Controller front panel, with the panel open.

Terminal block connector

Dip switches



The connector is labeled as follows from top to bottom.

Position Signal Description 1 R+ Receiver + 2 R– Receiver – 3 T+ Transmitter + 4 T– Transmitter – 5 SH Cable Shield

Baud Rate The RS-485 expansion board can support data communication rates from 300 to 115,200 baud. The software controls baud rate on a slave-device basis. For information about configuring baud rate, see “Communication Port Configuration” in section 8, “SAM Controller Programming.”

Biasing Resistors The RS-485 expansion board comes standard with 1K biasing resistors. To change the value of biasing resistors, remove R1 and R4 and replace with new values. See Figure 6-5 for resistor locations.

Termination Resistors 120-Ohm termination resistors are pre-installed at locations R3 and R6. These resistors can be activated in the circuit by setting dipswitches 3 and 4 to the ON position. See Figure 6-5 for resistor locations.

In two-wire mode, only one terminating resistor needs to be active (that is, only set dipswitch 3 or 4 to the ON position).

Terminating resistors should only be used on the ends of the RS-485 data line.

Constant Receiver Enable/Disable The RS-485 expansion board comes standard with the receiver set up for constant receiver mode. It can be set up for receiver disabled during transmission by setting dipswitch 5 to the ON position. See Figure 6-5 for dipswitch locations.

• Constant receive mode should be used for four-wire mode.

• Receiver disabled during transmission should be used for two-wire mode.



For information about how to enable and disable receiver mode, see “Communication Port Configuration” in section 8, “SAM Controller Programming.”

Data Line Polarity The polarity of the two RS-485 lines must be correct. The “+” lines should be connected together, and the “–” lines should be connected together between devices on the network. If a device uses “A” and “B” designation, then you must determine which terminal “A” or “B” is the “+” terminal. When no data is being transmitted, the “–” terminal should be negative with respect to the “+” terminal.

Dipswitch Configuration Dipswitch assignments for two-wire and four-wire mode are provided in the tables below. See Figure 6-5 for dipswitch locations on the RS-435 expansion board.

Dipswitch Assignments OFF Four-Wire Mode

Dipswitch 1 ON Two-Wire Mode — Connects RX+ and TX+ OFF Four-Wire Mode

Dipswitch 2 ON Two-Wire Mode — Connects RX- and TX- OFF No Termination for RX

Dipswitch 3 ON 120 Ohm Termination for RX OFF No Termination for TX

Dipswitch 4 ON 120 Ohm Termination for TX

OFF Receiver Always Enabled (Four-Wire Mode) Dipswitch 5

ON Receiver Disabled During Transmission (Two-Wire Mode) Dipswitch 6 NA Not Used

Two-Wire Mode Configurations

Dipswitch Settings

Mode State 1 2 3 4 5 6

ON Constant Receiver Enabled No Terminating Resistors OFF

ON Receiver Disabled on Transmit No Terminating Resistors OFF

ON Constant Receiver Enabled Terminating Resistors Connected OFF

ON Receiver Disabled on Transmit Terminating Resistors Connected OFF



Four-Wire Mode Configurations

Dipswitch Settings

Mode State 1 2 3 4 5 6

ON Constant Receiver Enabled No Terminating Resistors OFF

ON Receiver Disabled on Transmit No Terminating Resistors OFF

ON Constant Receiver Enabled Terminating Resistors Connected OFF

ON Receiver Disabled on Transmit Terminating Resistors Connected OFF

Note: The setting assigned for dipswitch 6 has no effect on performance.

6.6 Turbine Meter Board The optional turbine meter board (Part No. 060.0221) serves as a conditioning board for the turbine meter. See Figure 6-6.

Figure 6-6. Turbine Meter Board and Ground Wire

Quick connect terminal



The terminal connections are shown in the table below.

Connector Function OUT1 Pulse Output #1 (open collector) GND Signal Ground OUT2 Pulse Output #2 (open collector) GND Signal Ground +12V 10 TO 15 VDC Input Power GND Signal Ground IN1 Turbine Meter #1 Input (millivolt AC signal) GND Signal Ground CHGND Chassis Ground IN2 Turbine Meter #2 Input (millivolt AC signal) GND Signal Ground CHGND Chassis Ground

The turbine meter board includes a 1/4-inch quick connect terminal for an earth ground (chassis ground). A green ground wire is included with this board, and it is imperative that the ground wire be connected to the hinge screw on the front panel.

6.7 VSD Configuration VSD configuration requirements depend on the brand of VSD used. Many VSDs on the market can be configured to properly interface with the SAM PCP Controller. The information below is therefore general in nature. Refer to the VSD manufacturer’s instructions for specific details about configuring the drive.”

Note: The VSD must be capable of using an external voltage signal for speed control.

Program the reference speed input in the drive to analog DC voltage. 0-10 VDC is preferred. 0-5 VDC is also acceptable, but it requires the 0-5–VDC voltage module to be installed in the SAM PCP Controller VSD expansion board (Part No. 520.5003A). If the only option in the drive is a 4-20 MA input, an optional analog expansion board #520.5004 is available that provides a 4-20 MA output.



If the drive has an H-O-A switch, the Hand side should be wired so that the drive’s keypad operates the well (start/stop control and speed reference setting) when the switch is in the Hand position. The Auto position side then looks to the drive’s external control connections for run/stop contacts and speed control input, which is connected to the SAM PCP Controller.

Make note of the analog speed reference scaling in the drive (usually in Hz). For example, if 0-10 VDC is used, the minimum frequency is 0 Hz and the maximum frequency is 90 Hz. The drive uses these parameters for scaling of the analog reference. A 10-VDC reference from the SAM PCP Controller tells the drive to operate at 90 Hz.

Drives typically have plenty of parameters that determine how the system works. Some consideration should be given to the following features and how they affect the operation of the progressing cavity pump:

• Ramp to speed on startup

• Flying catch start if the progressing cavity pump is already in motion when a start command is given

• Coasting to stop/or ramp to stop

• Verify that the correct motor parameters are entered

• Auto restart on a drive fault; retry attempts are allowed

Refer to the drive’s manufacturer for proper setup and commissioning of the drive for warranty purposes.

Issue Date: 1/18007 Revision 1.00 7-1

Section 7

PCP Parameter Programming

Parameter values that define variable speed drive control action and production must be properly programmed before you can obtain accurate and reliable PCP control and historical data.

Note: Only information about programming PCP configuration is described in this section. For information about programming configuration parameters that control operations of the SAM PCP Controller, see section 8, “SAM Parameter Programming.”


7.1 Overview of PCP Parameter Programming.................................... 7-1 7.2 Configuring Control Parameters .................................................... 7-3 7.3 Configuring Parameter Violations ............................................... 7-14 7.4 Configuring End Devices ............................................................. 7-20 7.5 Configuring Production and Motor Information.......................... 7-23 7.6 Configuring Special Features ....................................................... 7-26

7.1 Overview of PCP Parameter Programming

Several PCP configuration screens are used to program general parameters that control PCP operations at the wellsite.

• Minimum and maximum operation speeds allowed

• Speed and production violations

• End device parameter configurations


7-2 Revision 1.00 Issue Date: 1/18007

SAM 3/1

• Production input and speed output

• Special features

General PCP parameter programming must be completed regardless of the type of end devices used in the system or else effective well control, well monitoring, and well data accumulation is not possible.

The actual PCP configuration values are available under the PCP Configuration Menu screen (Figure 7-1). To display this screen, first select 3. CONFIGURATION from the Main Menu screen and then select 1. PCP CONFIGURATION from the Configuration Menu screen.

Figure 7-1. PCP Configuration Menu Screen

Note: A user password is required to access this menu screen if password protection is enabled. For information about passwords, see “Changing Passwords” in section 8 “SAM Controller Programming.”

All PCP programming parameter values are entered through an interface using the 20-key operator interface keypad mounted in the SAM PCP Controller enclosure. For information about this operator interface and how to use it, see “Controller Operator Interface” in section 2, “Description of the SAM PCP Controller System.”

Section 7: PCP Parameter Programming


SAM 3/1/1

Operator Interface Keypad Programming All SAM PCP Controller programming parameter values are entered through the 20-key operator interface keypad mounted in the SAM PCP Controller enclosure. For information about this operator interface and how to use it, see “Controller Operator Interface” in section 2, “Description of the SAM PCP Controller System.”

RAM Backup Protection Many of the parameters programmed for PCP control are stored in RAM on the SAM PCP Controller circuit board. This memory is supported during power outages by a lithium battery located near the top of this circuit board. Failure to include the battery will cause the SAM PCP Controller to loose programming when the power switch is turned off.

Before programming the SAM PCP Controller, ensure that the shorting jumper is on both pins so that the battery is included in the circuit. Battery disconnect jumper pins are located next to the battery. If the battery is not included, the SAM PCP Controller will loose programming when the power switch is turned off. The battery jumper configuration can be checked by looking down between the expansion board and the main board from the top. If the jumper is not on both pins, the expansion board must be temporarily removed to properly place the jumper. For more information about the battery, see “Battery Disconnect Jumper Pins” in section 6, “Hardware Configuration.”

7.2 Configuring Control Parameters PCP control parameters control operations of the progressing cavity pump, such as

• Power on and off delays

• Minimum and maximum pump operating speed

• Settling and sampling periods

• Maximum speed increases and decreases



These control parameters are configured through two Control Parameter CFG screens. To display these screens, select 1. CONTROL PARAMETERS CFG from the PCP Configuration Menu screen. You can toggle between screens by pressing <NEXT>.

Each screen is described separately below.

Screen 1 of 2 Figure 7-2 is an example of the first Control Parameter CFG screen.

Figure 7-2. Control Parameters CFG Screen (1 of 2)

Data Field Descriptions Information about each data field for this screen is provided below.

Power On Delay

Specify the time, in seconds, that the SAM PCP Controller must wait before issuing a command to start the PCP pump. When power is applied to the SAM PCP Controller, the initial control state is Downtime Power On Delay. The SAM PCP Controller delays starting the pumping unit for the number of seconds specified. This feature is included to allow an operator to stagger the startup of multiple pumping units on a transformer bank or distribution line after a power outage. The default value is 10 seconds.



This feature is only available under the following conditions:

• Automatic restart when the Peak Energy Management feature is enabled

• Restart after a power shutdown or power outage

Start Alert Delay

Specify the time, in seconds, that the SAM PCP Controller must wait before issuing a command to start the pump. This feature is either a stand-alone function or it is embedded in the Power On Delay process.

For example, when Start Alert is embedded in the Power On Delay process, a Power On Delay equaling 30 seconds and Start Delay equaling 10 seconds will cause the Well State to switch to a Start Alert state of 20 seconds for the Power On Delay.

Start Alert is executed whenever the SAM PCP Controller attempts to restart the motor due to any of the following conditions:

• Automatic restart due to Peak Energy Management feature

• Restart after a power shutdown or outage

• After Downtime period

• Operator Start command

• Reset Malfunctions command

Number of Start Up Ramp

Specify a value to be used to calculate the speed ramp rate and the number of ramp up steps during the starting period.

Start Up Period

Specify the time period, in seconds, that the SAM PCP Controller is allowed to ramp the speed from the Minimum Operating Speed to the target Start Up Speed in an interval defined in the Number of Start Up Ramp field during the Starting state.

For example, when the Start Up Period equals 120 seconds, The Number of Start Up Ramp equals 5, Start Up Speed equals 250 RPM, and Minimum Operating Speed equals 50, the speed will ramp at the rate of 40 RPM every 24 seconds.



Start Up Speed

Specify the target speed that the pump is to operate at by the end of the Start Up Period. This is only used by the Production Control operation mode.

For other operation modes, the SAM PCP Controller uses the following as the startup speed:

Operation Mode Start Up Speed Production Control Pre-programmed startup speed. Speed Control Speed Control Run Speed Host Host ON/OFF: ON Speed or Host HI/LO: HI Speed Timed Timed ON/OFF: ON Speed or Timed HI/LO: HI Speed Monitor N/A

Power Off Delay

Specify the delay time, in seconds, before the SAM PCP Controller turns off the pump. This period allows the SAM PCP Controller to decrease the speed to Minimum Operating Speed in an interval defined by the Number of Power Off Ramp.

For example, when Power Off Delay equals 30 seconds, Number of Power Off Ramp equals 3, Current Speed equals 400 RPM, and Minimum Operating Speed equals 100, the speed will decrease by the rate of 100 RPM every 10 seconds.

Number of Power Off Ramp

Specify the value used to calculate the speed decrease rate during the Power Off Delay period.

Stopping Period

Specify the time period, in seconds, set for the SAM PCP Controller to attempt stopping the pump. During this period, the SAM PCP Controller continuously monitors the Speed Monitor Input when the rod is still rotating. When the stopping period expires and the rod is still rotating, the SAM PCP Controller declares Unable to Stop state. Otherwise, it declares a Stopped state and proceeds to the corresponding Downtime or Shutdown state.



Max Operating Rod Speed

Specify the maximum polished rod speed, in RPM, that the SAM PCP Controller will allow the pump to operate. If the controller algorithm, operator, or host tries to operate the drive above the maximum operating speed, the SAM PCP Controller will automatically clip the speed to the configured Maximum Operating Speed.

Min Operating Rod Speed

Specify the minimum polished rod speed, in RPM, that the SAM PCP Controller will allow the pump to operate. If the controller algorithm, operator, or host tries to operate the drive below the minimum operating speed, the SAM PCP Controller will automatically clip the speed to the configured Minimum Operating Speed.

Rod Speed at Full Scale

Specify the maximum polished rod RPM used for scaling the speed sent to the drive. This rod speed is automatically calculated when the Prime Mover type is Electric Motor, and editable when the Prime Mover type is Hydraulic. For information about programming for a prime mover, see “Configuring Production and Motor Information” on page 7-23.

If Prime Mover type is programmed as Hydraulic, a CALC option is available to the right that can display a screen to help you calculate a rod speed at full scale value (Figure 7-3). To display the screen, press <→> to highlight CALC, and then press <ENTER>.

Figure 7-3. Calculate Approx Rod Speed at Full Scale Screen



The Enter Hydraulic Pump RPM field highlights. Use the numerical keys to enter the pump RPM, and then press <ENTER>. The new calculated value displays in the Calc. Rod Speed at Full Scale field.

• If you want to keep the new calculated value, press <↓> to highlight STORE AND EXIT and press <ENTER>.

• If you want to keep the previous calculated value, press <↓> twice to highlight DISCARD AND EXIT and then press <ENTER>.

After you make a selection, you are returned to the Control Parameters CFG screen with the value displayed in the Rod Speed at Full Scale field.

Rod Speed at Min Scale

Specify the minimum polished rod RPM used for scaling the speed sent to the drive.

Screen 2 of 2 To display the second screen, press <NEXT>. Figure 7-4 is an example.

Figure 7-4. Control Parameters CFG Screen (2 of 2)

You can return to the first Control Parameters CFG screen (Figure 7-2) at any time by pressing <NEXT>.



Data Field Descriptions Information about each data field for this screen is provided below.

Down Time Period

Specify the time period, in hours and minutes, that the SAM PCP Controller will operate under a Downtime or Violation Run Minimum condition.

Operation Mode

Specify the mode of operation used by the SAM PCP Controller. The following choices are available:

• PROD CTRL — Production Control mode allows the SAM PCP Controller to operate under Lufkin Automation’s patented production control algorithm. The algorithm searches for the most efficient operating speed. Enabled violations are monitored and checked accordingly.

• SPEED CTRL — Speed Control mode allows you to specify a pre-defined speed. The speed can be changed at any time at an update rate of once a minute. Enabled violations, such as torque limiting, are still in effect in this operating mode.

• TIMED — Timed mode allows the SAM PCP Controller to automatically operate the motor in an ON/OFF or HI/LO speed cycle for specified time periods.

For TIMED ON/OFF, the SAM PCP Controller sends a command for the motor to start and remain operating during the Timed ON period, and it sends a command to the motor to shut down and remain off during the Timed OFF period.

For TIMED HI/LO, the SAM PCP Controller sends a command for the motor to operate at a high speed and continue operating at this speed during the entire TIMED HI time period, and then it sends a command for the motor to operate and remain operating at a slower speed during the entire TIMED LO time period. High speed is specified in the Max Operating Speed field, and low speed is specified in the Min Operating Speed field.

No violations are checked during Timed mode.



• HOST — Host mode allows you to control the motor operation either by manually switching the motor to HOST ON/OFF or by running the motor at HOST HI/LO speed. For HOST ON/OFF, the motor operates when the switch is set to ON and it turns off when the switch is set to OFF. For HOST HI/LO, the motor operates at high speed when the switch is set to HI, and it operates at a slower speed when the switch is set to LO. No violations are checked during this mode.

• MONITOR — Monitor mode allows the SAM PCP Controller to operate as a PCP data gathering unit only. The SAM PCP Controller will not start or stop the motor, send speed commands to the drive, or check for any violations.

Settling Period

Specify the settling period, in minutes, to be used when the PROD CTRL operating mode is selected. During this period, the SAM PCP Controller allows the system to stabilize before gathering data for sampling. All enabled violations are checked except for Low Production and High Production, which are checked at the end of the sampling period.

Sampling Period

Specify the sampling period, in minutes, to be used when the PROD CTRL operating mode is selected. During this period, the SAM PCP Controller gathers the data and averages it at the end of the sampling period. The average production value is then used to determine whether to increase or decrease the speed before the next settling/sampling cycle.

Max Speed Increase

Specify the maximum speed increase, in RPM, allowed every settling/sampling cycle. If the production control algorithm (PROD CTRL) suggests a speed increase greater than the Max Speed Increase value, the Max Speed Increase value overrides the speed increase suggested by the production control algorithm.

Max Speed Decrease

Specify the maximum speed decrease, in RPM, allowed every settling/sampling cycle. If the production control algorithm suggests a speed decrease greater than the Max Speed Decrease value, the Max Speed Decrease value overrides the speed decrease suggested by the production control algorithm.



Percent Min Speed Change

Specify the minimum speed change as a percent of the current control speed. This speed is used for special conditions when the SAM PCP Controller is required to challenge the process by either increasing or decreasing the speed. Some of the conditions and the responses the SAM PCP Controller will execute are provided below.

• When the speed decreases (due to decrease in production) for the specified consecutive speed decreases, the algorithm will challenge the process by increasing the speed by the Percent Min Speed Change value.

• When the SAM PCP Controller is running at maximum operating speed and no change in production occurs, the algorithm will decrease speed by the Percent Min Speed Change value.

• When the SAM PCP Controller is running at minimum operating speed and the Low and High Production violations are inactive, the algorithm will increase speed by the Percent Min Speed Change value.

• When no data exists for previous sampling history during the initial run of the algorithm, the algorithm will increase speed by the Percent Min Speed Change value.

Hard-Set Minimum Speed Change

Specify the minimum RPM that the rod speed will be changed, regardless of the minimum value specified for Percent Min Speed Change. This setting allows a sufficient speed change to occur at lower RPMs. For example, if you do not specify a hard-set minimum speed change and you are running at a rod speed of 50 RPM, an increase in speed by a minimum five percent would only give you a speed change of 2.5 RPM (50 × 5%).

Min Prod Change Requirements

Specify the required production change as a percent difference between the previous sampling period production and the current sampling period production. If the percent difference is less than the Minimum Production Change Requirement, the production control algorithm will consider the current state to be a NO CHANGE IN PRODUCTION and will reduce rod speed.



No of CSC Speed Dec Allowed

Specify the number of consecutive speed decreases allowed before challenging the production control algorithm and increasing speed. Otherwise the speed will continuously drop until you reach minimum speed specified in the Min Operating Speed field.

Momentary Speed Override

Use this feature to immediately change the speed of the PCP to the value specified in this field. This speed remains in effect until the end of the next sampling period or when a violation occurs.

To execute this override feature, highlight the EXECUTE field and then press <ENTER>. The message SPEED CHANGE INITIATED displays for a few seconds to notify you that the SAM PCP Controller executed this feature.

Stopping Protection Override

Specify whether you want to prevent or allow the pump to start even when the SAM PCP Controller detects polished rod rotation.

• Select YES to allow the pump to start even when polished rod rotation is detected.

• Select NO to prevent the pump from starting when polished rod rotation is detected. You cannot start the pump until the SAM PCP Controller does not detect rod speed.

WARNING: Selecting YES to override stop protection can cause pump damage or personnel injury to occur if you start the pump while it is rotating, especially during backspin.

Procedure Follow the steps below to program the PCP control parameters in both screens.

1. From the Main Menu screen, select 3. CONFIGURATION to display the Configuration Menu screen.




SAM 3/1/2

2. Select 1. PCP CONFIGURATION, and then select 1. CONTROL PARAMETERS CFG to display the first PCP Control Parameters CFG screen.

3. Press <↑> or <↓> to highlight the appropriate data field, and then press <EDIT>

4. Do one of the following:

• To enter numerical values, press <EDIT> and then press the number keys. After you press a key, the next digit to the right highlights. You can press <←> to return to a digit to the left to change it. After all numerical values are correct, press <ENTER>.

• To select field options, press <EDIT>, press <↑> or <↓>, and then press <ENTER>.

The next field highlights.

5. Repeat steps 3 and 4 for each field you want to edit.

6. When finished with all fields on this screen, press <NEXT> to display the second screen.


8. When finished editing fields, do either of the following:

• Press <EXIT> to return to the PCP Configuration Menu screen.

• Press <MENU> to return to the Main Menu screen.

The values you entered into both screens are saved.

7.3 Configuring Parameter Violations Several SAM PCP Controller control functions can be disabled (D) or enabled (E) individually by using the Violation Configuration programming screen (Figure 7-5). At times, disabling all control functions is helpful for troubleshooting purposes until the problem is resolved. You must remember to return to this screen and enable the control functions you need.

To display the Violation Configuration programming screen, select 2. VIOLATION CONFIGURATION from the PCP Configuration Menu screen.



Figure 7-5. Violation Configuration Programming Screen

Data Field Descriptions Rows Information about the data fields in each row is provided below. Each column is described at the bottom of this screen.

No RPM

Specify if you do not want the SAM PCP Controller to check for an RPM signal.

Low RPM

Specify the minimum pump motor speed allowed, in RPM. The current speed captured through the sensor connected to the polished rod is monitored and compared to the specified LIMIT value. This violation provides the SAM PCP Controller early warning with any evidence of a stalled pump or sensor malfunction at the rate of one-second resolution. Once it exceeds the CSC (consecutive) value, the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode. After the mode period expires, the SAM PCP Controller automatically restarts. If the violations continue and it exceeds the Consecutive Malfunction allowed, the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). After it enters this state, you must manually reset the malfunction.



Critical Torq

Specify the maximum motor torque allowed. The critical torque limit should be set higher than the Torq Limiting value described below. The current torque (an analog input from the variable speed drive) is compared to the specified LIMIT value. This is an instantaneous action that reduces the speed in a single step to the minimum operating speed (Low RPM). Once it exceeds the CSC (consecutive) value, the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode. After the mode period expires, the SAM PCP Controller automatically restarts. If the violation continues and it exceeds the Consecutive Malfunction allowed, the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). After it enters this state, you must manually reset the malfunction. For information about scaling the torque signal input, see “Configuring End Devices” on page 7-20.

Note: A CSC value of zero will shut down the pump or run the pump at minimum speed with no restarts.

Torq Limiting

Specify the desired maximum operating motor torque. This limit should be set lower than the Critical Torq limit value described above. The current torque (input from the drive) is compared to the specified LIMIT value to detect if the pump is beginning to show evidence of stalling or fluid starvation that can cause friction between the stator and elastometer, thus increasing the torque. Torque is monitored every second, and once it is violated, the SAM PCP Controller will decrease the speed by the specified torque limiting speed value, and continue reducing speed until the minimum operating speed is reached. At this state, the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode. After the mode period expires, the SAM PCP Controller automatically restarts. If the violation continues and it exceeds the Consecutive Malfunction allowed, the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). After it enters this state, you must manually reset the malfunction.



Low Prod

Specify the minimum amount of fluid production allowed. Production for the current sampling period is compared to this value to detect a fluid starvation/dry pump condition. This feature also helps monitor (at the rate of one-minute resolution) to detect if something is wrong with the production transmitter for Speed Control Operation mode or at the end of every sampling period for Production Control Operation mode. When a violation occurs, the SAM PCP Controller decreases motor speed by the value specified in the Hi/Lo Prod Speed Change field. Speed continues decreasing until it reaches the Minimum Operating Speed. At this state, the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode. After the mode period expires, the SAM PCP Controller automatically restarts. If the violations continue and it exceeds the Consecutive Malfunction allowed, the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). After it enters this state, you must manually reset the malfunction.

High Prod

Specify the maximum amount of fluid production allowed. Production for the current sampling period is compared to this value to detect a production transmitter malfunction at the rate of one-minute resolution for Speed Control Operation mode or at end of every sampling period for Production Control Operation mode. When a violation occurs, the SAM PCP Controller decreases rod speed by the value specified in the Hi/Lo Prod Speed Change field. Speed continues decreasing until it reaches the Minimum Operating Speed. At this state, the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode. After mode period expires, the SAM PCP Controller automatically restarts. If the violations continue and it exceeds the Consecutive Malfunction allowed, the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). After it enters this state, you must manually reset the malfunction.

Speed Diff

Specify the speed difference allowed between measured polished rod speed and the speed control output. The SAM PCP Controller compares the present rod speed captured through the sensor connected to the polished rod and the speed control output that the SAM PCP Controller sends to the variable speed drive. If the difference is greater than the speed difference limit, the SAM PCP Controller issues an alarm informing the operator that the controller and drive speeds are out of sync.



Columns Information about the data fields in each column is provided below.

E/D

Specify if the violation is to be enabled (E) or disabled (D).

LIMIT

Specify the limit required to trigger a violation.

CSC ALLOWED

Specify the number of consecutive times the SAM PCP Controller can detect the limit being violated before entering SHUTDOWN or MALF RUN MIN SPEED mode.

MLF ALLOWED

Specify the number of consecutive downtime cycles allowed before the SAM PCP Controller issues a Malfunction state. The action the Malfunction State issues depends on the action specified for DT ACTION. The malfunction must be manually reset to remove it from this state.

This feature is not available for Speed Diff.

DT ACTION

Specify the downtime action to occur once the violation exceeds the CSC ALLOWED consecutive violations allowed. The options available are:

• Shutdown (S) — Shuts down the pump during the Downtime period.

• Run Minimum (R) — Operates the pump at minimum operating speed during the Downtime period.


MLF ACTION

Specify the malfunction action to occur once the violation exceeds the MLF ALLOWED consecutive violations allowed. The options available are:

• Shutdown (S) — Shuts down the pump and remains shut down until the operator resets the malfunction.



• Run Minimum Speed (R) — Operates the pump at minimum operating speed until the operator resets the malfunction.


DELAY

Specify the delay time allowed before the SAM PCP Controller starts checking for violations. The countdown starts as soon as the controller switches to STARTING STATE. Any violations occurring during the start delay are not considered.

Procedure Follow the steps below to enable or disable the SAM PCP Controller control functions and specify violation values and actions.



2. Select 1. PCP CONFIGURATION, and then select 2. VIOLATION CONFIGURATION to display a Violation Configuration programming screen.






Note: If the control mode is changed, either manually or automatically, certain default control functions are automatically enabled.

5. Press <→> to move to the next field to the left in the row.



SAM 3/1/3


7. To change field values in the next row, press <↑> and <↓>.




The values you entered are saved.

7.4 Configuring End Devices All end device (wedge meter, turbine meter, scaled flow, etc.) configuration is done through the End Devices CFG programming screen (Figure 7-6). To display this screen, select 3. END DEVICES CFG from the PCP Configuration Menu screen.

Figure 7-6. End Devices CFG Programming Screen Example (for Electric Prime Mover and Wedge Meter)



Data Field Descriptions Information about each data field is provided below.

Speed Monitor Input

This field is defaulted to the TB4 (RPM) port. An analog input channel can be selected to monitor an analog speed. Virtual analog channel 3 is set as the default and cannot be changed.

Speed Control Output Channel

This field is hard coded to A01specifying the output port designated for speed control output, which is the output to the variable speed drive for speed control.

Production Input Channel

Select the option SCALED FLOW, WEDGE METER, or TURBINE METER.

• SCALED FLOW — When this option is selected, the following additional fields display:

– Scaled Production Analog # — Analog input channel used to measure flow. It is always set to virtual AI 1.

– Input Type — Refer to the end device for the range of output signal. Typical devices provide a 4 — 20 MA DC output, or a 1 — 5 VDC output.

– Scaled Min — Select the minimum scaled value, in engineering units.

– Scaled Max — Select the maximum scaled value, in engineering units.

• WEDGE METER — When this option is selected, the following additional fields display:



– Differential Pressure Analog # — Analog input channel used to measure pressure. It is always set to virtual AI 1.

– Input Type — Enter the range of the output from the end device. Typically either 4 — 20 Ma or 1— 5 VDC.

– Max Scaled Pressure — Specify the maximum scale of the transducer in inches of water.

– Min Scaled Pressure — Specify the minimum scale of the transducer in inches of water.

– Kd^2 — Specify the wedge meter flow coefficient. This value is the height of the wedge versus the diameter of the pipe squared.

– Fluid Density (in kg/m^3) — Specify the density of the fluid. Water is 1,000.

• TURBINE METER — When this option is selected, the Turbine Meter Factor field displays.

– Turbine Meter Factor — Specify the number of pulses generated by the meter that equal one gallon.

Motor Torque Analog #

Displays the analog input channel used to measure polished rod torque. Virtual analog channel 6 is set as the default and cannot be changed.

Hydraulic Pressure Analog

Displays the analog input channel used to control the hydraulic prime mover. This field cannot be edited and is only available if a hydraulic prime mover is specified. Virtual analog channel 6 is set as the default and cannot be changed.

Input Type

Specify the input signal type used for measuring motor torque.

Max Scaled Motor Torque

Specify the full scale of VSD analog output used for motor torque. This field is only available if an electric prime mover is specified.



Hydraulic Pressure Max Range

Specify the maximum hydraulic pressure allowed for the hydraulic prime mover when it is operating at full range. This field is only available if a hydraulic prime mover is specified.

Drive Fault Status Dig Channel

Specify the digital input port used for receiving the drive fault status. The choices are DI1 through DI64. For channels 10 and above, type the value for the tens and then type the value for the ones.

Procedure Follow the steps below to configure end devices.



2. Select 1. PCP CONFIGURATION, and then select 3. END DEVICES CFG to display an End Devices CFG programming screen.












SAM 3/1/4

The values you entered are saved.

7.5 Configuring Production and Motor Information

Production K-factor is used as a correction to measured production. The calculation parameter data is entered through the Production/Motor Information programming screen (Figure 7-7). To display this screen, select 4. PRODUCTION/MOTOR INFO from the PCP Configuration Menu screen.

Figure 7-7. Production/Motor Information Programming Screen Example (for Electric Prime Mover)


Prod K-Factor

Specify the K-factor multiplier to apply to the production input to refine the production calculation.

Theoretical Pump Displacement

Specify the pump manufacturer’s design displacement in barrels per 100 RPM.

Prime Mover Type

Specify whether the prime mover is Electric or Hydraulic driven.



• Electric — When this option is selected, the following additional fields display:

– Horse Power — Specify the rated horsepower of the pump motor. You should be able to find this information on the motor nameplate.

– Motor Full Load RPM — Specify the rated full load RPM of the pump motor. You should be able to find this information on the motor nameplate.

• Hydraulic — When this option is selected, the following additional fields display:

– Hydraulic Pump Max Displacement — Specify the maximum displacement of the hydraulic pump that is driving the hydraulic motor.

– Hydraulic Motor Displacement — Specify the maximum displacement of the hydraulic motor that is connected to the polished rod via belts and sheaves.

Sheave Ratio

Specify the ratio of motor RPM to rod RPM to yield the number of revolutions the motor makes for each revolution of the rod. This value allows you to convert RPM to rod speed. Take the size of the drive head sheave and divide it by the size of the motor sheave. For example; if drive head sheave equals 28 and motor sheave size equals 7, the sheave ratio equals 4.

You can use the CALC option located to the right of the field to automatically calculate this value. The SAM PCP Controller takes the current output speed to the drive and the current input RPM speed from the rods and calculates a new sheave ratio based on the difference. To use this option, press <→> to highlight CALC and then press <ENTER>. The value is calculated and displayed in the Sheave Ratio field.



SAM 3/1/5

Procedure Follow the steps below to configure production K-factor and motor information.



2. Select 1. PCP CONFIGURATION, and then select 4. PRODUCTION/MOTOR INFO to display Production/Motor Information programming screen.



• To enter numerical values, press <EDIT> and then press the number keys. After you press a key, the next digit to the right highlights. You can press <←> to return to a digit to the left to change it. After all numerical values correct, press <ENTER>.



5. When the value you want is correct press <ENTER>.





7.6 Configuring Special Features The Special Features programming screen (Figure 7-8) is used to configure parameters for the sand blowout (SBO) feature, such as rod torque, motor speed, and length of time used for sand blowout. You can also specify whether you want the VSD to be able to restart the pump when power has resumed after a power failure. To



display this screen, select 5. SPECIAL FEATURES from the PCP Configuration Menu screen.

Figure 7-8. Special Features Programming Screen


Feature Enabled

Specify whether to enable or disable the sand blowout feature.

Sandy Well High Torque Threshold

Specify the rod torque limit required to enable sand blowout control.

SBO State Speed Decrease

Specify the rod RPM speed decrease for each ramp down.

Speed Decrease Number of Ramp Down

Specify the number of consecutive ramp downs before sand blowout speed is initiated.

SBO State Speed Decrease Period

Specify the length of time to be in the speed decrease state to allow the fluid in the annulus to build up.

SBO Fast Speed Increase

Specify the rod speed to be used for sand blowout.



SBO State Speed Increase Period

Specify the length of time the motor is to run at the speed specified for sand blowout.

POWER FAILURE LOCKOUT: Feature Enabled

Specify whether you want the SAM PCP Controller to prevent the VSD from starting the pump after a power failure.

• To prevent the pump from starting, select Yes.

• To allow the pump to start, select No.

When Yes is selected to enable this feature, the operator must manually restart the pump.

This feature is used to clear out the buildup of sand above the pump to prevent high torque and possible rod parts.

Procedure Follow the steps below to configure for special features.



2. Select 1. PCP CONFIGURATION, and then select 5. SPECIAL FEATURES to display the Special Features programming screen for the sand blowout feature.








5. Repeat steps 3 and 4 or each field you want to edit.





Section 8

SAM Controller Programming

Parameter values controlling basic operations of the SAM PCP Controller must be properly programmed in order for any effective well management and control to occur.

Note: Only information about programming configuration parameters that control PCP operations of the SAM PCP Controller is described in this section. For information about programming general PCP parameters that control PCP monitoring and control, see section 7, “PCP Parameter Programming.”


8.1 Overview of SAM PCP Controller Parameter Programming ........ 8-2 8.2 RTU Level Menu ........................................................................... 8-4 8.3 Setting the Controller Date and Time ............................................ 8-5 8.4 Communication Parameters Configuration.................................... 8-7

8.4.1 Configuring Communication Parameters........................... 8-8 8.4.2 Configuring Modbus Transmission Mode ....................... 8-12

8.5 Modbus Master and Slave Device Configuration ........................ 8-14 8.5.1 Configuring Slave Device Parameters ............................. 8-15 8.5.2 Writing Register Values to Registers and the Slave

Device............................................................................... 8-22 8.5.3 Specifying a Polling Routine Rate ................................... 8-24 8.5.4 Configuring the Communication Expansion Port ............ 8-26

8.6 Changing Passwords .................................................................... 8-28 8.7 Resetting Parameters to Factory-Default Values ......................... 8-30 8.8 Configuring the Default Screen.................................................... 8-31 8.9 Setting Gauge Off Time and Peak Energy Management ............. 8-33 8.10 Auxiliary I/O Configuration......................................................... 8-36

8.10.1 Configuring Auxiliary Analog Inputs .............................. 8-37



8.10.2 Configuring Auxiliary Analog Outputs............................ 8-41 8.10.3 Configuring Auxiliary Digital Inputs and Outputs .......... 8-45 8.10.4 Configuring Auxiliary Accumulators............................... 8-48

8.11 Logic Expressions ........................................................................ 8-53 8.11.1 Programming a Logic Expression .................................... 8-54 8.11.2 Programming a Logic Expression Action ........................ 8-62 8.11.3 Clearing the Logic Expression State ................................ 8-65 8.11.4 Enabling and Disabling Logic Expressions ..................... 8-67

8.12 AGA 3 Parameter Configuration.................................................. 8-68 8.12.1 Configuring AGA 3 Parameters ....................................... 8-70 8.12.2 Configuring NX-19 Design Parameters ........................... 8-73 8.12.3 Configuring Temperature and Pressure............................ 8-75 8.12.4 Enabling and Disabling AGA 3 Calculations .................. 8-78

8.13 Custody Transfer .......................................................................... 8-79 8.14 Register Configuration ................................................................. 8-79

8.14.1 Configuring a Register Alarm.......................................... 8-80 8.14.2 Configuring a Register Log.............................................. 8-83 8.14.3 Configuring Register Calculations ................................... 8-88

8.15 Configuring and Enabling/Disabling HOA.................................. 8-94 8.16 Configuring Alarm (Coil) Tracking ............................................. 8-97 8.17 Configuring VSD Parameters....................................................... 8-99

8.1 Overview of SAM PCP Controller Parameter Programming

Several parameters need to be defined (programmed) that control basic daily routine operations performed by the SAM PCP Controller. Some of the necessary parameters include:

• Date, time, and user passwords

• Communication parameters

• Analog, digital, and accumulator values

• Logic expression commands

• AGA 3 parameters

Section 8: SAM Controller Programming


SAM 3/3

• Register logs and calculations

• Alarm parameters

• VSD parameters

The actual SAM PCP Controller configuration values are available under the SAM Configuration Menu screen (Figure 8-1). To access this screen, first select 3. CONFIGURATION from the Main Menu screen and then select 3. SAM CONFIGURATION.

Figure 8-1. SAM Configuration Menu Screen

Note: A user password is required to access this menu screen if password protection is enabled. For information about passwords, see “Changing Passwords,” on page 8-28.

Operator Interface Keypad Programming All SAM PCP Controller programming parameter values are entered through the 20-key operator interface keypad mounted in the SAM PCP Controller enclosure. For information about this operator interface and how to use it, see “Controller Operator Interface” in section 2, “Description of the SAM PCP Controller System.”



SAM 3/3/1

RAM Backup Protection Many of the parameters programmed for SAM control are stored in RAM on the SAM PCP Controller circuit board. This memory is supported during power outages by a lithium battery located near the top of this circuit board. Failure to include the battery will cause the SAM PCP Controller to lose programming when the power switch is turned off.

Before programming the SAM PCP Controller, ensure that the shorting jumper is on both pins so that the battery is included in the circuit. Battery disconnect jumper pins are located next to the battery. If the battery is not included, the SAM PCP Controller will loose programming when the power switch is turned off. The battery jumper configuration can be checked by looking down between the expansion board and the main board from the top. If the jumper is not on both pins, the expansion board must be temporarily removed to properly place the jumper. For more information about the battery, see “Battery Disconnect Jumper Pins” in section 6, “Hardware Configuration.”

8.2 RTU Level Menu Several fundamental operating parameters within the SAM PCP Controller need to be configured. Usually these parameters only need to be configured once, or at the most, on very rare occasions. The parameters include:

• Date and time, which is required for recording and plotting historical data

• Communication parameters, such as establishing baud rates, handshake protocol, and key up and key down times

• User and supervisor passwords to restrict unauthorized access to the configuration screens

• Restoration of factory-default parameters values

• Mainboard I/O diagnostics for troubleshooting purposes

These configuration operations are performed using options available through the RTU Level Menu screen (Figure 8-2). To display this screen, select 1. RTU LEVEL from the SAM Configuration Menu screen.



SAM 3/3/1/1

Figure 8-2. RTU Level Menu Screen

8.3 Setting the Controller Date and Time In order for historical data to be accurate, the date and time in the SAM PCP Controller must be programmed to agree with local time.

The SAM PCP Controller can automatically adjust the time setting for daylight saving time (DST). If your area does not recognize DST, disable the DST feature at this time. The North American — United States dates are used to define the beginning and end of the DST period.

Date and time are set using the Clock Calendar Configuration screen (Figure 8-3). To display this screen, select 1. CONTROLLER DATE AND TIME from the RTU Level Menu screen.



Figure 8-3. Clock Calendar Configuration Screen

Procedure Follow the steps below to set the date and time.

1. From the Main Menu screen, select 3. CONFIGURATION, and then select 3. SAM CONFIGURATION to display the SAM Configuration Menu screen.


2. Select 1. RTU LEVEL, and then select 1. CONTROLLER DATE AND TIME to display the Clock Calendar Configuration screen.

The New Date field highlights.

3. Press <EDIT> and use the number keys to enter the present month/date/year, and then press <ENTER>. Be sure to use the date format shown of MM/DD/YYYY.

4. Press <↓> until the New Time field highlights.

5. Press <EDIT> and use the number keys to enter the present local time, and then press <ENTER>. Be sure to use the 24-hour clock format of HH:MM:SS.



SAM 3/3/1/2

6. If you want to use daylight saving time, make sure the Enable DST field reads “ENABLE.” If it does not, press <↓> to highlight this field, press <EDIT>, press <↑> or <↓> to toggle to ENABLE, and then press <ENTER>.


• To return to the RTU Level Menu screen, press <EXIT>.

• To return to the Main Menu screen, press <MENU>.

The SAM PCP Controller now resumes operations based on the new date and time you programmed.

8.4 Communication Parameters Configuration

If the SAM PCP Controller has data telemetry equipment (radio, cell phone, etc.) connected to it, you must program the communication parameters. Default parameter values are preset with factory-default values that you may need to edit.

Communication parameters are programmed using the options available under the Communication Parameters Menu screen (Figure 8-4). To display this menu, select 2. COMMUNICATION PARAMETERS from the RTU Level Menu screen.

Figure 8-4. Communication Parameters Menu Screen



SAM 3/3/1/2/1

8.4.1 Configuring Communication Parameters The communication parameters that you usually need to configure are:

• RTU address

• Data transmission rate

• Keying properties

• Handshake protocol

These parameters are programmed using a Communication Parameters Menu screen similar to Figure 8-4. To display this screen, select 1. COMMUNICATION PORT CFG from the Communication Parameters Menu screen.

Figure 8-5. Communication Administration Screen




RTU Address

Specify a unique identifier number for the controller that must be coordinated with the address entry in the host computer SCADA software. The SAM PCP Controller uses standard RTU Modbus protocol for address settings of 247 and below. The Extended Lufkin Automation Modbus (ELAM) protocol is used for addresses of 248 through 2295. ELAM protocol allows for much larger blocks of data to be transmitted, and it also allows standard Modbus messages to be combined together. For more information on the ELAM protocol, contact your Lufkin Automation representative.

Radio Port Baud Rate

The SAM PCP Controller supports a range of data transmission rates from 300 to 115,200 baud. The baud rate of the front panel DB-9 RS-232 laptop port can be set at a different value from that of the radio port.

Delay before Key Up

The time delay, in milliseconds, from the time that the controller recognizes an incoming message addressed to it before the RTS line is raised to key the radio to send a reply.

Key Up Time

Once the RTS line is raised, the controller will delay this amount of time before actually starting to send data.

Key Down Time

At the end of the message string, the RTS is held high for this amount of time.

Enable/Disable Radio CTS and DCD

The SAM PCP Controller does not need these “handshake” signals, but if your radio requires that protocol, they can be enabled. Typically, leave this value set to DISABLE.



Character Gap Timeout

The SAM PCP Controller uses RTU Modbus communication protocol. In that protocol, the end of a message is marked by a break or gap in the message string that is greater than 3.5 data characters in length. In some communication networks, repeaters or relay stations may break a message into two or more parts with gaps between the parts. If those gaps are longer than the 3.5-character time, the SAM PCP Controller will not receive a valid message. These situations can resolve by programming a longer character gap timeout.

Expansion Comm. Mode Option

The SAM PCP Controller processor has a second communication port that is presently used for the Modbus master function. The settings available include:

• RS485

• RS232

• FSK Modem

• Ethernet

• None

Expansion Comm Baud Rate

The SAM PCP Controller supports a range of data transmission rates from 300 to 115,200 baud on the expansion port.

Key Up Time

Once the RTS line is raised from the second communication port, the SAM PCP Controller will delay this amount of time before actually starting to send data.

Key Down Time

At the end of the message string from the second communication port, the RTS is held high for this amount of time.

Enable RTS/CTS

For the second communication port, the SAM PCP Controller does not need these “handshake” signals, therefore leave this value set to DISABLE.



Reset Comm Regs to Default

Executing this option resets all communication parameters, including the RTU Address, to the factory default values. This option should only be executed by a trained Lufkin Automation technician.

Procedure Follow the steps below to configure the communication parameters.



2. Select 1. RTU LEVEL, and then select 2. COMMUNICATION PARAMETERS to display the Communication Parameters Menu screen.

3. Select 1. COMMUNICATION PORT CFG. The Communication Administration screen appears with the RTU Address field highlighted.

4. Press <↓> until the first field you want to change is highlighted.







• To return to the Communication Parameters Menu screen, press <EXIT>.




SAM 3/3/1/2/2

The communication parameters you configured now take affect in the SAM PCP Controller.

8.4.2 Configuring Modbus Transmission Mode You can program the parity and stop bits for the Modbus transmission to ensure that it is compatible with the host SCADA software. All other fields must remain as shown to support the Modbus RTU protocol used by the SAM PCP Controller. This programming is done through a Modbus Transmission Mode CFG screen similar to Figure 8-6. To display this screen, select 2. MODBUS TRANMISSION MODE CFG from the Communication Parameters Menu screen.

Note: The same parameters should be applied for the laptop and radio ports, because the laptop port is really the same communications port, but redirected to the front panel with DTR.

Figure 8-6. Modbus Transmission Mode CFG Screen


Transmission Mode

Only the Modbus RTU protocol is supported.



Data Bits, Stop Bits, and Parity

These three fields define the data format to be used by the SAM PCP Controller.

For Parity, the choices are NO PARITY and ODD/EVN. NO PARITY should be selected to support the Modbus RTU protocol.

These settings must be the same as the host SACADA software.

Error Checking

Only the CRC (Cyclical Redundancy Check) Modbus protocol is supported.

Procedure Follow the steps below to configure the communication parameters.




3. Select 2. MODBUS TRANSMISSION MODE CFG.

The Modbus Transmission Mode CFG screen appears with the Parity field highlighted.







SAM 3/3/1/2/3

5. Repeat step 3 and 4 for each field you want to edit.


• To return to the Communication Parameters Menu screen, press <EXIT>.


The communication parameters you configured now take affect in the SAM PCP Controller.

8.5 Modbus Master and Slave Device Configuration

A SAM PCP Controller equipped with an RS-485 communication expansion board (Part No. 520.5012) can use the Modbus Master function and be programmed to poll and collect data from a maximum of 10 slave devices. The SAM PCP Controller plays the role of master unit and the other devices are configured as slave devices.

Slave Device #1 is automatically configured with all necessary parameters when a Rosemount 3095FB device is selected for one or more of the process variable inputs in the monitored transmitter configuration.

If necessary, you can change the Modbus communication configuration to accommodate these devices. Typically, you will not use this configuration option. If you do need to change the Modbus configuration, contact your Lufkin Automation representative for information about this process.

A maximum of 125 data registers can be read from each configured RTU slave device. The SAM PCP Controller can automatically poll the slave devices at a programmable interval.

The SAM PCP Controller can also be configured to write data to the slave devices configured to it. Desired values can be programmed for a maximum of 25 registers in each slave device. The write function requires a manual command to execute.

Modbus/slave device configuration involves the following five processes:

• Assigning a number to a slave device

• Configuring slave device communication parameters



SAM 3/3/1/2/3/1

• Configuring a Modbus slave device

• Specifying a polling routine rate

• Configuring a transmission mode for compatibility with host SCADA software

All Modbus and slave device configuration is done with the options available under the Modbus Master Menu screen (Figure 8-7). To display this menu, select 3. MODBUS MASTER CFG from the RTU Level Menu screen.

Figure 8-7. Modbus Master Menu Screen

Note: The SAM PCP Controller must be programmed to recognize an RS-485 communication expansion board before any Modbus master/slave device programming can occur. For information about expansion board configuration, see “Configuring the Communication Expansion Port” on page 8-26.

8.5.1 Configuring Slave Device Parameters The SAM PCP Controller can be programmed to poll a maximum of 10 slave devices. Each Modbus RTU to be polled by the SAM PCP Controller must have a slave device number assigned to it, and each device must be programmed separately. This programming is done using the Modbus Master Config selection screen (Figure 8-8). To display this screen, select 1. CONFIGURATION from the Modbus Master Menu screen.



Figure 8-8. Modbus Master Config Screen

After you assign a number to a slave device, you should see a slave device communication configuration screen similar to Figure 8-9 with the slave device number you selected displayed at the top of the screen, such as “Slave Device 1.” You need to use these fields to specify the type of slave device used as an RTU and its communication parameters. You can also return to this screen at any time when you need to change parameter values.

Note: Refer to the user manual for the slave device for information about its parameters.



Figure 8-9. Slave Device Communication Configuration Screen


RTU ADDRESS

Each slave device must have a different address number. Address numbers of less than 247 are indicated by the standard Modbus guidelines. The address must match the slave device setting.

DEVICE TYPE

Three options are available for specifying a slave device type.

• MODBUS SLAVE — Select for any RTU that uses Modbus RTU protocol.

• SIEMENS LS1000 LEVEL SENSORS — A special application of the RS-485 master/slave capabilities of the SAM PCP Controller.

• Rosemont 3095 — Slave Device #1 is automatically configured with all necessary parameters when a Rosemount 3095FB device is selected for one or more of the process variable inputs in the monitored transmitter configuration. The pre-set parameters include the Rosemount factory default data transfer rate of 9600 baud.

BAUD RATE

Select from a range of options from 300 to 115,200 baud. The value must match the slave device setting.



DATA BITS, STOP BITS, and PARITY

These three fields define the data format to be used by the SAM PCP Controller. These settings must be the same as the slave device.

DELAY BEFORE KEY UP

Specify the time, in milliseconds, that the processor needs to pause before raising the RTS line when the SAM PCP Controller is ready to poll a slave device.

KEY UP TIME

Specify the time, in milliseconds, that are to be added before data is actually transmitted once the RTS line is raised.

KEY DOWN TIME

Specify the time, in milliseconds, that the RTS line is held high at the end of the outgoing message string.

# FAILURES ALLOWED

Specify the number of times that the SAM PCP Controller will continue to try to poll a slave device once that device is enabled. If the SAM PCP Controller does not receive a valid response after this number of consecutive polling attempts, a communication failure alarm is flagged for the slave device to alert the operator that data from the slave is not current. Communication failure flags can be checked using the local LCD display. For more information, see the description about the Status field.

TIMEOUT

Specify the time, in milliseconds, that the SAM PCP Controller waits after sending a poll message to check the reply message buffer.

STATUS

This field is used to enable or disable the polling of the slave device. Polling must be enabled to activate the polling function. If a slave device is to be offline for service, disable it to prevent nuisance communication failure alarms.



Address Association to Registers After the type of slave device used is specified as an RTU, and the slave device communication parameters to be used for it are specified, you need to configure register addresses to register indices. The Modbus Master function is capable of reading data from a maximum 125 register addresses per Modbus slave device. These addresses are associated to register indices in groups of 20 to a screen. This configuration is performed using a Register Address Configuration Programming Screen similar to Figure 8-10. To display this screen, at the Slave Device Communication Configuration screen, press <NEXT>.

Figure 8-10. Register Address Configuration Programming Screen

The numbers in the Register Index column are the numbers assigned in the SAM PCP Controller buffer of values. The values in the Register Address column must be programmed with the register numbers in the slave device that contain the data you want to read. You need to perform this operation separately for each Modbus slave device on the data network.

When you assign register numbers, keep in mind the generic Modbus organization guidelines. This type of organization minimizes the number of data transmissions required to read all of the desired data, and it reduces data access time.

• Group together all registers read with a given function code

• Read contiguous groups of registers where possible



• Arrange the Register Address column with the smaller register numbers at the top of each group

Procedure Follow the steps below to configure slave device parameters.



2. Select 1. RTU LEVEL and then select 2. COMMUNICATION PARAMETERS to display the Communication Parameters Menu screen.

3. Select 3. MODBUS MASTER CFG, and then select 1. CONFIGURATION to display the Modbus Master Config selection screen.

Slave Device 1 highlights.

4. Press <↑> or <↓> to highlight the slave device you want to configure.


a. For all numbers, press <↑> or <↓> to scroll through the list to highlight the device number you want assigned, and then press <ENTER>.

b. For numbers 1 through 9, press the number key representing the slave device number. For 10, press <↓> to highlight it, and then press <ENTER>.

Note: Every slave device that is to be polled by the SAM PCP Controller must have a number assigned to it.

A Slave Device Communication configuration screen similar to Figure 8-9 displays.



6. Press <↑> or <↓> to highlight the data field you want to edit and then do one of the following:


• To select field options, press <EDIT>, press <↑> or <↓> to scroll through available options. Press <ENTER> when the desired option is displayed.


Note: If the slave device is to be offline for service, select DISABLED in the Status field to disable it. This action prevents nuisance communication failure alarms from displaying.

7. When all parameters are specified correctly, press <NEXT>. The screen that appears next is determined by the type of slave device specified in the Device Type field.

8. Make sure all fields in the Slave Device Communication configuration screen (Figure 8-9) have the correct data entered in them, and then press <NEXT> to display the Register Address Configuration programming screen (Figure 8-10).

9. Press <↑> or <↓> to highlight the Register Address field you want to configure, and then press <EDIT>.

10. Press the number keys to enter the value you want, and then press <ENTER>.

11. Repeat steps 9 and 10 for each field on the screen you want to configure.

12. To configure the next group of 20 register numbers, press <NEXT> to display the next screen, and then repeat steps 9 through 11.

13. When all register numbers are configured, do one of the following:

• Press <EXIT> to return to the Slave Device Communication Configuration screen (Figure 8-9).




SAM 3/3/1/2/3/2

The slave device parameters are saved.

8.5.2 Writing Register Values to Registers and the Slave Device

The Modbus Master function can write register values to one or multiple registers of a Modbus slave device. Register values can be assigned to a maximum of 25 register addresses. After the addresses are configured, you need to specify the Modbus slave device that is to receive these values and then write them to it. The Modbus Master Write Utility programming screen (Figure 8-11) is used to write and send to the slave device. To display this screen, select 2. WRITE UTILITY from the Modbus Master menu screen.

Figure 8-11. First Modbus Master Write Utility Programming Screen

The SAM PCP Controller writes to one register at a time, so the Modbus guidelines regarding function codes and contiguous registers do not affect a write operation.

The remaining five register values appear on a second screen similar to Figure 8-12. This screen is also where you find the option to write the values to the Modbus slave device.



Figure 8-12. Second Modbus Master Write Utility Programming Screen with Write Option

Procedure Follow the steps below to write register values to register addresses and the slave device.



2. Select 1. RTU LEVEL and then select 2. WRITE UTILITY to display the Communication Parameters Menu screen.

3. Select 3. MODBUS MASTER CFG, and then select 2. WRITE UTILITY to display the Modbus Master Write Utility screen.

The Register Address field for Register Index 1 highlights.

4. Press <↑> or <↓> to highlight the Register Address field you want to configure, and then press <EDIT>.




SAM 3/3/1/2/3/3

6. Press <→> to highlight the corresponding Register Value field, and then press <EDIT>.


8. Press <←> and then press <↑> or <↓> to highlight the next Register Address field you want to configure.

9. Repeat steps 5 through 9 for each Register Address/Register Value pair you want to configure.

10. After you configure the first 20 pairs on this screen, press <NEXT> to configure the remaining five pairs. Repeat steps 5 through 9 for them also.

11. When finished configuring the pairs, press <↓> to highlight the Device Number field.

12. Press <EDIT>, press the number keys to enter the device number of the Modbus slave device to which you want to write the register values, and then press <ENTER>.

13. Press <↓> to highlight the Write to Device field, and then press <ENTER>.

The SAM PCP Controller writes the register values to the specified register addresses in the slave device.


• Press <EXIT> to return to the Modbus Master Config Selection screen.


The register values written to the register addresses and the slave device are saved.

8.5.3 Specifying a Polling Routine Rate The Modbus Master function uses a polling routine to retrieve data from all enabled slave devices in the data network. You can specify the poll rate (or interval) for the routine.



The polling routine occurs after the SAM PCP Controller sends a polling message to a slave device. After the timeout interval elapses, the reply buffer is checked. If the reply is valid, the register index is updated with the new value. If the reply is invalid or no reply occurs, the consecutive communication failure counter is incremented. The next polling message is transmitted without further delay. After all programmed poll messages are completed, the SAM PCP Controller remains idle for the remainder of the poll rate time.

Here is an example for a wellsite that has two slave devices connected to the SAM PCP Controller. Each device requires five data transmissions to read all of the desired data, and each data reading takes 500 milliseconds. The timeout is set for 600 milliseconds to give some leeway for the data response. The total poll time for both devices will be 5 × 600 = 3,000 milliseconds per device times two devices, which equals 6,000 milliseconds, or 6 seconds. The quickest possible poll rate would therefore be 6 seconds.

Poll rate times around 60 seconds are recommended. Data from a slave device would be no more than 1 or 2 minutes old when read from the SCADA software, which should be adequate time for this type of historical supervisory data. The Modbus Master function is not designed for an online realtime control function application.

The Master Communications Setup programming screen (Figure 8-13) is used to specify the poll routine rate. To display this screen, select 3. MASTER CONFIGURATION from the Modbus Master Menu screen.

Figure 8-13. Master Communication Setup Programming Screen



SAM 3/3/1/2/1

Procedure Follow the steps below to configure the poll routine rate.



2. Select 1. RTU LEVEL and then select 2. COMMUNICATION PARAMETERS to display the Communication Parameters Menu screen.

3. Select 3. MODBUS MASTER CFG to display the Modbus Master Menu screen, and then select 3. MASTER CONFIGURATION.

The Master Communication Setup programming screen appears with the Poll Rate field highlighted.

4. Press <EDIT> and use the number keys to specify the desired poll rate in seconds.

5. When the rate is correct, press <ENTER> to complete the programming.


• Press <EXIT> to return to the Modbus Master Menu screen.


The polling routine rate value is saved.

8.5.4 Configuring the Communication Expansion Port

The SAM PCP Controller must be programmed to recognize the RS-485 communication expansion port. This configuration is accomplished using the Expansion Comm. Mode Option field in a Communication Administration screen similar to Figure 8-14. To display this screen, select 1. COMMUNICATION PORT CFG from the Communication Parameters menu screen.



Figure 8-14. Communication Administration Screen Displaying Options for Configuring the RS-485

Procedure Follow the steps below to configure the communication expansion port.



2. Select 1. RTU LEVEL, and then select 2. COMMUNICATION PARAMETERS, and then select 1. COMMUNICATION PORT CFG to display the Communication Administration screen.

3. Press <↓> until the Expansion Comm. Mode Option field highlights, and then press <EDIT>.

Note: You will not see most of the fields shown in Figure 8-14 until after you select RS485.

4. Press <↑> or <↓> to scroll through the available options until the RS485 option displays, and then press <ENTER>.

Configure this field for RS-485



SAM 3/3/1/3

A new Communication Administration screen similar to Figure 8-14 appears.

You do not need to program the baud rate or other handshake and timing parameters. These parameters are overridden when a slave device is programmed.

5. Press <EXIT> to return to the Communication Parameters menu screen.

You are now ready to configure slave devices.

8.6 Changing Passwords The SAM PCP Controller has available two levels of password protection (User and Supervisory) for programming parameters. By default, both passwords levels are disabled so that you can commission the controller with a minimum of difficulty.

Passwords are assigned and enabled/disabled with a Password Administration screen similar to Figure 8-15. To display this screen, select 3. PASSWORD ADMINISTRATION from the RTU Level Menu screen.

Figure 8-15. Password Administration Screen




Password Control — The following options are available:

• DISABLE BOTH — Disables the password protection feature for users and supervisors (SUPV).

• ENABLE BOTH — Enables the password protection feature for users and supervisors.

• USER Password Only

• SUPV Password Only

When password protection is enabled, you can change either password.

User Password

Specify a password that can be used for all PCP Configuration and SAM PCP Configuration operations, except operations available under the RTU Level Menu screen.

SUPV Password

Specify a password that can be used for all PCP Configuration and SAM PCP Configuration operations, including operations available under the RTU Level Menu screen.

The factory default is set for no password, so full access to all programming menus is available on new units until passwords are assigned.

Procedure Follow the steps below to change a password.

1. From the Main Menu screen, select 3. CONFIGURATION, and then select 3. SAM CONFIGURATION to display the SAM Configuration Menu screen


2. Select 1. RTU LEVEL, and then select 3. PASSWORD ADMINISTRATION.

The Password Administration screen appears with the Password Control field highlighted.



SAM 3/3/1/4

3. If one of the ENABLED options is not displayed, press <EDIT>, press <↓> to select the desired option, and then press <ENTER>.

4. Change the password you want changed (USER or SUPV) by doing the following:

a. Press <↓> to highlight the New Password field, press <EDIT>, use the number keys to enter a four-digit number, and then press <ENTER>.

b. Press <↓> to highlight the Verify New Password field, press <EDIT>, use the number keys to enter the same four-digit number, and then press <ENTER>.

5. Repeat step 4 if you need to change another password.

6. When finished, do one of the following:

• Press <EXIT> to return to the RTU LEVEL Menu screen.


The passwords are changed.

8.7 Resetting Parameters to Factory-Default Values

This feature returns many parameters to a factory-default value. Make sure that you really need to use this feature. Normally, parameters will not need to be reset.

To execute this operation, select 4. RESET TO DEFAULTS from the RTU Level Menu screen. After you execute this operation, the user-defined parameters cannot be easily restored. Each parameter must be re-programmed one field at a time.

When this option is selected, a message appears with the YES option highlighted.

Procedure Follow the steps below to reset the SAM PCP Controller to the factory-default settings.



SAM 3/3/1/5



2. Select 1. RTU LEVEL, and then select 4. RESET TO DEFAULTS.

A message appears to confirm that you want to reset to the factory-default parameter values.


• To restore the factory default settings, make sure YES is highlighted, and then press <ENTER> to complete the reset process.

• To cancel the reset operation and keep the current settings, press <←> or <→> to highlight NO, and then press <ENTER> to abort the reset procedure.

4. When finished, do either of the following:

• Press <EXIT> to return to the SAM Configuration Menu screen.


The SAM PCP Controller is reset to the factory-default settings.

8.8 Configuring the Default Screen You can specify the screen that automatically displays when no keypad activity occurs for eight minutes. This screen is the screen you will normally see when you arrive at the wellsite.

The PCP Status screen is the screen normally used, and it is the default screen set at the factory. At any time, you can specify the Main Menu screen or the Gas Measurement screen as the default screen, or you can restore the PCP Status screen. You can also specify the units of measurement for production volumes displayed by the SAM PCP on this screen.

You specify the default screen with the Additional Configuration screen (Figure 8-16). To display this screen, select 5. ADDITIONAL CONFIGURATION from the RTU Level Menu screen.



Figure 8-16. Additional Configuration Screen used to Specify the Default Screen

Procedure Follow the steps below to reset the SAM PCP Controller to the factory-default settings.



2. Select 1. RTU LEVEL, and then select 5. ADDITIONAL CONFIGURATION.

The Additional Configuration screen appears with the No Key Operation Default Screen field highlighted.

3. Press <EDIT>and then <↑> or <↓> to scroll through the options until the screen you want is displayed, and then press <ENTER>.



SAM 3/3/2




The SAM PCP Controller from now on will display your selection as the default screen.

8.9 Setting Gauge Off Time and Peak Energy Management

Gauge off time (GOT) is the time of day that the SAM PCP Controller updates all of the 60-day historical data buffers. This time is typically set for early in the morning shortly before operator personnel report for work so that the SAM PCP Controller can display valid and fresh data from the previous day for analysis.

Oil producers may have contracts with their electric power provider to minimize power consumption during peak demand times of the day in return for a more economical rate. The SAM PCP Controller has a Peak Energy Management feature that has the controller shut down the pump during peak times, go into a Downtime Peak Energy Management state, and suspend all normal operation. You can program the period of day and which days this function is to take affect. Normal operation resumes at the end of the programmed period.

The Gauge Off Time/Peak Energy Management screen (Figure 8-17) is used to specify GOT and Peak Energy Management times. To display this screen, select 2. GAUGE OFF/PEAK ENERGY MGNT from the SAM Configuration Menu screen.



Figure 8-17. Gauge Off Time/Peak Energy Mgnt Screen


Gauge Off Time

Specify the time of day that the SAM PCP Controller updates all of the 60-day historical data buffers. Time is specified using the 24-hour clock format of HH:MM:SS.

Peak Energy Management

Specify whether you want the Peak Energy Management function to take affect.

• To disable it, select DISABLE. This feature can be useful when times are specified for its use, but you want it cancelled temporarily, such as when you are servicing or testing the equipment. Disabled is the default state.

• To enable it, select ENABLE. After you select this option, additional fields display for you to specify the days and times this feature is to take affect.



– Period — Specify the start time for the desired shutdown period, and then the end time. End time must be later in the day than the start time. The period may not include a rollover to the next day. For example, a start time of 22:00 and a stop time of 03:00 are not allowed.

– Days Applicable — Specify which days this feature is to take affect by selecting between ENABLE and DISABLE. The same time period applies to each day of the week that is enabled.

Procedure Follow the steps below to program GOT and peak energy management.



2. Select 2. GAUGE OFF TIME/PEAK ENERGY MGNT to display the Gauge Off Time/Peak Energy Mgmt screen with the Gauge Off Time field highlighted.

3. Press <EDIT>, use the number keys to specify the gauge off time, and then press <ENTER>. Be sure to use the 24-hour clock format of HH:MM.

4. To enable Energy Peak Management, press <↓> to highlight the Peak Energy Management field.

5. Press <EDIT> and then press <↑> or <↓> to scroll to ENABLE, and then press <ENTER>.

6. Fields for Period and Days Applicable display.

7. Do the following to specify the start and stop times for Peak Energy Management:

a. Press <EDIT> and then press the numerical keys to specify the start time. After you press a number key for the digit that is highlighted, the next digit to the right highlights. You can press <←> to return to a digit to the left.

b. After the time is specified for the start time, press <ENTER>.



SAM 3/3/3/1

c. Press <↓> or <→> to highlight the field for specifying the stop time.

d. Repeat steps a and b to specify the numerical values in this field.

e. Press<↓>.

The time field for Monday highlights.

8. Press <EDIT> and then press <↑> or <↓> to scroll between ENABLE and DISABLE, and then press <ENTER>.

The field for the next day highlights.

9. Press<↓>.

10. Repeat steps 8 and 9 for each day.




The times for GOT and Peak Energy Management are saved.

8.10 Auxiliary I/O Configuration The SAM PCP Controller firmware design supports analog inputs and outputs, digital inputs and outputs, and accumulators. Up to 32 auxiliary analog inputs and eight analog outputs can be configured. Sixty-four discrete points can also be configured for virtual digital inputs, digital outputs, and accumulators. All 64 can be configured for the digital inputs and outputs. Ten of them can be configured for accumulators. Optional expansion board hardware is required to implement these auxiliary inputs and outputs.

The hardware design of the SAM PCP Controller is modular in concept to allow auxiliary I/O circuit boards to be developed as customer applications arise. An auxiliary expansion board (Part No. 520.5003) is included in the SAM PCP Controller to provide eight analog inputs and two analog outputs. Three of the analog inputs (AI1, AI3, and AI6) are hard-coded for use by the PCP control algorithm. The PCP control algorithm will not work properly if these three inputs are programmed from the default values. The other five analog inputs are available to monitor other wellhead process variables.



SAM 3/3/3/1/1

Four points available on the motherboard can be configured for the digital input/output points or for accumulators. Optional expansion boards can be used to provide other points.

The SAM PCP Controller uses a “virtual I/O” concept that allows you to program any hardware point as any logical input/output point. During the initializing process, the SAM PCP Controller firmware reads the expansion port to identify which expansion boards are installed. Expansion board address numbers, and in many cases the available range of inputs/outputs, are hardware-configured by jumpers on the expansion board.

All inputs and outputs are configured through the options available on the AUX I/O Configuration Menu screen (Figure 8-18). To display this screen, select 3. AUX I/O from the Auxiliary Functions Menu screen.

Figure 8-18. AUX I/O Configuration Menu Screen

8.10.1 Configuring Auxiliary Analog Inputs Analog inputs are configured through the AUX Analog Input Configuration programming screen (Figure 8-19). To display this screen, select 1. AUX ANALOG INPUT CONFIGURATION from the AUX I/O Configuration Menu screen.



Figure 8-19. AUX Analog Input Configuration Programming Screen

The top portion of this screen lists all 32 of the potentially available “logical” analog input points. The SAM PCP Controller must be told which physical input is associated with that “logical” or virtual input point. After the input is selected, the Setup portion of the screen can be used to define the logical points.

Note: The current operating status of analog inputs is available on a SAM status screen. For information about this screen, see section 9, “Status Screens.”


Board #

Enter the physical board number as set by the jumpers on the board. The motherboard is always designated as Board #0.

Channel #

Enter the physical terminal designation on the expansion board to which the transmitter is connected.

Units

Specify the engineering units for device being measured.



Range

Specify one of the following input ranges that the SAM PCP Controller is to expect from the process transducer:

• 1 — 5V

• 0 — 5V

• 4 — 20ma

• 0 — 20ma

Min. Value

Enter the engineering units for the minimum output level from the transducer/transmitter. This value will typically be zero, but if the transducer has a known offset, the SAM PCP Controller is able to compensate if the correct value is entered in this field.

Max. Value

Enter the full scale engineering value for the maximum output from the transducer.

Logging

This is not a selectable item.

Alarms and Alerts

The SAM PCP Controller can set flags for the following analog input conditions if limit setpoints are programmed and the alarm status is enabled:

• Low (Alert)

• Low (Alarm)

• High (Alert)

• High (Alarm)

Low and high alert and alarm setpoints should be entered in Engineering units.

Analog input alarms can be used as Logic Expression inputs to control wellsite functions.

Low and High Delay

Specify the delay time before the alarm is declared.



Alarm Status

Be sure to enable alarm status if this feature is to be used.

Capability and Current Readings

The Capability and Current Readings portions of the programming screen are read only.

• Capability is a report about what the SAM PCP Controller reads during the initialization process regarding the hardware capabilities of the expansion board.

• Current reading indicates the present value of that input.

Engineering Value

Indicates the present value of that input expressed in engineering units.

Procedure Follow the steps below to configure analog inputs.



2. Select 3. AUXILIARY FUNCTIONS to display the Auxiliary Function Config Menu screen.

3. Select 1. AUX I/O to display the AUX I/O Configuration Menu screen.

4. Select 1. AUX ANALOG INPUT CONFIGURATION to display the AUX Analog Input Configuration programming screen.

The field for AI 1 highlights in the top portion of the screen.

5. Press <←>, <→>, <↑>, and <↓> to highlight the analog input (AI) you want to configure, and then press <ENTER> to move into the Setup portion of this screen.

The Board # field highlights.



SAM 3/3/3/1/2

6. Press <↑> and <↓> to highlight the data field you want to edit, and then do one of the following:




7. Repeat step 6 for each data field you want to edit.

8. When you are finished configuring the analog input, press <EXIT> to save your settings and return to the analog input selection portion of the screen to configure another analog input.

9. Repeat steps 5 through 8 for each analog input you want to configure.

10. When you are finished configuring analog inputs, do one of the following.

• Press <EXIT> twice to return to the AUX I/O Configuration Menu screen.


The analog input values are saved.

8.10.2 Configuring Auxiliary Analog Outputs Analog outputs are configured through the AUX Analog Output Configuration programming screen (Figure 8-20). To display this screen, select 2. AUX ANALOG OUTPUT CONFIGURATION from the AUX I/O Configuration Menu screen.



Figure 8-20. AUX Analog Output Configuration Programming Screen

The SAM PCP application firmware supports only analog output number 1 (AO 1). The following programming information is provided for informational purposes only. Default settings for analog outputs should only be changed by a qualified Lufkin Automation technician.

The top portion of this screen lists all eight of the potentially available “logical” analog output points. The SAM PCP Controller must be told which physical output is associated with that “logical” or virtual output point. After the output is selected, the Setup portion of the screen can be used to define the logical points.

Note: The current operating status of analog outputs is available on a SAM status screen. For information about this screen, see section 9, “Status Screens.”


Board #




Channel #


Units

Specify the engineering units for the device being controlled.

Range

Specify one of the following output ranges that the SAM PCP Controller is to use:

• 0 — 5V

• 0 — 10V

• 4 — 20ma DC

Min. Value

Enter the engineering units that you desire to display on the Aux I/O Status screen when the analog output is set for zero.

Max. Value

Enter the full-scale engineering value to be displayed on the Aux I/O Status screen for the maximum analog output.

Note: Min and Max scaling values are used for the status display only.

Override Val

Specify the value to output through the analog output if the override feature is enabled. When override is enabled, the application has no control over the analog output.

Override

Enable or disable the override feature.

Volt Range (Capability)

Describes the minimum and maximum (range) of the voltage signal that can be output from the channel for the analog output selected.

Resolution

Indicates the number of bits (resolution) that make up a full scale signal for the analog output selected.



Raw (Current Readings)

Describes the current reading in an unscaled format. This ranges from zero to 23 bits of resolution.

Voltage (Current Readings)

Displays the current voltage being output from the channel.

Procedure Follow the steps below to configure analog outputs.





4. Select 2. AUX ANALOG OUTPUT CONFIGURATION to display the AUX Analog Output Configuration programming screen.

The field for AO 1 highlights in the top portion of the screen.

5. Press <←>, <→>, <↑>, and <↓> to highlight the logical point of interest (AO) and then press <ENTER> to move into the Setup portion of this screen.







SAM 3/3/3/1/3



8. When you are finished configuring the analog output, press <EXIT> to save your settings and return to the analog output selection portion of the screen to configure another analog input.

9. Repeat steps 5 through 8 for each analog output you want to configure.

10. When you are finished configuring analog outputs, do one of the following.



The analog output values are saved.

8.10.3 Configuring Auxiliary Digital Inputs and Outputs

Digital inputs and outputs are configured through a Digital Configuration programming screen similar to Figure 7-22. To display this screen, select 3. AUX DIGITAL I/O CONFIGURATION from the AUX I/O Configuration Menu screen.

Figure 7-22. Digital Configuration Programming Screen



The top portion of this screen lists all potentially available “logical” digital input/output points. The SAM PCP Controller must be told which physical input/output is associated with that “logical” or virtual input/output point. After the input/output is selected, the Setup portion of the screen can be used to define the logical points.

Note: The current operating status of digital inputs is available on a SAM status screen. For information about this screen, see section 9, “Status Screens.”

Field Descriptions Information about each data field is described below.

Board #


Channel #


State Change Delay

Specify the number of seconds that a digital state change must be observed before SAM PCP Controller acknowledges the change.

Input/Output

Specify whether the digital point is for Input or Output.

Alarm State

If the alarm is enabled, the alarm state is the digital state which triggers an alarm.

Alarms Enabled

Tells if the alarming functionality for the digital inputs is enabled.

Procedure Follow the steps below to configure digital inputs and outputs.







4. Select 3. AUX DIGITAL I/O CONFIGURATION to display the Digital Configuration programming screen.

The field for D 01 highlights in the Digital Input or Output (top) portion of the screen.

5. Press <←>, <→>, <↑>, and <↓> to highlight the logical digital point of interest and then press <ENTER> to move into the Setup portion of this screen.







8. When you are finished configuring the digital input or output, press <EXIT> to save your settings and return to the Digital Input or Output selection portion of the screen to configure another analog input.

9. Repeat steps 5 through 8 for each digital input and output you want to configure.

10. When you are finished configuring digital inputs and outputs, do one of the following:



SAM 3/3/3/1/4



The digital inputs and outputs are configured.

8.10.4 Configuring Auxiliary Accumulators Digital inputs can be configured as accumulators. The discrete input points on the SAM PCP Controller are pulled up internally and must be switched down to DC common by a dry contact closure to “accumulate.” The SAM PCP Controller will reliably count contact closures up to a maximum frequency of about 500 HZ. The motherboard inputs are not designed to work with inputs direct from a turbine meter pickup.

One advantage of having accumulator input capability included in the SAM PCP Controller is the ability to monitor the operation of facilities adjacent to a pumped well without having the additional cost of installing a remote terminal unit (RTU) and data telemetry equipment for that facility. For example, produced volume for a well with an ESP can be monitored by the SAM PCP Controller on an adjacent pumped well, and the data collected can be read for both wells with a single telemetry network.

Note: The current operating status of accumulator inputs is available on two SAM status screens. For information about these screens, see section 9, “Status Screens.”

Accumulator Programming The SAM PCP Controller firmware design supports a maximum of 10 accumulator inputs. The motherboard has four auxiliary digital points that can be configured as accumulators. Optional expansion board hardware is required to take advantage of the additional accumulators that the firmware can support. For more information about the expansion board, contact you Lufkin representative.

The SAM PCP Controller uses a “virtual I/O” concept that allows an operator to program any hardware point as any logical input/output point. The virtual I/O for the SAM PCP Controller must be defined using an AUX Accumulator Configuration screen similar to Figure 8-21. To display this screen, select 4. AUX ACCUMULATOR CONFIGURATION from the AUX I/O Configuration Menu screen.



Figure 8-21. AUX Accumulator Configuration Screen

This screen is divided into three portions. The top portion lists all potentially available “virtual” or logical accumulators supported by the firmware. The SAM PCP Controller must be told the physical input point that is to be associated with any given logical/virtual accumulator. After you select an accumulator, the fields in the Setup portion become active for you to define. The Current Reading portion displays the number of pulses counted in the last second. This field only provides information and cannot be edited.


Board #

The motherboard is always board # 0. Board numbers are assigned to expansion boards by setting dip switches on those boards.

Channel #

The table below provides the channel number designations for digital points on the motherboard.

Channel # Physical Marking1 DIO5 (TB5-9) 2 DIO6 (TB5-11) 3 DIO7 (TB5-13) 4 DIO8 (TB5-15)



A DC common terminal is provided next to each digital input terminal so you can conveniently terminate the second lead from the dry contact input.

Units

The SAM PCP Controller offers approximately 29 options for the unit of measurement to be associated with each auxiliary input. The units selected only displays on the status screen of the SAM PCP Controller local LED display. It is logically related to the PPM field below, but the unit selected does not impact the actual scaling of the accumulator input.

PPM

Pulses per unit of measure (PPM) is an integer that programs the SAM PCP Controller to scale this given number of pulses counted at the defined accumulator input point as a single Unit. The range is 1 – 999,999.

Rate Interval

User-defined sampling period, in minutes. The range is 0 to 1440 minutes. As an example, if a value of 8 is programmed, a 24-hour rate will be calculated based on the number of pulses accumulated during the most recent eight-minute period. The formula for this example of a rate interval of 8 minutes is as follows:

minutes8 minutes1440

PPMminutes8 last forpulses of #Rate ×=

User Defined Accumulator Period

The SAM PCP Controller will accumulate a total for this user-defined number of days. The range is 1 to 365 days. At the end of the user-defined period, the accumulated value for that period is saved in a “Previous User-defined Accumulator” register in the memory map and then the accumulator is cleared to start the accumulation for the next user-defined period. In addition to the User Defined Accumulator Period, the SAM PCP Controller also maintains a 60-day record of the totals accumulated for the each of the previous sixty 24-hour days specified by Gauge Off Time.

Reset Total Accu

Press <0> and <1> to reset the total accumulated value since the last reset of this value.

A message displays to inform you that the value was cleared.



Reset Today’s Accum

Press <0> and <2> to reset the total accumulated value since Gauge Off Time.


Reset User Define Accum

Press <0> and <3> to reset the user-defined accumulated value, which normally is reset at the rate interval.


Number of Pulses/Sec

Displays the actual number of pulses read for the second that just expired.

Procedure Follow the steps below to configure accumulators.





4. Select 4. ACCUMULATOR to display the AUX Accumulator Configuration screen (Figure 8-21).

The field for ACCUM 1 highlights in the top portion of the screen.

5. Press <←>, <→>, <↑>, and <↓> to highlight the accumulator you want to configure, and then press <ENTER> to move into the Setup portion of this screen.








7. Repeat step 6 for each field you want to edit.

8. When you are finished configuring the accumulator, press <EXIT> to save your settings and return to the accumulator selection portion of the screen to configure another accumulator.

9. Repeat steps 5 through 8 for each accumulator you want to configure.

10. When you are finished configuring accumulators, do one of the following:



The values for accumulators are saved.

Procedure for Resetting Accumulator Totals Accumulator totals for the selected accumulator can be reset (cleared) using the AUX Accumulator Configuration screen by pressing the key combinations indicated at the bottom of the Setup portion of the programming screen.



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8.11 Logic Expressions Logic expressions can be written and used to perform actions when a specific well condition occurs at the wellsite.

The SAM PCP Controller can monitor well conditions from analog and/digital input signals from a variety of sensors or transmitters used to monitor conditions. Logic expressions can be programmed in the SAM PCP Controller using these sensor inputs to make decisions, such as

• Starting or stopping the pump

• Turning on one of the extra digital outputs to start a pump

• Closing a valve

• Sounding an alarm

The SAM PCP Controller logic expression feature uses the three fundamental Boolean logic operators AND, OR, and NOT. A maximum of eight logical statements can be programmed to act on a selected digital output when a prescribed combination of input conditions occurs.

Multiple logic expressions can be chained so that the result of one logic expression of higher priority can be used as an input in another logic expression of lower priority. Logic expression priority is based on the line/row number. That is, logic expression 1 has a higher priority than logic expression 2.

In order to use the logic expression function, it is necessary to

1. Configure the auxiliary analog inputs and/or digital inputs/outputs ahead of time so that they can be included in the logic expression (see “Configuring Auxiliary Analog Inputs on page 8-37 and “Configuring Auxiliary Digital Inputs and Outputs” on page 8-45)

2. Enable the logic expression function

3. Program each logic expression needed

4. Program the type of action desired if the condition specified by the logic expression occurs (proves true)

After a logic expression (complete with the desired action) is programmed and enabled, its function can be disabled when necessary for operational reasons.



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Note: A Clear Logic Expression State option is included so that a latched output can be cleared or reset. See page 8-65 for more information.

All logic expression enabling, programming, clearing, and enabling/disabling features are performed using the options available on the Logic Expression Configuration Menu screen (Figure 8-22). To display this menu, select 2. LOGIC EXPRESSION from the Auxiliary Function Config Menu screen.

Figure 8-22. Logic Expression Configuration Menu

Note: Options 1 through 3 are not accessible when the Logic Expression feature is “disabled.” For information about enabling logic expressions, see “Enabling and Disabling Logic Expressions” on page 8-67.

8.11.1 Programming a Logic Expression A logic expression must be written (programmed) to define the condition that triggers an action when the expression is proven true. An expression is proven true when the condition defined by the expression occurs.



Note: The logic expression feature must be enabled before a logic expression can be programmed. When it is disabled, the message NOT REQUIRED displays. For information about enabling logic expressions, see “Enabling and Disabling Logic Expressions” on page 8-67.

You can write eight logic expressions to define eight unique conditions. The Program Logic Expression programming screen (similar to Figure 8-23) has a row for each logic expressions that can be programmed. To display this screen, select 1. PROGRAM LOGIC EXPRESSION from the Logic Expression Configuration Menu screen

Figure 8-23. Program Logic Expression Programming Screen

All logic expressions already programmed are displayed (row 1 is an example). Any row not having a logic expression programmed displays the message No Logic Expression.

Note: Auxiliary analog inputs and digital inputs/outputs must be configured before they can be included in a logic expression. For help programming auxiliary inputs and outputs, see “Auxiliary I/O Configuration” on page 8-36.



Entry code options display at the bottom of the screen when you press <EDIT> to program the logic expression. . These entry code options define the number keys you press for selecting various inputs and outputs, logical operators, and alarms. The three entry code groups are described in the subsection below. You can scroll through the entry code groups by pressing <NEXT>. As you write an expression, the SAM PCP Controller automatically presents the most likely entry code group for the next character entry.

After you complete an expression and press <ENTER>, the SAM PCP Controller automatically checks the expression to verify that the expression is valid. VALID displays to the right of the expression row if it is valid. If the expression is invalid, a syntax error message displays prompting you to correct the invalid parameter. For a list of the error messages possible and their definitions, see “Syntax Error Messages” on page 8-58.

Entry Code Groups Three entry code groups are available:

• Channel selection

• I/O and Logic Selection

• Alarm and Special Selection

Channel Selection Channel selection entry codes correspond one-to-one to the actual numbers for the desired channel. Channel number selection must always be two digits (01, 09, 23, etc.). Channel numbers are the virtual, or logical, input/output point numbers configured as described in “Configuring Auxiliary Analog Inputs” on page 8-37 and “Configuring Auxiliary Analog Outputs” on page 8-41.

I/O and Logic Selection The table below describes the codes that can be used for input/output (I/O) and logic selection.



Key No. Selection Made Using this Key 1 “M” output point = one of the four dedicated discrete points on TB5

on the motherboard, and are labeled: • M01 = DIO1 (TB5-1) Error Lamp • M02 = DIO2 (TB5-3) Motor Control • M03 = DIO3 (TB5-5) Start Alert

• M04 = DIO4 (TB5-7) Fault Output 2 “D” discrete point = virtual digital input or output 3 “A” analog input 4 “C” accumulator input 5 “ [ “ = Opening bracket for nesting logical operations 6 “ ] ” = Closing bracket for nesting logical operations 7 “ * ” = Logical AND operator 8 “ + ” = Logical OR operator 9 “ ‘ “ = Logical NOT operator 0 “ X “ =End of logical expression

Alarm and Special Section The table below describes the codes that can be used for alarm and special selection.

Key No. Selection Made Using this Key 1 H = Analog input in High Alarm state. Analog input alert states

cannot be used as logic expression inputs. 2 L = Analog input in Low Alarm state. Analog input alert states

cannot be used as logic expression inputs. 3 Erase Logic Expression. This selection erases the logic expression

highlighted by the cursor. 4 Erase All Logic Expression. This selection erases all programmed

logic expressions. 5 Character definition. This selection presents a screen that defines

characters used in writing logic expressions.

Syntax and Programming Rules A list of the syntax and programming rules that must be followed are provided below.

• Maximum number of characters per expression is 40.

• Each expression must contain the X character to signify the end of the expression.

• Spaces between characters before X character are not allowed.



• No adjacent operators are allowed except + or *.

• No adjacent parenthesis of different types; that is, “) (”.

• Dxx or Mxx (with xx representing the channel number) are the only parameters/characters allowed on the left side of the “=” character.

• AI, DI, and DO that have been configured as auxiliary inputs/outputs can be assigned.

• Logical “NOT” must always be at the end of the IO block. For example, A01L′ is valid and ′A01L is invalid.

• Low and High flags can only be assigned to analog inputs with High/Low flag enabled.

• Always write expressions in consecutive number to avoid priority conflict. Do not skip a line.

• Any character after X is invalid.

Syntax Error Messages The table below defines the logic expressions error messages that may appear when an invalid logic expression is written.

Error Code No Error Code Definition 00 None 01 End of expression not defined 02 Multiple terminating characters 03 First character not an output 04 Wrong equal sign location 05 Wrong motherboard digital channel 06 Wrong digital channel 07 Wrong analog channel 08 Wrong accumulator channel 09 Wrong analog alarm 10 Wrong accumulator alarm 11 Mismatching parenthesis 12 Start with OR 13 Start with AND 14 Start with NOT 15 Start with close parenthesis 16 End with OR



Error Code No Error Code Definition 17 End with And 18 End with open parenthesis 19 Illegal space 20 Or out of order 21 And out of order 22 Open parenthesis out of order 23 Close parenthesis out of order 24 Not out of order 25 Input out of order 26 Analog not configured 27 Analog alarms not enabled 28 Digital not configured as output 29 Invalid main board number 30 Accumulator not configured 31 Digital not configured

Logic Expression Example An operator wants to monitor flow line pressure and be able to shut down the pumping unit if the pressure falls too low or rises too high. A leak detector is also connected to shut down the pumping unit in the event of a stuffing box leak.

A pressure transmitter is installed on the flow line and connected to the SAM PCP Controller as auxiliary analog input A01. High and low alarm levels are configured and enabled.

A float switch type of stuffing box leak detector is connected to the SAM PCP Controller and configured as auxiliary digital input D01. The switch contacts are normally closed and open when fluid accumulates from a leak.

The logic expression required is M02=A01H+A01L+D01X.

The keystrokes sequence used to program this expression is provided below.

1. <EDIT>

2. <1> (display M)

3. <0>

4. <2>



5. <3> (display A)

6. <0>

7. <1>

8. <1> (display H for high)

9. <8> (display + for logical OR)

10. <3> (display A)

11. <0>

12. <1>

13. <2> (display L for low)

14. <8> (display + for logical OR)

15. <2> (display D)

16. <0>

17. <1>

18. <0> (display X for end of expression)

19. <ENTER>

20. Press <EXIT> to program the desired action.

Procedure Follow the steps below to write a logic expression. This procedure can also be used to modify an existing expression.



2. Select 3. AUXILIARY FUNCTIONS and then select 2. LOGIC EXPRESSION to display the Logic Expression Configuration Menu screen.



3. Select 1. PROGRAM LOGIC EXPRESSION to display the Program Logic Expression programming screen (Figure 8-23).

Note: If the logic expression feature is not enabled, enable it now.

4. Highlight the row you want used for the logic expression and press <EDIT>. The first character at the left hand end of the row highlights.

5. Use the keypad to enter the characters needed by referring to the entry code group at the bottom of the screen.

The first three characters of the expression must define the digital output on which you want to act.

a. The first character must therefore be “M” (motherboard output point) or “D” (virtual discrete point).

b. The next two characters are the channel number. Channel numbers must be two digits. For example, virtual channel 1 is entered as 01.

After the digital output to use is defined, the SAM PCP Controller automatically adds the “=” sign.

6. Enter the characters to write the desired logic expression, keeping in mind the syntax and programming rules discussed on page 8-57.

7. Enter “X” as the final character on the line to signify the end of the expression.

8. After the logic expression row reads as desired, press <ENTER>.

The SAM PCP Controller automatically checks the logic expression to verify that it is valid.

• If the expression is valid, VALID displays to the right of the row.

• If the expression is invalid, an error message displays to prompt the necessary action that must be taken to make it valid. A list of possible syntax error messages is defined in the table in “Syntax Error Messages” beginning on page 8-58.

9. Press <EXIT>.

You can now use the Program Logic Expression Action option to program the desired action for the logic expression.



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8.11.2 Programming a Logic Expression Action After you write a logic expression, you must program an action for the expression. A Program Logic Expression Action programming screen similar to Figure 8-24 is used to write actions. To display this screen, select 2. PROGRAM LOGIC EXPRESSION ACTION from the Logic Expression Configuration Menu screen.

Note: The logic expression feature must be enabled before a logic expression action can be programmed. When it is disabled, the message NOT REQUIRED displays. For information about enabling logic expressions, see “Enabling and Disabling Logic Expressions” on page 8-67.

Figure 8-24. Program Logic Expression Action Screen

Column Descriptions Information about each column is provided below.

Action

An action must be programmed for each logic expression. The available options for a program action are linked to the type of digital output to be acted upon.

A logic expression written to act on the motor control output M02 has the following action options available:



• START — When the logic expression proves true, start the pumping unit. Pump until pump off is detected, or one of the other control limits is violated, such as peak torque allowed.

• MALF — When the logic expression proves true, stop the pumping unit. Restart it after the programmed down time for the number of successive retries. If the consecutive Malf. Allowed count limit is reached, shut down the unit in a Malfunction Logic state. Operator intervention is required to clear and restart the unit.

• STOP — When the logic expression proves true, stop the unit in normal downtime. The unit automatically starts after the programmed downtime expires.

A logic expression written to act on a general-purpose digital output has the following action options available:

• FLAG — When the logic expression proves true, set a flag to alert the operator. No control action is taken.

• TEMP — When the logic expression proves true, close the programmed digital output. Continue to evaluate the logic expression and hold output on/closed as long as the logic expression proves true. When the logic expression proves false, open the output.

• LATCH — When the logic expression proves true, close the programmed digital output and hold it closed until an operator clears the latch.

To clear a latched output, go to the Logic Expression Configuration menu (Figure 8-22) and select 3. CLEAR CURRENT LOGIC EXPR STATE.

• TIMER — When the logic expression proves true, close the programmed digital output and hold it closed for the programmed Timer Period. When the timer period times out, open the digital output and re-evaluate the logic expression.



Consec. Malf Allowed or Timer Period

Accessibility to this column depends on the action programmed for the logic expression.

• If the programmed action is MALF, edit this column to program the desired number of consecutive malfunctions allowed, which is the number of retries allowed before the pumping unit is shut down in a Malfunction well state. Operator intervention is required to reset the unit.

• If the programmed action is TIMER, edit this column to program the desired time in minutes to hold closed the designated digital output.

Logic Time Delay

This is a delay before executing the programmed action when a logic expression proves true. This time delay is in addition to any programmed time delays for the analog alarms and/or digital inputs that are included in a logic expression. Time delays are programmed from the auxiliary input configuration screens discussed in “Configuring Auxiliary Analog Inputs” on page 8-37 and “Configuring Auxiliary Digital Inputs and Outputs” on page 8-45.

Procedure Follow the steps below to program a logic expression action.



2. Select 3. AUXILIARY FUNCTIONS and then select 2.LOGIC EXPRESSION to display the Logic Expression Configuration Menu screen.

3. Select 2. PROGRAM LOGIC EXPRESSION ACTION to display the Program Logic Expression Action programming screen.

4. Highlight the Action column field in the row for the logic expression to be programmed and press <EDIT> to enter the edit mode.

5. Press <↑> and <↓> to view the options available.



SAM 3/3/3/2/3

6. Press <ENTER> when the desired option displays.

7. Use arrow keys to move cursor to the next field to be programmed (for example, Logic Time Delay), and then press <EDIT> to enter the edit mode.

8. Use the number keys to enter the desired value and then press <ENTER> to select the entered value and end the edit mode for that field.

9. Repeat steps 7 and 8 until all fields are programmed as desired.

10. After all the fields on this screen are programmed as desired, do either of the following:

• Press <EXIT> to return to the Logic Expression Configuration Menu screen.


The logic expression program is saved.

8.11.3 Clearing the Logic Expression State If a logic expression is programmed with a latch action, you can reset the logic expression and clear the latched output by using the Clear Current Logic Expr State screen (similar to Figure 8-25). To display this screen, select 3. CLEAR CURRENT LOGIC EXPR STATE from the Logic Expression Configuration Menu screen.

Note: The logic expression feature must be enabled before a logic expression state can be cleared. When it is disabled, the message NOT REQUIRED displays. For information about enabling a logic expression, see “Enabling and Disabling Logic Expressions” on page 8-67.



Figure 8-25. Clear Current Logic Expr State Screen

Procedure Follow the steps below to clear the logic expression state.



2. Select 3. AUXILIARY FUNCTIONS and then select 2.LOGIC EXPRESSION.

3. Select 3.CLEAR CURRENT LOGIC EXPR STATE to display the Clear Current Logic Expr State screen.

4. Press <↑> and <↓> to highlight the logic expression to be cleared, and then press <ENTER>. A pop up window appears to acknowledge that the logic state is cleared.

Notice that row 9 offers the option to clear all logic expression states.



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5. When finished clearing the action, do either of the following:

• Press <EXIT> to return to the Logic Expression Configuration Menu screen.


8.11.4 Enabling and Disabling Logic Expressions The logic expression feature must be enabled before a logic expression can be programmed. If the logic expression feature is not enabled, a “Not Required” response displays when you try to program an expression.

This toggle feature allows you to enable and disable these expressions. After a logic expression and action are programmed, you can temporarily disable the logic expression (complete with the desired action), if necessary, for operational reasons. The programmed expression and action are retained in memory so it is not necessary to re-program the expression when you are ready to again enable the logic expression.

The present enable/disable status can be easily determined by looking on the Logic Expression Configuration menu below option 4. It reads either LOGIC EXPRESSION – ENABLE if logic expressions are presently disabled or LOGIC EXPRESSION – DISABLE if they are enabled.

Procedure Follow the steps below to enable or disable the logic expression feature.


2. Select 3. AUXILIARY FUNCTIONS and then select 2. LOGIC EXPRESSION to display the Logic Expression Configuration Menu screen.

3. Select 4. ENABLE/DISABLE LOGIC EXPRESSION.

A message appears asking you to confirm that you want to enable or disable the log expression.

• If the logic expression feature is already disabled, ENABLE LOGIC EXPR? displays.



SAM 3/3/3/3

• If the logic expression feature is already enabled, DISABLE LOGIC EXPR? displays.

4. Press <←> and <→> to highlight the YES response and then press <ENTER>.

Below option 4, you are informed whether the Logic Expression feature is enabled or disabled.

After the Logic Expression feature is enabled, the other logic expression features can be used.

8.12 AGA 3 Parameter Configuration The SAM PCP Controller can perform AGA 3 gas flow rate calculations and accumulate gas production volume data. AGA-3 is calculated once a second, and NX-19 supercompressibility is calculated once a minute and every time setup parameters are modified.

For flange tap measurement, the SAM PCP Controller implements the AGA-3 1992 Factors method of gas flow calculation. The AGA-2 1985 Pipe Flow Calculation method is used for pipe tap measurement and NX-19 calculation methods are used for the supercompressibility factor. For more detailed explanations about the parameters available for AGA 3 configuration, see Appendix B, “AGA 3 Definitions.”

In order to perform these operations, process transmitters must be installed and connected to available analog inputs on the SAM PCP Controller expansion board to monitor line pressure and pressure drop (DeltaP) across an orifice plate. The DeltaP input is required. Line pressure is optional.

You must configure the analog channels that will be used by the AGA algorithm to calculate gas flow. The SAM PCP Controller can use analog channel inputs for the following three gas meter run parameters.

• Differential pressure

• Static (gauge) pressure

• Flowing temperature



The SAM PCP controller requires that the differential pressure measurement be provided using an analog input channel. Static pressure and flowing temperatures can either be entered as constant values by the user or supplied through analog input channels. For details about how to configure analog channels, see “Configuring Auxiliary Analog Inputs” on page 8-37.

The best method for you to use to configure all necessary parameters for AGA calculations is to perform all operations in the following order:

1. Configure analog input channels (page 8-37)

2. Configure AGA 3 parameters (8-70)

3. Configure NX-19 parameters (8-73)

4. Configure temperature and pressure (8-75)

The first three options available under the AGA Configuration menu (Figure 8-26) are used to configure AGA 3, NX-19, and temperature and pressure. To display this menu, select 3. AGA from the Auxiliary Function Config Menu screen.

Figure 8-26. AGA Configuration Menu Screen



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Before you configure parameters, you must use the fourth option to enable the AGA calculation operations. If they are not enabled and you try to select any of the first three options, the message “NOT REQUIRED” displays and you remain at the AGA Configuration Menu screen. To enable the operations, select 4. ENABLE/DISABLE AGA CALCULATIONS. For more information about this operation, see “Enabling and Disabling AGA 3 Calculations” on page 8-78.

8.12.1 Configuring AGA 3 Parameters Use the AGA 3 Design Parameters screen (Figure 8-27) to configure AGA parameters. To display this screen, select 1. CONFIGURE AGA 3 PARAMS from the AGA Configuration Menu screen.

Figure 8-27. AGA 3 Design Parameters Screen

Note: Before you can configure parameters, you must enable the AGA 3 calculation operations. To enable them, select 4. ENABLE/DISABLE AGA CALCULATIONS. For more information about this operation, see “Enabling and Disabling AGA 3 Calculations” on page 8-78.




TAP TYPE

Specify the type of pressure tap. The choices available are:

• FLANGE

• PIPE

FLANGE is the default value.

TAP LOCATION

Specify the location of pressure tap. The choices available are:

• UPSTREAM

• DOWNSTREAM

UPSTREAM is the default value.

ORIFICE MATERIAL

Specify the material used to construct the orifice. The choices available are:

• STAINLESS

• MONEL

• CARBON

STAINLESS is the default value.

ORIFICE DIAMETER

Specify the measured diameter of the orifice in inches. The default value is 4.000 in.

PIPE MATERIAL

Specify the material used to construct the pipe. The choices available are:

• STAINLESS

• MONEL

• CARBON



STAINLESS is the default value.

PIPE DIAMETER

Specify the measured diameter of the pipe in inches. The default value is 8.07 in.

MEASUREMENT TEMP

Specify the temperature at which the orifice diameter was measured. The default value is 68° F.

SPECIFIC GRAVITY

Specify the gravity of the gas. The default value is 0.60.

VISCOSITY

Specify the viscosity of the gas. The default value is 0.01027 cP.

ISENTROPIC EXPONENT

Specify the ratio of specific heat at constant pressure to specific heat at constant volume (cp/cv) for the given gas composition. The default value is 1.30000.

CALIBRATION FACTORS

Specify a value to calibrate the meter. Associated factors are Fam, Fwt, Fpwl, Fhgm, and Fhgt. The default value is 1.00.

COMPRESSIBLE FLUID

• Specify whether the fluid is compressible. This answer determines if the expansion factor Y is calculated. NO is the default value.

Procedure Follow the steps below to configure AGA 3 design parameters.



2. Select 3. AUXILIARY FUNCTIONS and then select 3. AGA to display the AGA Configuration Menu screen.



SAM 3/3/3/3/2

3. Select 1. CONFIGURE AGA 3 PARAMS to display the AGA 3 Design Parameters programming screen.

The Tap Type field highlights.






• Press <EXIT> to return to the AGA Configuration Menu screen.


The AGA 3 configuration values are saved.

8.12.2 Configuring NX-19 Design Parameters Use the NX-19 Design Parameters programming screen (Figure 8-28) to configure NX-19 parameters. Make the appropriate selections and enter the correct data in each field. Default values are provided for all data fields, but for best results, thought needs to be given to the data in each and every field. To display this screen, select 2. CONFIGURE NX-19 PARAMS from the AGA Configuration Menu screen.



Figure 8-28. Configure NX-19 Parameters Programming Screen



SPECIFIC GRAVITY

Specify the specific gravity of the gas, which is the same value as the specific gravity on the AGA3 Design Parameters screen (Figure 8-27 on page 8-70). The default value is 0.60.

CO2 MOLE FRACTION

Specify the mole fraction of CO2. Note that 5.93% should be entered as 0.05930. The default value is 0.00000.

N2 MOLE FRACTION

Specify the mole fraction of N2. Note that 5.93% should be entered as 0.05930. The default value is 0.00000.



SAM 3/3/3/3/3

Procedure Follow the steps below to configure NX-19 design parameters.



2. Select 3. AUXILIARY FUNCTIONS and then select 3. AGA to display the AGA Configuration menu.

3. Select 2. CONFIGURE NX-19 PARAMS to display the NX-19 Design Parameters programming screen.

The Specific Gravity field highlights.








The NX-19 configuration settings are saved.

8.12.3 Configuring Temperature and Pressure Use the Temperature/Pressure Configuration programming screen (Figure 8-29) to configure temperature and pressure values required for AGA 3 gas calculations. Make the appropriate selections and enter the correct data in each field.

Default values are provided for all data fields, but for best results, thought needs to be given to the data specified in every field. To display this



screen, select 3. CONFIGURE TEMPERATURE AND PRESSURE from the AGA Configuration Menu screen.

Figure 8-29. Temperature/Pressure Configuration Programming Screen



BASE PRESSURE

Specify the base pressure for the volume flow rate calculation. The default value is 14.73 PSIA.

BASE TEMPERATURE

Specify the base temperature for volume flow rate calculation. The default value is 60º F.

ADJ PRESSURE

Specify the pressure to add to static “gauge” pressure to get “absolute” static pressure. The default value is 14.73 PSIA.



DIFFERENTIAL PRESSURE

Select from available analog input channels. Analog channels must be setup using the AUX Analog Input Configuration Programming screen (Figure 8-19 on page 8-38). The default value is AI1.

STATIC PRESSURE

Specify the analog input channel to be assigned for static pressure, or enter a user-defined value. Analog channels must be set up using the AUX Analog Input Configuration Programming screen. The default value is AI02.

FLOWING TEMPERATURE

Specify the analog input channel to be assigned for flowing pressure, or enter a user-defined value. Analog channels must be set up using the AUX Analog Input Configuration Programming screen. The default value is CONST 060.00 F.

Procedure Follow the steps below to enter the temperature and pressure configuration parameters.



2. Select 3. AUXILIARY FUNCTIONS and then select 3. AGA to display the AGA Configuration Menu screen.

3. Select 3. CONFIGURE TEMPERATURE AND PRESSURE to display the Temperature/Pressure Configuration programming screen.

The Base Pressure field highlights.





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The temperature and pressure configuration parameters are saved.

8.12.4 Enabling and Disabling AGA 3 Calculations The Enable/Disable AGA Calculations option on the AGA Configuration menu (Figure 8-26) is a toggle option for turning on and off the AGA 3 calculation feature. The present on/off state of AGA 3 calculations is displayed below option 4. After the AGA 3 calculations feature is enabled, the other AGA 3 calculation features can be used.

Below option 4, you can see whether the AGA Calculations feature is presently enabled or disabled.

Procedure Follow the steps below to enable and disable the AGA 3 calculations feature.



2. Select 3. AUXILIARY FUNCTIONS and then select 3. AGA to display the AGA Configuration menu.

3. Select 4. ENABLE/DISABLE AGA CALCULATIONS.

A message appears asking you to confirm that you want to enable or disable the AGA 3 calculations.



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SAM 3/3/3/4

• If the logic expression feature is already disabled, ENABLE AGA CALCS? displays.

• If the logic expression feature is already enabled, DISABLE AGA CALCS? displays.

4. Press <←> and <→> to highlight the response you want, and then press <ENTER>.

Your selection immediately goes into affect and is displayed below option 4.

8.13 Custody Transfer If the SAM PCP Controller has EFM (electronic flow measurement or electronic flow metering) capabilities, you can access the Custody Transfer Main Menu screen. Custody transfer operations are where you program configuration parameters for transmitters, gas mixture, well stream variables, low flow cutoff, pipe diameters, and plate sizes. These menu options should be used as an alternative method for configuring EFM parameters.

An easier method you can use to perform custody transfer is to use the SAM EFM Utility software available from Lufkin Automation. This interface can be installed on a laptop computer connected to the communications port on the SAM PCP Controller. All custody transfer operations can be password-protected so that users can only have access to these operations and no other SAM PCP Controller programming privileges, if desired. For more information about the SAM EFM Utility software, refer to the SAM EFM Utility Software User Manual (099.5070) or contact your Lufkin Automation representative.

8.14 Register Configuration The SAM PCP Controller has three features that you can use to work with registers. They are:

• Configuring eight register alarms based on any of the measured or calculated values in the controller memory files

• Configuring ten historical plots from any physical input or calculated value in the SAM PCP Controller



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• Configuring ten register calculations that are a combination of status values from different register logs to obtain new values that can be used for monitoring and creating register alarms

Each feature is a separate option available under the Register Function Config Menu screen (Figure 8-30). To display this menu, select 4. REGISTER FUNCTIONS from the SAM Configuration Menu screen.

Figure 8-30. Register Function Config Menu Screen

8.14.1 Configuring a Register Alarm The SAM PCP Controller has a register alarm feature that allows you to program for actions based on any of the measured or calculated values in the controller memory files. You can configure a total of eight register alarms. This feature complements the logic expression capabilities to give the SAM PCP Controller some flexibility to perform functions other than PCP control. These features might be useful when a wellsite is near a pump station and you want to monitor and control other process variables, such as tank level, tank pressure, by-pass valve activity, etc.

Register alarms are configured using the Register Alarm Config screen similar to Figure 8-31. To display this screen, select 1. REGISTER ALARM CONFIG from the Register Function Config Menu screen.



Figure 8-31. Register Alarm Config Screen

Note: You must configure the digital output you want to control before you can configure the register alarm. For information about configuring digital outputs, see “Configuring Auxiliary Digital Inputs and Outputs” on page 8-45.


Register Number

Select the virtual register number you want to assign to a register alarm.

Reg Address

Specify the actual register address you want to use for the selected virtual alarm register. Addresses are listed in the PCP register map. Contact your Lufkin Automation representative to obtain the latest register map.

Reg Type

Specify the type of register you want to use. Choices are WORD (16-bit integer), FLOAT (32-bit floating point value), and LONG (32-bit integer value).



HIGH Alarm DO Control Channel

Specify the digital output channel that the register alarm is to control when the action is required for the High Alarm Limit violation.

Action Mode

Specify the action the digital output channel is to perform when the action is required for the High Alarm Limit violation. Choices are DYNAMIC, LATCHED, TIMER, and PULSE.

High Alert Limit

Specify the alert setpoint value that must be exceeded for the SAM PCP Controller to consider the monitored value a violation.

High Alarm Limit

Specify the high point you want used as the violation setpoint to trigger the alarm.

High Delay Limit

Specify the amount of time, in milliseconds, that the High Alarm Limit value is to exist (delay) before the value is considered a violation.

LOW Alarm DO Control Channel

Specify the digital output channel that the register alarm is to control when the action is required for the Low Alarm Limit violation.

Action Mode

Specify the action the digital output channel is to perform when the action is required for the Low Alarm Limit violation. Choices are DYNAMIC, LATCHED, TIMER, and PULSE.

Low Alert Limit

Specify the alert setpoint value that the present monitored value must fall below for the SAM PCP Controller to consider the monitored value a violation.

Low Alarm Limit

Specify the low point you want used as the violation setpoint to trigger the alarm.

Low Delay Limit

Specify the amount of time, in milliseconds, that the Low Alarm Limit value is to exist (delay) before the value is considered a violation.



SAM 3/3/4/2

Procedure Follow the steps below to configure a register alarm.



2. Select 4. REGISTER FUNCTIONS and then select 1. REGISTER ALARM CONFIG to display the Register Alarm Config screen.

The Register 1 field highlights.

3. Press <↑> and <↓> to select the register you want to configure and then press <ENTER>.

The Reg Address field highlights.

4. Do one of the following to specify values for each remaining field:





• Press <EXIT> to return to the Register Function Config Menu screen.


The configuration settings for the register alarm are saved.

8.14.2 Configuring a Register Log You can configure an historical plot for any of the data in the SAM PCP Controller. Any physical input or calculated value in the SAM PCP Controller memory can be sampled and stored in a buffer for display. Plot resolution is programmable to capture a value as



often as once per minute or only once per day. A total of ten plots can be configured.

Register logs are configured using the Register Logging Config screen similar to Figure 8-32. To display this screen, select 2. REGISTER LOG CONFIGURATION from the Register Function Config Menu screen.

Figure 8-32. Register Logging Config Screen Example

You can display this information as a plot by selecting the Register Log Plots option, which is available under the Historical Data Menu screen. For information about this historical plot, see “Register Log” in section 10, “Historical Data.”


Register Number

Select the virtual register number you want to assign to a register log.

Reg Category

Specify the category of data to be polled. Several categories are available. The category selected displays its own subset of fields that require you to configure additional parameters.

• None — Select this option when you want to cancel a register log already configured. No additional fields display.



• Analog Input Data — Select this option when you want to configure a register log for data acquired from an analog input channel. The following additional fields display:

– Analog Input # — Specify the analog input channel used for the data you want to log.

– Data to Log — Specify whether the analog data is scaled or raw.

• Accumulator Data — Select this option when you want to configure a register log for data acquired from an accumulator input channel. The following additional fields display:

– Accumulator # — Specify the accumulator channel used for the data you want to log.


• Register Data — Select this option when you want to configure a register log for data acquired from a memory register. The following additional fields display:

– Register # — Specify the actual register address used for the data you want to log. Addresses are listed in the PCP register map. Contact your Lufkin Automation representative to obtain the latest register map.

– Register Type — Specify the type of register used for the register address. Choices are WORD (16-bit integer), FLOAT (32-bit floating point value), LONG (32-bit integer value), and COIL.

• Slave Data — Select this option when you want to configure a register log for data acquired from a slave device. For information about slave devices, see “Modbus Master and Slave Device Configuration” on page 8-14

The following additional fields display:



– Device # — Specify the slave device whose data you want to log.


– Register Index — Specify the index of the data point being read from the slave device. This index can be found in the Modbus Master configuration for that particular device. For more information, see “Configuring Slave Device Parameters” on page 8-15.

• AGA Data — Select this option when you want to configure a register log for calculated AGA 3 data. For more information about AGA 3, see “AGA 3 Parameter Configuration” on page 8-68.

One additional field displays.

– AGA Log Data — Specify the type of AGA 3 data being measured. Choices are Flow Rate, Diff. Pressure, Static Pressure, Flowing Temperature, and Supercompressibility.

Sample Mode

Specify whether you want the data logged as an average value during the sample period or you want a value logged once during each sample period. The duration of a sample period is specified with the Sample Rate field.

Sample Rate

Specify how often, in seconds, you want the data sampled.

Logging Enabled

Specify whether you want to start logging the data specified for the register.

• To start the logging process, select YES.



• To prevent the logging process from occurring, select NO. This option is useful when you want to configure the parameters now and then start logging data at a later date, or to turn off the logging process if you need to service the end device configured for the register log.

Procedure Follow the steps below to configure a register log.



2. Select 4. REGISTER FUNCTIONS and then select 2. REGISTER LOG CONFIGURATION to display the Register Logging Config screen.

The REGISTER 1 field highlights.

3. Press <↑> or <↓> to select the virtual register you want used to log the historical data, and then press <ENTER>.

The Reg Category field highlights.

4. Press <EDIT>, press <↑> or <↓> to select the register category type you want, and then press <ENTER>.

For all register category options except None, additional fields display that are specific to your category choice.

5. Do one of the following to specify values for each remaining field (including Sample Mode, Sample Rate, and Logging Enabled):






SAM 3/3/4/3

6. After you are finished specifying values for all fields, save the register log configuration. Highlight the SAVE CONFIGURATION field, and then press <ENTER>.

A Save Configuration message displays for a few seconds to inform you that the data is saved for the register log.

Note: If you exit the Register Logging Config screen without saving the configuration, all parameters values are not saved to the register you selected.


• Press <EXIT> to return to the Register Function Config Menu screen.


The register log configuration settings are saved.

8.14.3 Configuring Register Calculations You can combine status values from different register logs to obtain new values that can be used for monitoring and creating register alarms. You can configure up to ten register calculations.

You can display the calculated results in the Programmable Calculations Status screen. For information about the features this screen has, see “Displaying Register Calculations Status” in section 9, “Status Screens.”

Three screens are used to configure register calculations. The first screen is the Programmable Calculations screen (Figure 8-33), which you use to select a programmable calculation register that is to contain the register calculation. To display this screen, select 3. REGISTER CALCULATIONS CONFIG from the Register Function Config Menu screen.



Figure 8-33. Programmable Calculations Screen

After you select a programmable calculation register in the Programmable Calculations Setup screen, the Programmable Calculation screen displays (Figure 8-34), which is where you combine the status values (referred to as inputs) for your calculation. The configuration process involves specifying an input value, choosing an operation (+, −, ×, ÷), and then selecting a second input value. You can only define two input values and one operation for each calculation register.

Figure 8-34. Programmable Calculation Screen



After you press <ENTER> on the highlighted EDIT field or an input, the Programmable Calculation Input Setup screen (Figure 8-35) displays for you to define the input type you want used in the calculation.

Figure 8-35. Programmable Calculation Input Setup Screen Example

After you define the input and save its configuration, you are returned to the Programmable Calculation screen where you can define the operation you want performed on the inputs. After it is defined, you can define the second input for the calculation using the same methods as you did for the first input. When the calculation is correctly configured, you can return to the Programmable Calculation Setup screen to configure another register calculation.


Reg Category

Specify the category of data to be polled. Several categories are available. The category selected displays its own subset of fields that require you to configure additional parameters.

• None — This option indicates that no data is to be used in the calculation. This option is illogical and would therefore never be selected.



• Analog Input Data — Select this option when you want to use data acquired from an analog input channel as an input to a calculation. The following additional fields display:

– Analog Input # — Specify the analog input channel used for the data you want to use.


• Accumulator Data — Select this option when you want to use data acquired from an accumulator input channel as an input to a calculation. The following additional fields display:

– Accumulator # — Specify the accumulator channel used for the data you want to use.


• Register Data — Select this option when you want to use data acquired from a memory register as an input to a calculation. The following additional fields display:

– Register # — Specify the register address used for the data you want to use in the calculation. Addresses are listed in the PCP register map. Contact your Lufkin Automation representative to obtain the latest register map.


• Slave Data — Select this option when you want to use data acquired from a slave device as an input to a calculation. For information about slave devices, see “Modbus Master and Slave Device Configuration” on page 8-14



The following additional fields display:

– Device # — Specify the slave device whose data you want to log.


– Register Index — Specify the index of the data point being read from the slave device. This index can be found in the Modbus master configuration for that particular device. For more information, see “Configuring Slave Device Parameters” on page 8-15.

• AGA Data — Select this option when you want to use calculated AGA 3 data as an input to a Register Calculation. For more information about AGA 3, see “AGA 3 Parameter Configuration” on page 8-68.


– AGA Log Data — Specify the type of AGA 3 data being measured. Choices are Flow Rate, Diff. Pressure, Static Pressure, Flowing Temperature, and Supercompressibility.

• Constant — A data type of constant is selected to use a constant number as an input to a calculation.


– Value — Specify the constant value to be used as an input to the register calculation.

• Calculator Result — This data type allows the use of the result of another register calculation in the current calculation. This result provides the ability to create longer calculations with a series of single calculations.




– Equation Num — Specify the number of the register calculations from which the result is to be pulled.

Procedure Follow the steps below to configure a register calculation.



2. Select 4. REGISTER FUNCTIONS and then select 3. REGISTER CALCULATIONS CONFIG to display the Programmable Calculations screen.

The PROGRAMMABLE CALCULATION 1 field highlights.

3. Press <↑> or <↓> to select the field you want used to configure the calculation data, and then press <ENTER>.

The Programmable Calculation screen displays with the EDIT field highlighted for Input 1.

4. Press <ENTER>.

The Programmable Calculation Input Setup screen displays with the Reg Category field highlighted.

5. Press <EDIT>, press <↑> or <↓> to select the register category type you want, and then press <ENTER>.

For all register category options except None, additional fields display that are specific to your category choice.







7. After you finish specifying values for all fields, save the configuration. Highlight the SAVE CONFIGURATION field, and then press <ENTER>.

A Save Configuration message displays for a few seconds to inform you that your data is saved for the register log.

8. Press <EXIT> to return to the Programmable Calculation screen.

Note: If you exit the Programmable Calculation Input Setup screen without saving the configuration, all parameters values are not saved for the input.

9. Press <→> to highlight the CHANGE field for Operation.

10. Press <ENTER> to scroll through the four possible operations (+, −, ×, ÷) you can perform.

When the correct operation is selected, press <→> to highlight the EDIT field for Input 2.

11. To configure the register category type for Input 2, repeat steps 4 through 8.


• Press <EXIT> to return to the Programmable Calculations Setup selection screen to configure another register calculation.


8.15 Configuring and Enabling/Disabling HOA



SAM 3/3/5

You can allow the SAM PCP Controller to monitor the status to know if SAM control has been bypassed when the HOA switch is set to Hand. When SAM control is in Hand mode, the SAM PCP Controller ignores input data about pumping activity and makes no control decisions. The pump or downtime decision is made by the operator and requires operator intervention to change. A global data message can be sent to all SAM control units on the radio network to place them in the Downtime-HOA OFF well state. The SAM PCP Controller controls would stop the wells and keep them down until receiving a command to re-start.

You can configure the SAM PCP Controller to monitor HOA activity and monitor the digital input channels used for Hand and Auto monitoring using the HOA Configuration screen (Figure 8-36). To display this screen, select 5. HAND/OFF/AUTO (HOA) from the SAM Configuration Menu screen.

Figure 8-36. HOA Configuration Screen


HOA ENABLE/DISABLE

Specify whether you want the SAM PCP Controller to monitor HOA activity.

HOA Hand DI Channel

Specify the digital channel number that the SAM PCP Controller will use to go into a Pumping HOA Hand well state when grounded.



HOA Auto DI Channel

Specify the digital channel number that the SAM PCP Controller will use to go into normal operation mode when grounded.

Note: When both the Hand and Auto DI channels are open, the SAM PCP Controller is in a DT/HOA Off well state.

Note: It is an invalid HOA state to have both the Hand and Auto digital channels grounded.

Procedure Follow the steps below to enable or disable HOA monitoring.



2. Select 5. HAND/OFF/AUTO (HOA) to display the HOA Configuration screen.

The HOA Enable/Disable field highlights.

3. Press <EDIT>.

4. Do either of the following:

• To disable HOA monitoring, select DISABLE.

• To enable it HOA monitoring, select ENABLE.

5. Press <↓> to highlight the first DI Channel field.

6. For each of the DI Channel fields, press <EDIT> and then press the number keys. After you press a key, the next digit to the right highlights. You can press <←> to return to a digit to the left to change it. After all numerical values are correct, press <ENTER>.


• To return to the SAM Configuration Menu screen, press <EXIT>.



SAM 3/3/6


The state you specified for HOA monitoring is saved in the SAM PCP Controller.

8.16 Configuring Alarm (Coil) Tracking The amount of time that the SAM PCP Controller is in a particular alarm condition can be accumulated. These alarm flags are referred to as “coils.” A record of how many minutes each configured alarm/coil was set for the day is maintained for each of the most-recent 60 days. Ask your Lufkin Automation representative for more information.

This alarm information can be a displayed as a plot by using the 60 Day Coil Track option, which is available under the Historical Data Menu screen. For more information, see “60 Day Alarm Tracking” in section 10, “Historical Data.”

Coil tracking is configured with the Coil Tracking Configuration screen (Figure 8-37). To display this screen, select 6. ALARM TRACKING CONFIGURATION from the SAM Configuration Menu screen.

Figure 8-37. Coil Tracking Configuration Screen




INDEX

A reference to show which coil is being configured. This field cannot be edited.

COIL #

Specify the number in the PCP register map you want to configure to monitor. Contact your Lufkin Automation representative to obtain the latest register map.

TRACKING FUNCTIONALITY

Specify how multiple coils occurring simultaneously are monitored. Choices are:

• Normal

• First Occurrence

• Cascading

TRACKING ENABLED

Specify whether you want the coil tracking function to be enabled or disabled. ENABLE must be selected to use this function. DISABLE when you want specify the configuration (or keep an existing configuration), but you do not want it to go into effect presently.

Procedure Follow the steps below to configure for coil tracking.



2. Select 6. ALARM TRACKING CONFIGURATION to display the Coil Tracking Configuration screen.

The COIL # field for INDEX 1 highlights.

3. Do the following for each coil you want to configure.

a. If you want to select a specific COIL # field, press <↑> or <↓>, to highlight it.



SAM 3/3/7

b. When the field is highlighted, press <EDIT>.

c. Press the numerical keys to enter numerical values,. After you press a number key for the digit that is highlighted, the next digit to the right highlights. You can press <←> to return to a digit to the left.

d. After all numerical values for the field are correct, press <ENTER>. The next field highlights.

e. Repeat steps a through d for each COIL # field you want to configure.

4. When you are finished configuring coils, press <↓> to highlight the TRACKING FUNCTIONALITY field.

5. Press <EDIT>, press <↑> or <↓> to select how you want multiple occurrences of coil alarms to occur, and then press <ENTER>.

6. Press <↓> to highlight the TRACKING ENABLED field.

7. Press <EDIT>, press <↑> or <↓> to select between ENABLED and DISABLED, and then press <ENTER>.




The coil tracking configuration is saved in the SAM PCP Controller.

8.17 Configuring VSD Parameters The VSD parameters operate in conjunction with the existing standard safety violation parameters. This conjunction provides a complete solution for control of a pumping unit system that uses a generic VSD.

Lufkin Automation offers a SAM VSD controller package that combines the PCP controller function in the same cabinet as a variable speed drive. This user manual does not address the SAM PCP Controller/VSD combo product. For information about the combo product, refer to the SAM Well Manager™ — Variable Speed Drive Progressing Cavity Pump User Manual (Part No. 099.5029).



For the generic VSD application, only one VFD/VSD Parameters screen (Figure 8-38) is used to configure VSD parameters and operating speed ranges.

To display the VSD screens, select 7. VFD/VSD PARAMETERS from the SAM Configuration Menu screen. To navigate between screens, press <NEXT>.

Note: VSD configuration screens are not available if the prime mover specified is Hydraulic. When you attempt to select this option, a message appears for a few seconds informing you that a hydraulic unit is specified, and you remain at the SAM Configuration Menu screen. To change the configuration to an electric prime mover, go to the Production/Motor Information screen and select the Electric option in the Prime Mover Type field. For more information about this screen and field, see “Configuring Production and Motor Information” in section 7, “PCP Parameter Programming.”

VSD Parameters The first screen is the VSD Parameters screen (Figure 8-38), which you use to select a VSD type and specify its allowable minimum and maximum operating speeds.

Figure 8-38. VFD/VSD Parameters Screen



Data Field Descriptions Information about each data field for the VFD/VSD Parameters screen is provided below.

VFD Drive Type

Select the type of variable speed drive being used. The options available are:

• Lufkin LFKA-1 — Select when using a Lufkin variable speed drive. Refer to the SAM Well Manager™ — Variable Speed Drive Progressing Cavity Pump User Manual (Part No. 099.5029).

• Others — Select when using a generic inverter drive. This is the only option supported by the user manual you are reading.

Scaling Unit

Specify the engineering units to be associated with the display of the analog output value to the drive. The scaling unit corresponds to the maximum speed and minimum speed fields. It is easiest to match this with the units being used in the drive (for example, Hz). Available options are %, V, mA, SPM, RPM, and Hz (default).

Maximum Speed

Select a value to match the engineering unit maximum in the drive. This parameter associates the engineering value of maximum speed with the maximum hardware analog output (10 VDC or 5 VDC, depending on the header block selected). For example, if the drive scales the analog speed reference so that 0 to 10 VDC input corresponds to 0 to 90 Hz, the maximum speed in the SAM PCP Controller should be set at 90 Hz.

Minimum Speed

Select a value to match the engineering unit minimum in the drive. This parameter associates the engineering value of the minimum speed with the minimum hardware analog output (0 VDC). For example, if the drive scales the analog speed reference so that 0 to 10 VDC input corresponds to 0 to 90 Hz, the minimum speed in the SAM PCP Controller should be set at 0 Hz.



Procedure Follow the steps below to configure the VSD parameters.



2. Select 7. VFD/VSD PARAMETERS to display the VFD/VSD Parameters screen.

Note: You cannot access the screens for this command if the prime mover type specified is hydraulic. For more information, see the Note on page 8-100.

The VFD Drive Type fields highlight.




4. When you are finished programming parameters, do either of the following:



The VSD parameters are saved in the SAM PCP Controller.


Section 9

Status Screens

The SAM PCP Controller has several status screens that display information about current values for measured process variables, alarms and alerts, and reminders for you about how control parameters are configured.


9.1 Overview of the Status Screens...................................................... 9-2 9.2 Displaying the Status of PCP Parameters ...................................... 9-2

9.2.1 Current PCP Operating Status............................................ 9-2 9.3 Displaying the Status of SAM PCP Controller Parameters ........... 9-7 9.4 Auxiliary Functions........................................................................ 9-8

9.4.1 Auxiliary Input Status Screens........................................... 9-9 9.4.2 Displaying AUX Analog Input Status.............................. 9-10 9.4.3 Displaying AUX Analog Output Status ........................... 9-11 9.4.4 Displaying Digital Input Status ........................................ 9-12 9.4.5 Displaying AUX Accumulator Status .............................. 9-14 9.4.6 Displaying AUX I/O Boards Status ................................. 9-15 9.4.7 Displaying AGA 3 Status................................................. 9-16 9.4.8 Displaying Logic Expression Status ................................ 9-19

9.5 Register Functions........................................................................ 9-20 9.5.1 Displaying Register Digital Output Status ....................... 9-21 9.5.2 Displaying Register Calculations Status .......................... 9-22

9.6 Displaying Alarm/Alert Status ..................................................... 9-23 9.7 Displaying Alarm Tracking Status............................................... 9-24 9.8 Displaying the Status for a Modbus Master Slave Device........... 9-26 9.9 VSD Diagnostics .......................................................................... 9-28



SAM 1

9.1 Overview of the Status Screens Two types of status screens can be displayed.

• PCP Status screens displaying information about the primary PCP control functions. Most of this data is based on parameter values configured through the PCP Configuration Menu screens (see section 7, “PCP Parameter Programming”).

• Several SAM Status screens displaying information useful to check and troubleshoot background tasks that the SAM PCP Controller performs (page 9-7). Most of this data is based on parameter values configured through the SAM Configuration Menu screens (see section 8, “SAM Controller Programming”).

Both status screen types are accessed from the Main Menu screen.

9.2 Displaying the Status of PCP Parameters

The SAM PCP Controller PCP Status screen presents a combination of current operating values and some historical data about the PCP function.

To display the PCP Status screens, select 1. PCP STATUS from the Main Menu screen. Screen contents are described below.

9.2.1 Current PCP Operating Status Information about the current PCP operating status and some historical data about motor performance and production are displayed on a status screen similar to Figure 9-1. This information provides the operating conditions of the well that are usually of most interest to the operator.

Section 9: Status Screens


Figure 9-1. PCP Status Screen Example

By default, the SAM PCP Controller automatically returns to this screen when no keypad activity occurs for eight minutes. Therefore, most of the time this screen displays when you arrive at the site. If it does not display, you can configure it as the default screen using the Additional Configuration feature. For more information, see “Configuring the Default Screen” in section 8, “SAM Controller Programming.”

The exact information presented on the status screen depends on the end devices used, control mode selected, and control functions enabled.

When you are finished with this screen, press <EXIT> or <MENU> to return to the Main Menu screen.

Data Field Descriptions Information about the data field is provided below.

Note: All of the data fields described below may not necessarily be displayed due to your PCP configuration.

Top Row Section The very top row, starting from the left side, shows the following information:

• States the firmware version number and version checksum for that version. This information is helpful when speaking with technical support.



• States the present date and time programmed for the SAM PCP Controller. For information about date/time programming, see “Setting the Controller Date and Time” in section 8, SAM Controller Programming.”

Status Section RTU ADDRESS

If the SAM PCP Controller is part of a SCADA network, it must have a unique address. This address allows the central host computer software to identify and interrogate this specific SAM PCP Controller. The address is programmed at the RTU level under the Communication Parameters option. For information about this feature, see “Communication Parameters Configuration” in section 8, “SAM Controller Programming.”

Current Well State

States the present operating state of the SAM PCP Controller. This state is not operator-programmable. For descriptions about SAM PCP Controller well states, see Appendix A, “Well State List.”

Elapsed Time

States how long (HHH:MM:SS format) the SAM PCP Controller has been in the state specified in Current Well State.

Gauge-OFF Time

States the time of day that the SAM PCP Controller updates all of the historical data buffers.

Operation Mode

States the current operation mode that the SAM PCP Controller is programmed to operate. Five operation modes are available.

• PROD CTRL

• SPEED CTRL

• TIMED

• HOST

• MONITOR



For descriptions about these modes, see “Configuring Control Parameters” in section 7, “PCP Parameter Programming.”

Current Prod Rate

States the barrels per day production rate calculated at the end of the most recent sampling period.

Projected Prod

States the production rate projected for the 24-hour period based on the amount produced so far for the 24-hour period.

Today’s Prod Since GOT

States the total production that has occurred since gauge off time (GOT) was reset.

Yesterday’s Prod

States the total production for the previous 24-hour day as defined by Gauge Off Time.

Current Control Speed

States the present RPM of the pump.

Current Motor Torque

States the present torque of the motor.

Bottom Section Columns The columns in the bottom section represent the following information:

E/D

States whether the function is enabled (E) or disabled (D).

LIMIT

Most of these malfunction controls have a user-defined limit, such as low RPM, low prod, or high torque.

CURR

States the present value for the feature specified in the row.

MLF Allowed

States the number of consecutive malfunctions allowed before an alarm is triggered.



MLF Current

States the number of malfunctions that have occurred since last reset.

Bottom Section Rows The rows in the bottom section represent the following information:

No RPM

Monitors the RPM channel and alarms when no RPM is detected. Once it exceeds the consecutive (CSC) value, the SAM PCP Controller either operates in Downtime or Violation Run mode. After the Downtime or Violation Run period expires, the SAM PCP Controller automatically restarts.

Low RPM

States the minimum pump speed allowed, in RPM. The current speed captured through the sensor connected to the rod is monitored and compared to the specified LIMIT value. Once it exceeds the CSC value, the SAM PCP Controller either operates in Downtime or Violation Run mode. After the Downtime or Violation Run period expires, the SAM PCP Controller automatically restarts.

Critical Torq

States the maximum rod torque allowed. Once it exceeds the CSC value, the SAM PCP Controller immediately switches to either Downtime or Violation Run mode.

Torq Limiting

States the desired maximum operating torque. The current torque (input from the drive) is compared to the specified LIMIT value to detect if the pump is beginning to show evidence of stalling or fluid starvation that can cause friction between stator and elastometer, thus increasing the torque. When the torque value is violated, the SAM PCP Controller starts slowing down the pump by steps until either the torque goes below the limit or the pump reaches minimum speed.

Low Prod

States the minimum amount of fluid production allowed. This feature monitors (at the rate of one-minute resolution) the fluid produced and slows down the pump when it goes below the limit. This feature is to prevent pump off and for detecting if something is wrong with the production transmitter. For Speed Control Operation mode, or the end of the sampling period for Production Control Operation mode, when a violation occurs, the SAM PCP Controller decreases rod speed until minimum speed is reached and then shuts down the pump.



SAM 2

High Prod

States the maximum amount of fluid production allowed. Production for the current sampling period is compared to this value to detect a production transmitter malfunction at the rate of one-minute resolution for Speed Control Operation mode, or the end of the sampling period for Production Control Operation mode.

Speed Diff

States the speed difference allowed between the measured polished rod speed and the control output. The SAM PCP Controller compares the present pump rod speed captured through the sensor connected to the speed control output that the SAM PCP Controller sends to motor drive. If the difference is greater than the Speed Difference Limit, the SAM PCP Controller issues an alarm informing the operator that the controller and the drive are out of synch in terms of speed.

Pump Eff

States the efficiency of the pump, in percent, for the previous minute based on current production and speed as compared to the pump manufacturer’s specifications.

9.3 Displaying the Status of SAM PCP Controller Parameters

You can display several status screens that contain information useful for checking and troubleshooting background tasks that the SAM PCP Controller performs. These screens provide the following types of status information:

• Analog I/O, digital I/O, accumulator, and AGA 3 calculations

• Values for programmed registers and register calculations

• Alarms/alerts that are set and alarm tracking

• Register addresses and values for Modbus slave devices

• VSD parameters and VFD/SAM parameter comparisons

These screens are available through the SAM Status Menu screen (Figure 9-2). To display this menu, select 2. SAM STATUS from the Main Menu screen.



SAM 2/1

Figure 9-2. SAM Status Menu Screen

9.4 Auxiliary Functions Several auxiliary (AUX) status screens are used to view current values for all the process variable transmitters connected to the SAM PCP Controller. Analog I/O, digital I/O, accumulator values, and AGA 3 status can be displayed.

If the SAM PCP Controller is equipped with optional I/O expansion boards, current values for each configured auxiliary or expansion I/O points can be seen on these status screens. The SAM PCP Controller uses a 12-bit A/D converter for auxiliary analog points. Raw numbers will therefore be in the range of zero to 4095.

Status screens are also available for the following:

• AGA 3 calculations

• Programmed logic expressions

• Alarms and alerts

An Auxiliary Functions Status Menu screen (Figure 9-3) is used as a secondary menu to access the I/O type you want displayed and the status of auxiliary boards. To display this menu, select 1. AUXILIARY FUNCTIONS from the SAM Status Menu screen.



SAM2/1/1

Figure 9-3. Auxiliary Functions Status Menu Screen

9.4.1 Auxiliary Input Status Screens You can display the status of analog I/O, digital I/O, accumulators, and boards. This information is displayed on separate status screens that are selected from the AUX I/O Status Menu screen (Figure 9-4). To display this menu, select 1. AUX I/O STATUS from the Auxiliary functions Status Menu screen.

Figure 9-4. AUX I/O Status Menu Screen



SAM 2/1/1/1

9.4.2 Displaying AUX Analog Input Status You can use an AUX Analog Input Status screen similar to Figure 9-5 to display status data about the analog inputs. To display this screen, select 1. AUX ANALOG INPUT STATUS from the AUX I/O Status Menu screen.

Figure 9-5. AUX Analog Input Status Screen

Auxiliary analog inputs are displayed in sets of eight per screen. The present status for auxiliary analog inputs 1 through 8 displays on the first screen (see Figure 9-5). Press <NEXT> to display the next set of eight.

Auxiliary analog input channels are configured using the Auxiliary Analog Input Configuration screen. For information about this screen, see “Configuring Auxiliary Analog Inputs” in section 8, “SAM Controller Programming.”


AI#

States the virtual analog input number as programmed in section 8..

Raw Counts

States the numerical representation of the present value of the analog input as a raw BCD number (0 to 4095).



SAM 2/1/1/2

Scaled Value

States the present value of the analog input in engineering units.

Units

States the unit of measurement used.

Alarm E/D

States whether an alarm is enabled (E) or disabled (D) for the channel.

When you are finished with this screen, do either of the following:

• Press <EXIT> to return to the AUX I/O Status Menu screen.


9.4.3 Displaying AUX Analog Output Status You can use an AUX Analog Output Status screen similar to Figure 9-5 to display status data about the analog outputs. To display this screen, select 2. AUX ANALOG OUTPUT STATUS from the AUX I/O Status Menu screen.

Figure 9-6. AUX Analog Output Status Screen

Auxiliary analog output channels are configured using the Auxiliary Analog Input Configuration screen. For information about this screen, see “Configuring Auxiliary Analog Outputs” in section 8, “SAM Controller Programming.”




AO#

States the virtual analog output number as programmed in section 8.

Raw Counts

States the numerical representation of the present value of the analog output as a BCD number (0 to 4095).

Scaled Value

States the present value of the analog output in engineering units.

Units

States the unit of measurement used.




9.4.4 Displaying Digital Input Status You can use a Digital Status screen similar to 9-13 to display status data about the digital inputs. This data is useful for verifying the operation of input switches. To display this screen, select 3. AUX DIGITAL I/O STATUS from the AUX I/O Status Menu screen.



Figure 9-7. Digital Status Screen

Auxiliary digital inputs status screens only display the open or closed state for each input that is configured. The present status for auxiliary digital inputs 1 through 32 displays on the first screen (see Figure 9-7). Press <NEXT> to display the next set of digital inputs.

Digital channels are configured using the Digital Configuration screen. For information about this screen, see “Configuring Auxiliary Digital Inputs and Outputs” in section 8, “SAM Controller Programming.”


DIG#

States the digital channel number.

State

States whether the digital channel is open or closed.






SAM 2/1/1/4

9.4.5 Displaying AUX Accumulator Status The SAM PCP Controller firmware design supports a maximum of ten accumulator inputs. The motherboard has four auxiliary digital points that can be configured as accumulators. Optional expansion board hardware is required to take advantage of the additional six accumulators that the firmware can support.

You can use an Aux Accumulator Status screen similar to Figure 9-8 to display status data about the auxiliary accumulators. To display this screen, select 4. AUX ACCUMULATOR STATUS from the AUX I/O Status Menu screen.

Figure 9-8. AUX Accumulator Status Screen

These inputs provide the ability to monitor the operation of facilities adjacent to a well without having the additional cost of installing a remote terminal unit (RTU) and data telemetry equipment for that facility.


Accum #

States the virtual channel number for the accumulator.

Units

States the unit of measurement to be associated with each auxiliary input.



SAM 2/1/1/5

PPM

States the pulses per unit of measure (PPM). This value is an integer that programs the SAM PCP Controller to scale this given number of pulses counted at the defined accumulator input point as a single unit. The range is 1 to 999,999.

Rate/User Defined Interval

States the sampling period, in minutes.

Current Rate

States the instantaneous present value.




9.4.6 Displaying AUX I/O Boards Status You can use the AUX I/O Boards Status screen (Figure 9-9) as a troubleshooting tool to see if the different auxiliary I/O boards are present and working properly. A total of eight boards can be stacked to the motherboard. For each board, you can see its operating state, model, build, checksum, and the number each has available for I/O configuration. To display this screen, select 5. AUX BOARD STATUS from the AUX I/O Status Menu screen.

Figure 9-9. AUX I/O Boards Status Screen




NUM

States the board number as defined by the board dip switches.

STATE

Present state of the expansion board.

MODEL

Model number read from the expansion board processor on power up.

VER

States the firmware version of the board.

BUILD

States the secondary version description.

XSUM

Displays the board’s checksum number. This number is used to check the validity of the firmware. It should match the number written on the chip on the board.

AI

States the number of analog inputs available on the board.

AO

States the number of analog outputs available on the board.

ACC

States the number of pulse accumulators available on the board.

DIG

States the number of digital inputs/outputs available on the board.




9.4.7 Displaying AGA 3 Status



SAM 2/1/2

If the SAM PCP Controller has proper optional hardware, and it is configured to perform the AGA 3 gas flow rate and volume calculations, you can display the calculation results on a status screen similar to Figure 9-10.

Note: If the AGA 3 Calculations feature is disabled, this screen will not show current data. For information about enabling it, see “Enabling and Disabling AGA 3 Calculations” in section 8, “SAM Controller Programming.”

Figure 9-10. AGA Status Screen


ENABLED

States whether or not the AGA calculations are enabled.

DIFFERENTIAL PRESSURE

States the present measured differential pressure.

FLOWING PRESSURE

States the present measured flowing pressure, or user-specified pressure if not measured.



FLOWING TEMPERATURE

States the present measured flowing temperature, or user-specified temperature if not measured.

SUPERCOMPRESSIBILITY

States the calculated supercompressibility factor.

FLOW RATE

States the present flow rate measured in MCF/DAY.

TODAY’S PRODUCTION

States the production since last gauge off time (GOT).

TOTAL PRODUCTION

States the total production accumulated since last reset.

Note: Press <DELETE> while viewing the AGA Status screen to reset the total production accumulator.


• Press <EXIT> to return to the Auxiliary Functions Status Menu screen.




SAM 2/1/3

9.4.8 Displaying Logic Expression Status You can display the present status for each logic expression and the action programmed for that expression on a Logic Expression Status screen similar to Figure 9-11. To display this screen, select 3. LOGIC EXPRESSION STATUS from the Auxiliary Functions Status Menu screen.

Note: If the Logic Expression function is disabled, this screen will not show current data. For information about enabling it, see “Enabling and Disabling Logic Expressions” in section 8, “SAM Programming.”

Figure 9-11. Logic Expression Status Screen

The present condition of each programmed logic expression is displayed at the far right edge of the screen as T for true or F for false.


LOGIC EXP

States the logic expression number.



SAM 2/2

Action

States the action parameters programmed for the logic expression. For descriptions about each action available, see “Programming a Logic Expression Action” in section 8, “SAM Controller Programming.”

Consec Malf Allowed or Timer Period(min)

States the action programmed for the logic expression.

• If the programmed action is MALF, it states the number of retries allowed before the pumping unit is shut down in a Malfunction well state.

• If the programmed action is TIMER, it states the desired time in minutes to hold closed the designated digital output.

Logic Time Delay (sec)

States the delay before executing the programmed action when a logic expression proves true. This time delay is in addition to any programmed time delays for the analog alarms and/or digital inputs that are included in a logic expression.


• Press <EXIT> to return to the Auxiliary Functions Status Menu screen.


9.5 Register Functions The SAM PCP Controller has status screens that can display the address and current value for any configured register alarm and the status values obtained from register calculations. Screens for displaying this data are available through the Register Functions Status Menu screen (Figure 9-12). To display this menu, select 2. REGISTER FUNCTIONS from the SAM Status Menu screen.



SAM 2/2/1

Figure 9-12. Register Functions Status Menu Screen

9.5.1 Displaying Register Digital Output Status The SAM PCP Controller has a register alarm feature that can be programmed for actions based on any of the measured or calculated values entered in the controller memory files. You can display a Register Digital Output Status screen similar to Figure 9-13 that shows the address and current value for each register alarm programmed. To display this screen, select 1. REGISTER DIGITAL OUTPUT STATUS from the Register Functions Status Menu screen.

Figure 9-13. Register Digital Output Status Screen




REG #

States the index of the register alarm described on that line.

ADDRESS

States the Modbus register address being monitored by the register alarm on that line.

CURRENT VALUE

States the value of the Modbus register being monitored by the register alarm on that line.


• Press <EXIT> to return to the Register Functions Menu screen.


9.5.2 Displaying Register Calculations Status You can combine status values from different registers to obtain new values that can be used for monitoring and creating register alarms. You can display the calculated results in a Programmable Calculations Status screen similar to Figure 9-14. To display this screen, select 2. REGISTER CALCULATIONS STATUS from the Register Functions Status Menu screen.



SAM 2/3

Figure 9-14. Programmable Calculations Status Screen

For information about configuring register calculations, see “Configuring Register Calculations” in section 8, “SAM Controller Programming.”


• Press <EXIT> to return to the Register Functions Menu screen.


9.6 Displaying Alarm/Alert Status If a dynamic alarm and/or alert condition exists anywhere in the SAM PCP Controller, an alarm alert box blinks on and off at the top of every screen. Figure 9-15 is an example of a screen displaying an Alarm/Alert notification.

Note: This notification box does not display when latched alarms are not cleared.

You can check which dynamic alarm/alert is set by using the Alarm Status screens. Eight screens are available. Figure 9-15 is an example of the first. To display this screen, select 3. ALARM STATUS from the SAM Status Menu screen.



SAM 2/4

Figure 9-15. Alarm Status (Log) Screen with Alarm Alert Message

Press <NEXT> to scroll forward through the Alarm Status screens.

When you are finished with the Alarm Status screens, do either of the following:

• Press <EXIT> to return to the SAM Status Menu screen.


9.7 Displaying Alarm Tracking Status You can view the number of times that the SAM PCP Controller went into a particular alarm condition for the day since gauge-off time (GOT). These alarm flags are referred to as “coils.” You can display this information on a Coil Tracking Status screen similar to Figure 9-16. To display this screen, select 4. ALARM TRACKING STATUS from the SAM Status Menu screen.

Note: You can view the coil tracking data displayed in a table and plotted for the amount of time each day for the previous 60 days. For information about this historical data, see “60 Day Alarm Tracking” in section 10, “Historical Data.”

Alarm Alert box



Figure 9-16. Coil Tracking Status Screen


INDEX

A reference to show which coil is configured.

COIL #

States the number in the PCP register map configured to be monitored. Contact your Lufkin Automation representative to obtain the latest register map.

TIME ACTIVE

Displays the total amount of time the alarm has been active since GOT.

# Occurrences

States how many times the particular alarm condition has occurred since GOT or the last time it was reset.



SAM 2/5

TRACKING FUNCTIONALITY

States how multiple coils occurring simultaneously are monitored. Choices are:

• Normal

• First Occurrence

• Cascading

TRACKING ENABLED

States whether the coil tracking function is enabled or disabled. For information about enabling/disabling tracking, see “Configuring Alarm (Coil) Tracking” in section 8, “SAM Controller Programming.”


• Press <EXIT> to return to the SAM Status Menu screen.


9.8 Displaying the Status for a Modbus Master Slave Device

At any time you can retrieve and display the register addresses and register values for a Modbus slave device configured to a Modbus master in the data network. This information is displayed in a Modbus Master Status Menu screen (Figure 9-17). To display this screen, select 5. MODBUS MASTER STATUS from the SAM Status Menu screen.



Figure 9-17. Modbus Master Status Menu Screen

Highlight the slave device you want displayed, and then press <ENTER>. A register address and register value status screen similar to Figure 9-18 appears for a Modbus slave device. You can press <NEXT> to view the next status screen.

Figure 9-18. Typical Status Screen for a Modbus Slave Device Showing Its Register Addresses and Values



SAM 2/6

When finished, do either of the following:

• Press <EXIT> to return to the Modbus Master Status Menu screen.


9.9 VSD Diagnostics The VFD COMM Diagnostics Menu screen offered by option 6. VFD COMM DIAGNOSTICS on the SAM Status Menu screen is meaningless when the SAM PCP controller is used with a generic variable speed drive. Therefore, no explanation about these features is included in this manual


Section 10

Historical Data

The SAM PCP Controller maintains historical data in various formats to provide useful information about PCP production and performance.


10.1 Overview of the Historical Data Features .................................... 10-2 10.2 Plotting Data Menu ...................................................................... 10-4 10.3 PCP Data ...................................................................................... 10-5

10.3.1 Starting Period.................................................................. 10-6 10.3.2 Normal Operation Period ................................................. 10-7 10.3.3 Power Off Delay Period ................................................... 10-7 10.3.4 Stopping Period ................................................................ 10-7

10.4 60 Day Historical Data................................................................. 10-7 10.4.1 60 Day Peak Speed Measured.......................................... 10-8 10.4.2 60 Day Peak Speed Output............................................... 10-8 10.4.3 60 Day Peak Torque......................................................... 10-8 10.4.4 60 Day Daily Production.................................................. 10-8 10.4.5 60 Day Pump Efficiency .................................................. 10-8

10.5 SAM Data..................................................................................... 10-9 10.5.1 Register Log ..................................................................... 10-9 10.5.2 60 Day Alarm Tracking.................................................. 10-10

10.6 AGA 3 Data................................................................................ 10-11 10.6.1 24 Hour AGA 3 Gas Flow.............................................. 10-11 10.6.2 60 Day AGA 3 Gas Flow ............................................... 10-12

10.7 Events ......................................................................................... 10-13 10.7.1 Event Log ....................................................................... 10-13 10.7.2 Alarm Log ...................................................................... 10-14



SAM 4

10.1 Overview of the Historical Data Features

The SAM PCP Controller saves in onboard memory historical data values for process variables, such as PCP production and performance, calculated flow rates and volumes, VSD performance, and alarm and event logs. This historical data can be retrieved and displayed for activity from the previous 24-hour period in one-minute intervals, or the daily average for the previous 60 days.

All historical data is accessed from the Historical Data Menu screen (Figure 10-1). To display this screen, select 4. HISTORICAL from the Main Menu screen

Figure 10-1. Historical Data Menu Screen

Data Display Formats Most historical data is displayed as a graphical plot while other data is only displayed in a table. Some data types can be displayed in both formats (see Figure 10-2 for examples). You can press <NEXT> to toggle between the formats for any screens that display NEXT at the bottom of them.

Note: Some screens accessed through the 60 Day Historical Data screen (see page 10-7) have the graphical plot and table data displayed in the same screen.

Section 10: Historical Data


Figure 10-2. Historical Data Displayed as a Graphical Plot and Table on Separate

Screens

Additional Display Options Additional “hotkey” functions are available when an OPTIONS field is available in the lower left corner of the screen and it is highlighted (see the left screen in Figure 10-2 for an example). To access the available hotkey functions, press <EDIT>. An Options title appears to the right of OPTIONS and the hotkeys available appear at the bottom of the screen. Not all historical screens have an OPTIONS field.

Plot Selection Options The number keys are designated as “toggles” to include or remove a process variable from the plot. A maximum of three variables can be plotted on a screen (see Figure 10-2). Press the designate key to add the variable, and then press it again to remove that variable.

Navigation Options Several screens that display as a graphical plot have navigation options that you can also use as hotkeys. These keys are described in the table below.

OPTIONS field

Hotkey functions

Options title



SAM 4/1

Key Function ← → Moves the dashed vertical line “pointer” to select a particular data

point. ENTER Centers the vertical dashed line pointer and the data point currently

selected by the pointer. This action allows you to redefine a “page” break.

↑ ↓ Selects the “page” of data points to be displayed. Data points are displayed in groups (or “pages”) of 240 as indicated.

NEXT Toggles the display between table data and a graphical plot.

Refresh Options Refresh options are available to allow you to refresh the data displayed on the screen manually or allow the SAM PCP Controller to automatically refresh as new data becomes available.

10.2 Plotting Data Menu The Plotting Data Menu screen (Figure 10-3) provides access to all historical data plots and most of the historical data tables. Only the alarm and event log are not accessed from this menu, but instead are available from the Events Menu screen (see page 10-13.).

Figure 10-3. Plotting Data Menu Screen



SAM 4/1/1

The types of historical data available from the Plotting Data Menu screen include.

• PCP data about normal pumping operations and pump activity (page 10-5)

• 60-day activity for production, peak motor speed and torque, and pump efficiency (page 10-7)

• Register log and alarm tracking activity (page 10-9)

• AGA 3 gas flow (page 10-11)

To display the Plotting Data Menu screen, select 1. PLOTTING from the Historical Data Menu screen.

10.3 PCP Data The PCP Data Menu screen (Figure 10-4) has options for you to view historical data about PCP activity, such as startup and shutdown activity, normal operations, and ramp down activity. This screen also provides access to another menu you can use to display 60-day plots (see “60 Day Historical Data” on page 10-7.). To display this menu, select 1. PCP Data from the Plotting Menu screen.

Figure 10-4. PCP Data Menu Screen



SAM 4/1/1

Multiple Plot Display When you use any one of the first four options, you can select and display up to three plots on the screen. In Figure 10-5, notice that the OPTIONS field in the lower left corner is highlighted. Press <EDIT> until Plot Selection Options appears, and then five “hotkey” options appear below this field. Press the number key representing the data type you want plotted. To remove a data type from the plot, press the number key again.

Figure 10-5. Screen with Three Plots Displayed

Tabular Data Display At any time you can press <NEXT> to display the data in tabular format. If you selected multiple plots for display, data for each selection displays in a separate column.

10.3.1 Starting Period You can display historical data of the selected variables from the time the well was at the Starting state. One sample point is recorded each second for the previous four minutes (240 sample points). All normal operations available using the Normal Operation Data option are available for Start Buffer. Data can be displayed as a table and graphical plot. You can select and display any three of these operations on one screen.

Plot types available for display



SAM 4/1/2

SAM 4/1/3

SAM 4/1/4

SAM 4/1/1/5

10.3.2 Normal Operation Period You can display historical data about several normal PCP operations for the previous 1,500 minutes (25 hours). Some of the normal operations include speed output, rod torque, pump efficiency, production, and measured speed. One sample point is recorded each minute for each operation. Data can be displayed as a table and graphical plot. You can select and display any three of these operations on one screen.

10.3.3 Power Off Delay Period You can display historical data about normal PCP operations from the time the well is at the ramp down state due to a violation or when the Start/Stop command is issued. One sample point is recorded each second for the previous four minutes (240 sample points). All normal operations available using the Normal Operation Data option are available for Power Off Delay. Data can be displayed as a table and graphical plot. You can select and display any three of these operations on one screen.

10.3.4 Stopping Period You can display historical data about the torsional effects of the polished rod on normal PCP operations after the pump receives no more power from the motor. One sample point is recorded each second for the previous four minutes (240 sample points). All normal operations available using the Normal Operation Data option are available for Stopping Period. Data can be displayed as a table and graphical plot. You can select and display any three of these operations on one screen.

10.4 60 Day Historical Data The 60 Day Historical Data Menu screen (Figure 10-6) has options to plot historical data for VSD speed and torque, fluid production, and pump efficiency for the previous 60 days. The daily values are updated each day at gauge off time (GOT). Day 1 is the most-recent day shown, which is yesterday. After 60 days, data from the oldest day is deleted from memory and replaced with data from the newest day. To display this menu, select 5. 60 DAY HISTORICAL DATA from the PCP Data Menu screen.



SAM 4/2/3

SAM 4/1/1/5/1

SAM 4/1/1/5/2

SAM 4/1/1/5/3

SAM 4/1/1/5/4

SAM 4/1/1/5/5

Figure 10-6. 60 Day Historical Data Menu Screen

10.4.1 60 Day Peak Speed Measured This plot displays the highest daily value recorded for measured polished rod speed.

10.4.2 60 Day Peak Speed Output This plot displays the highest daily value recorded for output polished rod speed output signal.

10.4.3 60 Day Peak Torque This plot displays the highest daily value recorded for polished rod torque.

10.4.4 60 Day Daily Production This plot displays the daily totals for measured production. The tabular numbers need to be divided by a factor of 10 for actual volumes.

10.4.5 60 Day Pump Efficiency This plot displays the average daily pump efficiency as compared with the measured production.



SAM 4/1/2

SAM 4/1/2/1

10.5 SAM Data The SAM Data Menu screen (Figure 10-7) has options to display 60-day historical data about the SAM PCP Controller activity.

• Plots displaying physical input or calculated values from configured register logs

• Plots and tables displaying the amount of time each day specific alarm coil actions occurred

To display this menu, select 2. SAM DATA from the Plotting Menu screen.

Figure 10-7. SAM Historical Data Menu Screen

10.5.1 Register Log The register log has a buffer with 1440 entries. Because each register log has a varying sample rate based on its particular setting, this buffer can store data for anything from one day (once-a-minute sampling) to 1440 days (once-a-day sampling).

The data displayed is based on parameters specified for the register log in the Register Logging Config screen, such as the category of data (analog input, accumulator, register log, etc.), sample rate, and whether the data is a sample point taken each period or a sample average for the period. For more information about this screen, see “Configuring a Register Log”, in section 8, “SAM Parameter Programming.”



SAM 4/1/2/2

Register log data displays in the Register Log screen (Figure 10-8). To display this screen, select 1. REGISTER LOG from the SAM Data Menu screen.

Figure 10-8. Register Log Screen

Selecting a Specific Log for Display You can select the register log you want plotted. A maximum of 10 logs are available, but the actual number available depends on which register logs were configured with the Register Logging Config screen. The log type displays above the plot. If you select a register log that is not configured, a message displays to inform you that it is not configured.

To select a plot, highlighting the Register Log field, press <EDIT>, use the number keys to specify the log, and then press <ENTER>.

10.5.2 60 Day Alarm Tracking This 60-day historical data is the amount of time each day that the SAM PCP Controller was in a particular alarm condition. This data can be displayed as a plot or table.

Alarm flags are referred to as “coils.” Alarm coils are configured using the Coil Tracking option. For information about this option, see “Configuring Alarm (Coil) Tracking” in section 8, “SAM Controller Programming.”



SAM 4/1/3/1

SAM 4/1/3

Selecting a Specific Alarm Coil for Display You can select for display any one of a possible sixteen different alarm coils. Use the procedure described below to display a specific alarm coil.

1. Press <EDIT>. The Coil Track # field at the top of the plot displays the current coil track number.

2. Press <↑> or <↓> to scroll through coil track numbers.

3. When the coil number displays, press <ENTER>.

10.6 AGA 3 Data The AGA Data Menu screen (Figure 10-9) has options for you to view AGA 3 historical data from the previous 24 hours and 60 days. To display this menu, select 3. AGA DATA from the Plotting Menu screen.

Figure 10-9. AGA Data Menu Screen

10.6.1 24 Hour AGA 3 Gas Flow Historical data collected over the previous 24-hour period for AGA 3 gas flow can be displayed as a graphical plot and in a table. This data can consist of 1,440 samples recorded in the data buffers at one-minute intervals or as 180 values that are an average value for an eight-minute interval. To display this screen, select 1. 24 HOUR AGA GAS FLOW from the AGA Historical Data Menu screen.



SAM 4/1/3/2

Note: This plot will not display when the AGA 3 calculation function is disabled. For information about enabling it, see “Enabling and Disabling AGA 3 Calculations” in section 8, “SAM Controller Programming.”

Figure 10-10. 24 Hour AGA 3 Gas Flow Plot

Plot Rescaling The Y-axis is automatically scaled to fit in the minimum and maximum values for the 24-hour period. This axis can be rescaled so that you can view small variances easily by editing the Y-AXIS SCALE field. This field is located along the right edge of the display screen. To change the rescaling, highlight the Pk or Min field, press <EDIT>, use the number keys to enter a new value, and then press <ENTER>. To return to the original scaling, press <DEL>.

10.6.2 60 Day AGA 3 Gas Flow The last 60-day averages of the calculated gas flow rate can be plotted and displayed as a table. To display this screen, select 2. 60 DAY AGA GAS FLOW from the AGA Historical Data Menu screen.

Note: This plot will not display when the AGA 3 calculation function is disabled. For information about enabling it, see “Enabling and Disabling AGA 3 Calculations” in section 8, “SAM Controller Programming.”



SAM 4/2/1

SAM 4/2

Plot Rescaling The Y-axis is automatically scaled to fit in the minimum and maximum values for the previous 60 days. This axis can be rescaled so that you can view small variances easily by editing the Y-AXIS SCALE field. This field is located along the right edge of the display screen.

To change the rescaling, highlight the Pk or Min field, press <EDIT>, use the number keys to enter a new value, and then press <ENTER>. To return to the original scaling, press <DEL>.

10.7 Events The Events Menu screen (Figure 10-11) has options for you to display historical logs of PCP control events and alarms that occurred. Both logs list the type of events that occurred along with time/date stamps for when they were recorded. To display this menu, select 2. EVENTS from the Historical Data Menu screen.

Figure 10-11. Events Menu Screen

10.7.1 Event Log The Event Log screen displays the recorded date and time that events relating directly to the PCP control processes occurred during the past 60 days. Figure 10-12 is an example. To display this screen, select 1. EVENT LOG from the Events Menu screen.



SAM 4/2/2

Figure 10-12. Event Log Screen

This event log is a complement to the maintenance log feature provided in the System Tools menu. For more information, see “Maintenance Log” in section 11, “System Tools.”

10.7.2 Alarm Log The Alarm Log screen can display a maximum of 100 recorded alarm logs with date and time stamps and descriptions of each alarm. Figure 10-12 is an example. To display this screen, select 2. ALARM LOG from the Events Menu screen.



Figure 10-13. Alarm Log Screen


SAM 5

Section 11

System Starting and Stopping

The PCP system can be started or stopped at the SAM PCP Controller or remotely by Modbus using the Start/Stop command available from the Main Menu screen. The action this command executes is based on the current state of the well.

Be aware that the pump cannot stop immediately due to residual polished rod rotation (torsion) from forward spin or backspin. The SAM PCP Controller has a safeguard feature to prevent the pump from being restarted when it detects polished rod rotation. If you attempt to restart the pump while rotation is detected, a message appears to warn you that the pump will not start.

You can override the stop protection feature, but Lufkin Automation does not recommend it. Pump damage or personnel injury can occur if you start the pump while it is rotating, especially during backspin. This safeguard feature should only be overridden for emergency purposes. For information about enabling and disabling the stop protection override, see “Configuring Control Parameters” in section 7, “PCP Parameter Configuration.”

After you select 5. START/STOP from the Main Menu screen, one of the following messages displays for five seconds:

• MOTOR STOP appears when the system is operating to notify you that the system is shutting down.

• MOTOR START appears when the system is shut down to notify you that the system is starting.



Note: When the system is stopped, the Current Well State field in the PCP Status screen reads SD – Operator Stop.


SAM 6

Section 12

Reset Malfunctions

When the SAM PCP Controller is in a malfunction state, the malfunction must be cleared. To reset malfunctions, select 6. RESET MALFUNCTIONS from the Main Menu screen.

Note: You can also use Reset Malfunctions to reset VSD drive faults and malfunctions.

After you select this command, the malfunctions are reset and the message Reset Malf Completed appears.


SAM 7

Section 13

Firmware Versions

A Code Versions and Checksum screen similar to Figure 13-1 lists the different firmwares installed in the SAM PCP Controller and their version numbers and checksums. When you contact technical support with questions, you should either have this screen displayed or write down these numbers. To display this screen, select 7. FIRMWARE VERSIONS from the Main Menu screen.

Figure 13-1. Code Versions and Checksum Screen


SAM 8

Section 14

System Tools

The SAM PCP Controller has several diagnostic tools for checking data communications, local keypad integrity, and other operational features in the controller.


14.1 Overview of the System Tools ..................................................... 14-1 14.2 Maintenance Log.......................................................................... 14-2 14.3 Main Board I/O Diagnostics ........................................................ 14-3

14.3.1 Main Board I/O Status...................................................... 14-4 14.3.2 Main Board Manual DIO Diagnostics ............................. 14-5

14.4 Communication Diagnostics ........................................................ 14-6 14.4.1 RX/TX Messages ............................................................. 14-7 14.4.2 MB Register Map Check.................................................. 14-8

14.5 Keypad ......................................................................................... 14-9

14.1 Overview of the System Tools Several useful diagnostic tools are available for troubleshooting PCP control system installations. They are primarily intended for use by trained Lufkin Automation service technicians. This section only provides a brief overview about them. For more information about these functions, contact your Lufkin Automation representative.

The diagnostic tools are accessed from the System Tools Menu screen (Figure 14-1). To display this menu, select 8. SYSTEM TOOLS from the Main Menu screen.



SAM 8/1

Figure 14-1. System Tools Menu Screen

14.2 Maintenance Log The maintenance log feature displays a record of the last 200 significant events. All events are recorded with a date/time stamp. This log can be useful for checking when programming changes were made, power outages occurred, etc.

This information is displayed in an Event Log screen similar to Figure 14-2. To display this screen, select 1. MAINTENANCE LOG from the System Tools Menu screen.

Section 14: System Tools


SAM 8/2

Figure 14-2. Event Log Screen

You can use key commands while viewing the event log data:

Key Function NEXT or ↓ Displays the next screen of events.

↑ Returns to the previous screen of events.

ENTER Returns to the first screen to view the most-recent events. DELETE Clears all events from the screen.

After you are finished viewing this screen, do one of the following:

• Press <EXIT>To return to the System Tools Menu screen.

• Press <MENU>To return to the Main Menu screen.

14.3 Main Board I/O Diagnostics The Main Board I/O Diagnostics Menu screen (Figure 14-4) has screens to view the status of the turbine meter and pump motor, and to view the status and diagnose digital inputs and outputs on the main board. To display this menu, select 2.MAIN BOARD I/O DIAG from the Systems Tools Menu screen.



SAM 8/2/1

Figure 14-3. Main Board IO Diagnostics Menu Screen

14.3.1 Main Board I/O Status The Main Board I/O Status screen (Figure 14-4) is a troubleshooting tool for the main board to determine the I/O status of signals for rod RPM and the turbine meter, and the status of the digital inputs and outputs. To display this screen, select 1. MAIN BOARD I/O STATUS from the Main Board I/O Diagnostics Menu screen.

Figure 14-4. Main Board I/O Status Screen



SAM 8/2/2

The turbine meter signal from the PCP interface board is connected to the digital input used for the crank switch in the PCP application. The Counts and HZ fields indicate whether the turbine meter input is working properly. The data is not scaled in flow rate, but is merely a raw number indication of input signal.

The open and closed status are represented by 0 (zero) and 1. Be aware that 0 and 1 do not represent the same status for both inputs and outputs.

• For digital inputs, 1 represents open and 0 represents closed.

• For digital outputs, 0 represents open and 1 represents closed.

If you have questions about the open/closed status of any of the digital inputs or outputs, use the Main Board Manual DIO Diag screen (see page 14-5).

If you need to check the operating status of any inputs and outputs for piggyback boards, use their status screens. For information about status screens, see section 9, “Status Screens.”




14.3.2 Main Board Manual DIO Diagnostics The Main Board Manual DIO Diag screen (Figure 14-4) is a troubleshooting tool to show the open and closed status of digital inputs and outputs on the main board. You can also use this screen to turn on and off specific digital outputs. To display this screen, select 2. MAIN BOARD MANUAL DIO DIAG from the Main Board I/O Diagnostics Menu screen.



SAM 8/3

Figure 14-5. Main Board Manual DIO Diag Screen

The open and closed status are represented by 0 (zero) and 1. Be aware that 0 and 1 do not represent the same status for both inputs and outputs.

• For digital inputs, 1 represents open and 0 represents closed.

• For digital outputs, 0 represents open and 1 represents closed.

You can turn on or off any specific digital output (but not digital inputs).

• To turn on a digital output, press its number on the keypad.

• To turn off a digital output, hold down <0> on the keypad and then press its number.




14.4 Communication Diagnostics The Communication Diagnostics Menu screen (Figure 14-6) provides options for troubleshooting radio network communications problems and for locating memory locations in the Modbus register map. To display this menu, select 3. COMMUNICATIONS from the System Tools Menu screen.



SAM 8/3/1

Figure 14-6. Communication Diagnostics Menu Screen

14.4.1 RX/TX Messages The RX/TX Messages screen (Figure 14-7) shows the hexadecimal characters received and transmitted by the SAM PCP Controller. This information should be useful when troubleshooting radio network communications problems. To display this screen, select 1. RX/TX MESSAGES from the Communication Diagnostics Menu screen.

Figure 14-7. RX/TX Messages Screen



SAM 8/3/2




14.4.2 MB Register Map Check The MB Register Map Check screen (Figure 14-8) is a quick reference for locating memory locations in the Modbus register map for certain types of data. This tool is only useful to a systems integrator that is writing host software for reading and displaying data from the SAM PCP Controller. For a copy of the complete Modbus register map, contact your Lufkin Automation representative.

To display this screen, select 2. MB REGISTER MAP CHECK from the Communication Diagnostics Menu screen.

Figure 14-8. MB Register Map Check Screen


• Press <EXIT>to return to the System Tools Menu screen.

• Press <MENU>to return to the Main Menu screen.



SAM 8/4

14.5 Keypad The Keypad Diagnostic screen (Figure 14-9) helps you determine if all keys on the SAM PCP Controller keypad are operating properly. To display this screen, select 4. KEYPAD from the System Tools Menu screen.

Figure 14-9. Keypad Diagnostic Screen

As you press each key on the membrane keypad, the corresponding square on the Keypad Diagnostic screen darkens. When you press a key and the square representing it on the screen does not darken, you need to return the SAM PCP Controller to Lufkin Automation for service.

When you test the <EXIT> key, a message appears below the key squares that asks you to indicate whether you want to continue with the keypad test or actually exit from the test. Do one of the following:

• Press <1> to continue testing.

• Press <2> to exit from the keypad test and return to the System Tools Menu screen.

When you are at the System Tools Menu screen, you can return to the Main Menu screen by pressing <MENU>.


SAM 3/2

Section 15

Quick Programming Using the Quick Start Feature

This section provides information about using the Quick Start feature. This feature is designed to help you quickly enter the basic programming parameters necessary to configure the SAM PCP Controller and get it into operation. This section also shows you typical representations of each configuration screen you will see.

The topics covered in this appendix include:

15.1 PCP Quick Start ........................................................................... 15-1 15.1.1 Quick Start Programming Processes ................................ 15-2 15.1.2 Methods for Navigating the Quick Start Programming

Screens ............................................................................. 15-2 15.2 Starting the Quick Start Process................................................... 15-3 15.3 Resetting Parameters to Factory-Default Values ......................... 15-3 15.4 Using the Quick Start Feature ...................................................... 15-4

15.1 PCP Quick Start The Quick Start feature is added to the application firmware to make the SAM PCP Controller more “user friendly.” Quick Start walks you through the screens necessary to program (configure) control parameters that enable the SAM PCP Controller to work properly. This screen display method simplifies the programming process because only the screens required for the selected end devices and control methods are presented.



15.1.1 Quick Start Programming Processes Quick Start involves four processes that must be performed in the following sequence:

1. Stopping the pump

2. Resetting operating parameters to factory-default values

3. Configuring operating parameters

4. Starting the pump

15.1.2 Methods for Navigating the Quick Start Programming Screens

The keys you need to press on the SAM PCP Controller operator interface keypad and the operations they will perform are provided below.

Moving Between Quick Start Feature Screens Use the methods below to move between Quick Start Feature screens.

• Press <NEXT> to move forward one screen in the Quick Start process.

• Press <EXIT> to move back one screen in order to double-check or change a parameter value that was entered.

Editing Parameters Use the procedure below to edit parameters on screen.

1. Press <↑> and/or <↓> to move the cursor to highlight the parameter of interest. Press <EDIT> and then do one of the following:

a. Use the number keys to write in the desired value.

b. Press <↑> and/or <↓> to display the options available for the field.

2. When the parameter field reads as desired, press <ENTER> to complete the edit/program operation.

Section 15: Quick Programming Using the Quick Start Feature


15.2 Starting the Quick Start Process To start the Quick Start feature, from the Main Menu screen, select 3. CONFIGURATION, and then select 2. PCP QUICK START. You are presented with an instructions screen similar to Figure 15-1.

Figure 15-1. PCP Quick Start Instructions Screen

15.3 Resetting Parameters to Factory-Default Values

Lufkin Automation recommends that you reset the SAM PCP Controller to the factory-default values. Resetting ensures that any previous programming of the SAM PCP Controller does not cause problems. This operation is not required.

WARNING: After you execute this operation, the user-defined parameters cannot be easily restored. Each parameter must be re-programmed one field at a time.

After the PCP Quick Start Instruction screen displays, press <EDIT>. A message appears for you to confirm that you want to reset to the factory-default parameter values.

• If YES is highlighted, press <ENTER>.

• If NO is highlighted, press <←> or <→> to highlight YES, and then press <ENTER>.



A notification appears informing you that the SAM PCP Controller is reset to the factory-default settings.

At the PCP Quick Start Instruction screen, use one of the following options:

• If you choose not to reset to the default values, press <NEXT> to continue with the Quick Start process.

• Press <EXIT> to cancel the Quick Start process.

15.4 Using the Quick Start Feature When the Quick Start feature begins, you are presented with several screens for you to enter basic programming information. Most screens contain several parameters that require you to enter values specific to your site setup and the end devices installed. Below each screen in this section you are directed where to find detailed descriptions about the screens and the fields they contain.

Configuring Communication Ports After you are finished with the Quick Start Instruction screen shown in Figure 15-1, press <NEXT>. A Quick Start Communication Administration screen similar to Figure 15-2 displays for you to begin the Quick Start setup process. This screen has the communication parameters that you usually need to configure, such as RTU Address, data transmission rate, keying properties, and handshake protocol. For information about the parameters on this screen, see “Configuring the Communication Expansion Port” in section 8, “SAM Controller Programming.”



Figure 15-2. Quick Start Communication Administration Screen

Specifying GOT and Peak Energy Management After you are finished specifying communication port parameters, press <NEXT> to display a Quick Start Gauge Off Time/Peak Energy MGNT screen similar to Figure 15-3. Gauge off time (GOT) is the time of day that the SAM PCP Controller updates all of the historical data buffers. Peak Energy Management is a time period during the day you want the controller shut down the pump because of contractual agreements with the electric power provider to receive a more economical rate. For information about these features and the parameters on this screen, see “Setting Gauge Off Time and Peak Energy Management” in section 8, “SAM Controller Programming.”



Figure 15-3. Quick Start Gauge Off Time/Peak Energy MGNT Screen

After you are finished specifying GOT and peak energy management parameters, press <NEXT> to display a Quick Start Production/Motor Information configuration screen similar to Figure 15-4. Production K-factor is used as a correction to measured production. Motor information includes whether the prime mover is electric-driven or hydraulic-driven, and additional motor information you should be able to find on the motor nameplate. Be aware that fields unique to the motor type will appear after you select it. For information about the parameters on this screen, see “Configuring Production and Motor Information” in section 7, “PCP Parameter Programming.”



Figure 15-4. Quick Start Production/Motor Information Screen

Configuring End Devices After you are finished specifying production and motor information parameters, press <NEXT> to display a Quick Start End Devices Configuration screen similar to Figure 15-5. End devices include meters for flow rate (wedge meter, turbine meter, or scaled flow), fluid pressure metering, and motor torque. For information about the parameters on this screen, see “Configuring End Devices” in section 7, “PCP Parameter Programming.”

Figure 15-5. Quick Start End Devices Configuration Screen



Configuring PCP Control Parameters After you finish configuring end devices, press <NEXT> to display a Quick Start Control Parameters CFG screen similar to Figure 15-6. PCP control parameters control operations of the progressing cavity pump, such as power on and off delays, minimum and maximum pump operating speed, settling and sampling periods, and maximum speed increases and decreases. For information about the parameters on this screen, see “Configuring Control Parameters” in section 7, “PCP Parameter Programming.”

Figure 15-6. Quick Start Control Parameters CFG Screen (Screen 1 of 2)

After you are finished specifying PCP control parameters on Figure 15-6, press <NEXT> to display a second Quick Start Control Parameters CFG screen similar to Figure 15-7.



Figure 15-7. Quick Start Control Parameters CFG Screen (Screen 2 of 2)

Configuring VSD Type and Operating Speed Parameters After you are finished specifying PCP control parameters, press <NEXT> to display a Quick Start VFD/VSD Parameters screen similar to Figure 15-8. This screen is where you select a VSD type and specify its allowable minimum and maximum operating speeds. For information about the parameters on this screen, see “Configuring VFD/VSD Parameters”, in section 8, “SAM Controller Programming.”

Note: VFD Drive Type of OTHERS must be selected to use the SAM PCP controller with a generic variable speed drive.



Figure 15-8. Quick Start VFD/VSD Parameters Screen

Configuring Parameter Violations After you are finished specifying VFD/VSD configuration parameters, press <NEXT> to display a Quick Start Violation Configuration screen similar to Figure 15-9. This screen is used to enable and disable several SAM PCP Controller control functions. You must remember to enable or disable the control functions you need later. For information about the parameters on this screen and how to enable/disable them later, see “Configuring Parameter Violations” in section 7, “PCP Parameter Programming.”



Figure 15-9. Quick Start Violation Configuration Screen

Quick Start Sequence Completion After you are finished specifying violation parameters, press <NEXT> to display a Quick Start Sequence Completion screen similar to Figure 15-9.

Figure 15-10. PCP Quick Start Sequence Completion Screen

All the parameter configuration values required for the Quick Start configuration process are completed. To exit from the screen, press <ENTER>. You are retuned to the Configuration Menu screen.



Additional parameter configurations, such as alarms, digital inputs and outputs, and logic expressions to fine-tune the PCP controller can now be performed using the configuration screens available.

• For information about configuring PCP control parameters, see section 7, “PCP Parameter Programming.”

• For information about configuring basic SAM PCP Controller parameters, see section 8, “SAM Controller Programming.”


Section 16

Sam Flash Upgrade Utility Software

Lufkin Automation offers a utility software that can help you easily and quickly program one or more SAM PCP Controllers at the wellsite ,create backup files storing these parameters, and upgrade the application firmware in the controller.


16.1 Software Overview....................................................................... 16-2 16.2 Sam Flash Upgrade Utility Screen ............................................... 16-2

16.2.1 File To Upload Section .................................................... 16-3 16.2.2 Comm Parameters Section ............................................... 16-5 16.2.3 Status Section ................................................................... 16-7 16.2.4 Message Window Section ................................................ 16-7 16.2.5 Command Buttons............................................................ 16-8

16.3 Installing the Software on a Laptop Computer ............................ 16-9 16.4 Specifying Communications Between the Controller

and Laptop.................................................................................. 16-10 16.4.1 Specifying the Communication Baud Rate in the

SAM PCP Controller...................................................... 16-11 16.4.2 Specifying Communication Parameters in the Laptop

Computer ........................................................................ 16-12 16.5 Connecting the Controller to the Laptop Computer................... 16-13 16.6 Establishing Communications Between the Controller

and Laptop Computer................................................................. 16-14 16.7 Saving the Controller Configuration to a File............................ 16-15 16.8 Uploading a Saved Configuration File into the SAM

PCP Controller ........................................................................... 16-16 16.9 Upgrading Application Firmware .............................................. 16-19



16.10 Disconnecting Communications Between the Controller and Laptop Computer................................................................. 16-21

16.1 Software Overview Programming the SAM PCP Controller with the local keypad at the wellsite involves several steps and takes considerable time. To expedite the programming process, especially when you need to program several controllers, you can use the Sam Flash Upgrade Utility software available from Lufkin Automation. This software can be used to download all programming parameters from one SAM PCP Controller to a laptop computer file. You can then upload this “template” file with the complete block of parameters to a new SAM PCP Controller. After the file is uploaded, you can selectively reprogram specific parameters using the local keypad.

You can also keep this file as a backup in case the controller programming is lost or corrupted or you need to upgrade the application firmware.

16.2 Sam Flash Upgrade Utility Screen The Sam Flash Upgrade Utility screen (Figure 16-1) is the interface used to:

• Download the configuration parameters to a configuration file

• Upload the configuration file to the SAM PCP Controller

• Upgrade application firmware

All operations are performed through this single screen. It is accessed after you launch the SAM Flash Upgrade Utility software.

Section 16: Sam Flash Upgrade Utility Software


Figure 16-1. Sam Flash Upgrade Utility Screen

If you do not have the Sam Flash Upgrade Utility software installed on your laptop computer or you do not know how to display it, see “Installing the Software on a Laptop Computer” on page 16-9.

This utility screen is divided into seven sections.

• File To Upload

• Comm Parameters

• Status Message

• Message Window

• Command Buttons

• Incoming Data

• Outgoing Data

Each section is described below.

16.2.1 File To Upload Section This section has fields used to select the application code you want uploaded to the SAM PCP Controller. You also can verify the upload file type and that the correct file will be uploaded by viewing its checksum number. Figure 16-2 is an example.



Figure 16-2. File To Upload Section Example

Data Field Descriptions Information about each field is provided below.

Filename

Name of the file selected for uploading.

Browse Button

Click this button to open a dialog box used to select the file for upload to the SAM PCP Controller. After a file is selected, its file name and path display in the Filename field and its type (Application, Low Level, or Table/Database displays in the Upload Type field.

Upload Type

The current type of firmware code file to be uploaded to the SAM PCP Controller. The type is selected using the Browse button. The supported upload types are:

• Application

• Low Level

• Table/Database

File Checksum

The checksum for the *.sam file selected.

Application Checksum

The checksum for the Application (App) file selected. A checksum value (other than 00000000) only displays in this field if Application displays in the Upload Type field.

Low Level Checksum

The checksum for the low level (LL) file selected. A checksum value (other than 00000000) only displays in this filed if Low Level displays in the Upload Type field.



16.2.2 Comm Parameters Section This section has fields for specifying the RTU address of the SAM PCP Controller and communication parameters, such as timeout values and baud rates. These communication values are necessary in order for the Sam Flash Upgrade Utility software to communicate with the SAM PCP Controller, retrieve the existing configuration parameters, and download the upgraded programming. Figure 16-3 is an example of the Comm Parameters section.

Figure 16-3. Comm Parameters Section Example


Comm Port

The communication port on the laptop computer where the RS-232 cable is connected.

Flash Upgrade Baud Rate

Baud rate of the laptop computer. Allowable baud rates are:

• 1200

• 2400

• 4800

• 9600

• 19200

• 38400

• 57600

• 115200

Most new laptop computer models can use 115200.



Timing Factor

The timing factor is only used for flash upgrades and must be adjusted for each user’s system. A lower value results in faster uploads. Too low a value can cause a communication failure when the upgrade is attempted.

RTU Address

The SAM PCP Controller address. This is necessary for transferring data between the SAM PCP Controller and laptop.

Config Save/Load Baud Rate

The baud rate used for reading and writing the SAM PCP Controller configuration parameters. The allowable baud rates are:

• 1200

• 2400

• 4800

• 9600

• 19200

• 38400

• 57600

• 115200

Note: RTU Address and Config Save/Load Baud Rate must be set with the same values as the values in the SAM PCP Controller. These values are set using the Communication Administration screen. For information about setting these parameters, see “Configuring Communication Parameters” in section, “SAM Controller Programming.”

Reply Timeout

The timeout between the computer sending a modbus request to the SAM PCP Controller and the response from the SAM PCP Controller.

Use Modbus to Start Upload

You can enable this feature to allow an upload to be performed automatically. The Sam Flash Upgrade Utility software uses Modbus communications to switch the controller into flash upload mode and start the uploading process automatically.



16.2.3 Status Section This section provides status information about the data being transferred between the SAM PCP Controller and the laptop computer. Figure 16-4 is an example of the Status section.

Figure 16-4. Status Section Example


Total

The total number of packets to transfer.

Current Packet

The current packet being transferred.

Retries

The number of retries attempted for the current packet.

Status Window

This window displays the current message pertaining to the system status.

Progress Indicator

This bar is active for any communications to the SAM PCP Controller. It provides a graphical representation of the time remaining until the task is completed.

16.2.4 Message Window Section This section is a scrollable window used to view the last 100 messages from the system. System messages allow you to track the success or failure of any task, such as a successful or unsuccessful configuration file upload, notification that the configuration file is being sent, or configuration verification failure. Error messages display in red text. Figure 16-5 is an example.



Figure 16-5. Message Window Example

16.2.5 Command Buttons Command buttons are clicked to perform the necessary operations that the upgrade utility software can offer. These operations include the following:

• Starting and stopping the upload process

• Connecting (establishing communications) and disconnecting with the SAM PCP Controller

• Retrieving (downloading) the configuration parameters presently defined in the SAM PCP Controller and restoring (uploading) them to it

Note: Before you use the command buttons, make sure that the laptop computer is connected to the SAM PCP Controller. For information about properly connecting both components, see “Connecting the Controller to the Laptop” on page 16-13.



Information about each button is described below.

Button Name Description

Start Upload Starts the process for uploading the application

firmware. Messages display in the Message window during the uploading process.

Abort Upload Ends the uploading process. The Message window

displays “User Aborted Upload” in red text after clicking this button.

Connect Opens (connects) the software access to the laptop computer communications port. After this button is clicked, the Comm Port field is grayed out and the Connect button is replaced with the Disconnect button.

Disconnect Closes (disconnects) the software access to the laptop

computer communications port. After this button is clicked, it is replaced with the Connect button.

Save Config Downloads the configuration parameters in the SAM

PCP Controller and saves them to a *.cfg file.

Load Config Uploads the configuration parameters to the SAM PCP

Controller that are saved to a *.cfg file.

Verify Config Confirms that the configuration parameters in the SAM PCP Controller match the parameters saved to the *.cfg file.

Exit Closes the Sam Flash Upgrade Utility screen and the software. If any upgrading process (Start, Save, Load, Verify) is in progress, it is immediately terminated.

16.3 Installing the Software on a Laptop Computer

The Sam Flash Upgrade Utility software must be installed on your laptop computer before you can upgrade the application firmware or upload/download control parameter data. The software operates in the Windows 2000 and XP operating systems. This software is available from your Lufkin Automation representative.

Procedure Use the steps below to install the Sam Flash Upgrade Utility software on the laptop computer.

1. Insert the diskette or CD ROM distribution disk(s) that has the Sam Flash Upgrade Utility software into the laptop computer.

2. Copy the installation file (SamFlashUpgradeSetup3_3.exe) to a folder on you laptop computer.



3. Double-click the installation file. An Install Wizard opens.

4. Follow the instructions provided in the Install Wizard.

5. After the installation is completed, the Flash Upgrade icon ( ) should exist on your desktop.

6. Run the software to ensure that it executes by doing either of the following:

• Double-click located on your laptop desktop.

• Click the Start button and then select Programs/Lufkin Automation/Sam Utilities/Flash Upgrade.

A Sam Flash Upgrade Utility screen similar to Figure 16-1 (page 16-3) opens.

7. Click to close the screen.

The Sam Flash Upgrade Utility software is now ready for use. You can now connect your laptop computer to a SAM PCP Controller and use the software to upgrade the flash ROM in the SAM PCP Controller.

16.4 Specifying Communications Between the Controller and Laptop

Specifying and synchronizing communication parameters between the SAM PCP Controller and the laptop computer is required to upload and download files. Two tasks are required to complete this process.

• Specifying the communication baud rate in the SAM PCP Controller

• Specifying communication parameters in the laptop computer

Each task is described separately below.



16.4.1 Specifying the Communication Baud Rate in the SAM PCP Controller

Lufkin Automation recommends that the SAM PCP Controller communicate with the laptop computer port at 115,200 baud. The SAM PCP Controller defaults to 115,200 baud on the laptop computer port. You can change the baud rate setting using the Communication Configuration screen in the SAM PCP Controller. For detailed information about this screen and specifying baud rate, see “Configuring Communication Parameters” in section 8, “SAM Controller Programming.”

Procedure Use the steps below to change the laptop computer port baud rate in the SAM PCP Controller.




3. Select 1. COMMUNICATION PORT CFG to display the Communication Administration screen.

4. Press <↓> to highlight the Laptop Port Baud Rate field, and then press <EDIT>.

5. Press <↑> or <↓> to change the baud rate until 115200 displays, and then press <ENTER> to save the setting.

Change this field value



6. Press <MENU> to return to the Main Menu screen.

The laptop computer port baud rate in the SAM PCP Controller is now changed.

Note: While you are at this screen, note the address specified in the RTU Address field for use later when you are configuring the laptop computer software.

16.4.2 Specifying Communication Parameters in the Laptop Computer

Lufkin Automation recommends that the SAM PCP Controller communicate with the laptop computer port at 115,200 baud. Other parameters, such as the correct RTU address and reply times, must be properly configured in order to communicate with a specific controller and upload the application firmware to it. All parameters are specified in the Comm Parameters section of the Sam Flash Upgrade Utility screen.

Procedure Use the steps below to specify communication parameters in the laptop computer.

1. Start the Sam Flash Upgrade Utility software using one of the following methods:

• Double-click located on the laptop desktop.


The Sam Flash Upgrade Utility screen should display.

2. In the Comm Parameters section, click the down arrow in the Comm Port field and then click the Comm port you are using on your laptop.

3. Click the down arrow in the Flash Upgrade Baud Rate field and click 115200.

4. If necessary, change the value in the Timing Factor field.



Timing factor is usually set to 20. It is primarily used to upload upgrade application firmware to flash memory. You may need to set it to a higher value, such as 100, for slower laptop computers. Try 20 first and determine if it is sufficient.

5. In the RTU Address field, type the RTU address to the same Modbus address used for the SAM PCP Controller as noted while performing the steps for specifying baud rate (see page 16-11).

6. In the Config Save/Load Baud Rate field, make sure the value specified is 115200.

7. In the Reply Timeout field, specify 100.

8. Select the Use Modbus To Start Upload check box.

The communication parameters are now specified for communicating with the SAM PCP Controller.

16.5 Connecting the Controller to the Laptop Computer

A standard nine-pin RS-232 cable is required to transfer the data from the laptop computer to the SAM PCP Controller. If your laptop computer has only USB ports, a USB to aerial converter is required. Contact your Lufkin Automation representative for assistance.

Procedure Use the steps below to connect the laptop computer to the SAM PCP Controller.

1. Connect one end of the RS-232 cable to the DB-9 communications port on your laptop computer.

2. Connect the other end of the RS-232 cable to the DB-9 communications port on the front of the SAM PCP Controller. This port is located to the right of the 20-key keypad and below where labeled COM PORT.

Connect RS-232 cable here



The controller is now connected to the laptop computer.

16.6 Establishing Communications Between the Controller and Laptop Computer

After all communication parameters are correctly specified in the SAM PCP Controller and laptop computer, and both devices are physically connected, you need to instruct the Sam Flash Upgrade Utility software to establish communication with the laptop computer.

Procedure Follow the step below to establish communications between the SAM PCP Controller and your laptop computer.

1. Make sure the Sam Flash Upgrade Utility software is running and that the Sam Flash Upgrade Utility screen is displayed.

2. In the Sam Flash Upgrade Utility screen, click to connect the software access to the laptop computer communications port.

3. Select the Use Config Save/Load Baud Rate option from the drop-down list.

Communications is now established between the controller and laptop computer. You can now upload and download configuration parameter data.

16.7 Saving the Controller Configuration to a File

The configuration parameters programmed in a SAM PCP Controller can be downloaded to your laptop computer and saved to a configuration (*.cfg) file. After this file is saved, you can keep it as a backup, and you can also download the parameters to other SAM PCP Controllers.

Procedure Use the steps below to download the configuration parameters and save them to a *.cfg file on your laptop computer.

1. Make sure the laptop computer is connected to the SAM PCP Controller. For this procedure, see “Connecting the Controller to the Laptop” on page 16-13.




• Double-click located on the laptop computer desktop.



3. Click to connect the software access to the laptop computer communications port.

A shortcut menu appears with two options.

4. Select the Use Config Save/Load Baud Rate option.

5. In the Sam Flash Upgrade Utility screen, click .

The Save File As dialog box appears.

6. In the Save in field, select a folder where you want the file saved.

7. In the File name field, type over “Well Name” with the name you want used for the file.

8. Click the Save command button.

The dialog box closes and the configuration parameters are saved to a *.cfg file on your laptop computer.

The Incoming Data window shows the actual data being transmitted from the SAM PCP Controller to the laptop computer.



16.8 Uploading a Saved Configuration File into the SAM PCP Controller

You can upload from your laptop computer a configuration (*.cfg) file containing the configuration parameters for a SAM PCP Controller to another SAM PCP Controller. Uploading is a quick and easy method for programming a SAM PCP Controller at the wellsite. After the file is uploaded, you can selectively reprogram specific parameters using the local keypad on the SAM PCP Controller.

Uploading also allows you to use a *.cfg file as a backup when controller programming is lost or corrupted. You will also need to create a backup file before you upgrade the application firmware in the controller because all programming is lost during an upgrade.

Note: You can only successfully upload a *.cfg file for a SAM PCP Controller to another SAM PCP Controller. The Sam Flash Upgrade Utility software warns you from uploading the file to another type of SAM controller, such as an RPC or Injection Well unit.

Procedure Use the steps below to upload configuration parameters to a SAM PCP Controller.

WARNING: When you upload a configuration file, all configuration parameters stored in the SAM PCP Controller are lost and overwritten with the parameters in the configuration file. If you do not already have a backup configuration (*.cfg) file for the controller, create one now for possible use later. For information about creating a file, see “Saving the Controller Configuration to a File” on page 16-15.










4. Select the Use Config Save/Load Baud Rate option.


The Configuration File to Restore dialog box appears.

6. In the Look in field, select the folder where the *.cfg file is stored.

All *.cfg files stored in the folder are displayed.

7. Do one of the following to select the file you need:

• Double-click the file name you need.

• In the File name field, type over “Well Name” with the file name you need, and then click Open.

Note: An alert dialog box similar to the one shown below appears advising you that the firmware version in the SAM PCP Controller is less than 4.01. Since installing lower version number only impacts the Rod Pump Control application for the SAM Well manager, ignore this alert and click Yes to continue the file upload.

Another alert dialog box appears informing you that some configuration parameters may need to be manually reconfigured by you after you uploaded the *.cfg file.




• To continue the uploading process, click Yes.

• To discontinue the uploading process, click No.

You can click if you want to display a window showing the data being uploaded to the controller.

Click when you want to close this window.

9. When finished, click to verify that the configuration parameters in the controller match the parameters saved to the *.cfg file.

• “Register Values in Sam Match File Values” displays in the Message window when they match.

• If an Unable to Verify message displays, double-check the Comm. Parameter settings and the RS-232 cable connection to the SAM PCP Controller.

The SAM PCP Controller now operates in its normal operation mode.

The SAM PCP Controller is now operating with the configuration parameters you uploaded. You many need to use the local keypad to check the parameters, and you may need to manually edit some of them.

16.9 Upgrading Application Firmware The primary purpose of the Sam Flash Upgrade Utility software is to upgrade the application firmware in the SAM PCP Controller. Flash upgrade files have the “*.sam” file extension. You can obtain these files from your Lufkin Automation representative.



Procedure Use the steps below to upload the updated controller firmware.

WARNING: All configuration programming in the controller is lost during the firmware upgrade. If you do not already have a backup configuration (*.cfg) file for the controller, create one now. For information about creating a file, see “Saving the Controller Configuration to a File” on page 16-15.

1. Copy the new application firmware file(s) to a folder on your laptop computer.








5. Select the Use Flash Upgrade Baud Rate option.


The File to Upload dialog box appears.

7. In the Look in field, select the folder where the *.sam file is stored.

All *.sam files stored in the folder are displayed.



8. Do one of the following to select the file you need:

• Double-click the file name you need.

• In the File name field, type the file name you need, and then click Open.

9. Click to start the uploading process.

Messages display during the uploading process in the Message window and the actual data being transmitted displays in the Outgoing Data window.

After the uploading process completes, the SAM PCP Controller reinitializes (reboots). Its operator interface reads “Reinitializing” during this process. After reinitializing is completed, the operator interface displays the first of the PCP Status screens.

The application firmware is now updated and operational.

The application firmware overwrites the programmed configuration parameters with factory-default values. You need to program the controller-specific configuration parameters into the SAM PCP Controller. You can program them manually, or if you have a backup *.cfg file containing them, use it.

• For information about uploading the *.cfg file, see “Uploading a Saved Configuration File into the SAM PCP Controller” on page 16-16.

• For information about manually programming the configuration parameters, see section 7, “Programming the SAM PCP Controller.”

16.10 Disconnecting Communications Between the Controller and Laptop Computer

After you are finished communicating with the SAM PCP Controller, you need to disconnect communications with the controller and laptop computer and close the SAM Flash Upgrade Utility software.



Procedure Use the steps below to disconnect the software access to the SAM PCP Controller and laptop computer and close the software.

1. Click to close (disconnect) the software access to the laptop computer communication port.

2. Click to close the SAM Flash Upgrade Utility screen.

You can now disconnect the cable connecting the SAM PCP Controller to the laptop computer.

Issue Date:1/18/08 Revision 1.00 A-1

Appendix A

Well State List

This appendix defines the well states displayed in the SAM PCP Controller. All well states are grouped into categories, which include:

A.1 Overview of Well States ............................................................... A-2 A.2 Normal Operation Well States ...................................................... A-2 A.3 Downtime and Malfunction Well States ....................................... A-4

A.3.1 Violation Conditions and Types............................................... A-4 A.3.2 Violation Run Well States ........................................................ A-5 A.3.3 Violation Downtime Well States.............................................. A-5 A.3.4 Malfunction Run Well States ................................................... A-6 A.3.5 Malfunction Shutdown Well States.......................................... A-6 A.3.6 Logic Expression Violation Well States .................................. A-6 A.3.7 Malfunction - Drive Fault......................................................... A-7 A.3.8 Miscellaneous Downtime States............................................... A-7

A.4 HOA Well States ........................................................................... A-8 A.5 Quick-Start Well States................................................................. A-8 A.6 Timed Mode Well States............................................................... A-8 A.7 Host Mode Well States.................................................................. A-9 A.8 Monitor Mode Well States .......................................................... A-10 A.9 Speed Control Well States........................................................... A-10 A.10 Sand Blowout Well States........................................................... A-10 A.11 Power Fail Lockout ..................................................................... A-10 A.12 Error Well States ......................................................................... A-11


A-2 Revision 1.00 Issue Date:1/18/08

A.1 Overview of Well States A well state can indicate a phase of normal operation, or it can alert the operator to a problem with the pumping equipment or the SAM PCP Controller system components (input devices), or it may indicate that someone has bypassed the SAM PCP Controller. When a well state indicates a problem, the operator should check the SAM PCP Controller installation and programming.

The SAM PCP Controller will be in only one of a number of well states at any given time. Its present well state can provide clues to the problem. The current well state displays on the top line of the PCP Status screen along with the time elapsed since being in that well state. For information about this screen, see “Current PCP Operating Status” in section 9, “Status Screens.”

A well state can indicate a phase of normal operation, or it may alert the user to a problem with the SAM PCP Controller input devices or the pumping equipment.

Some well states may not be observed on the local interface because they are transient well states having a very short duration. For example the Stopped well state quickly changes to one of the downtime or malfunction states to give the user more complete information about why the unit stopped. Other well states will typically be observed only through host computer software, since an onsite operator will be using other local interface screens, such as Load Calibration and Valve/CBE Check.

Note: Additional well states may appear that were not available when this list was published. If one should appear that is not defined, contact your Lufkin Automation representative for help.

A.2 Normal Operation Well States A Normal Operation well state indicates a phase of normal operation, and which usually means the operator does not need to be concerned about basic performance of the PCP system.

Well state and elapsed time of current state

Appendix A: Well State List


Power On Delay Initial Well State following a reboot of the SAM PCP CONTROLLER. The SAM PCP CONTROLLER waits the programmed number of seconds before starting the motor.

Duration: Programmable by user.

Starting Alert Digital Output 3 is held low for the programmed number of seconds to sound an optional audible start alert device.


Starting Unit SAM PCP CONTROLLER has pulled digital output 2 low to start the motor.

Duration: User-programmable Start Up Period length.

Settling Period This well state, allows the input parameters to settle after a control decision has been made. After this well state, the SAM PCP CONTROLLER will go to the Sampling Period well state.

Duration: Programmable by user

Sampling Period The SAM PCP CONTROLLER samples the flow rate for the predetermined sample period in order to determine the next control decision, which occurs at the end of this well state.


Power Off Delay The SAM PCP CONTROLLER decreases the speed output to the motor in the programmed number of steps.


Stopping Unit One of the enabled SAM PCP Controller control functions made a decision to stop the pumping unit. In this well state, the RPM input is checked until zero RPM is detected, telling the SAM PCP CONTROLLER that the rods have stopped spinning.

Duration: Until SAM PCP CONTROLLER senses a stopped condition or user-programmable time expires.



Stopped A transition state between stopping and the appropriate Downtime or Malfunction well state.

Duration: < 1 second

Unable To Stop The SAM PCP CONTROLLER enters this well state if the rods are turning after the user-programmable stopping period expires.

Duration: Once the rods stop turning, the SAM PCP CONTROLLER will go into a Downtime or Malfunction well state.

A.3 Downtime and Malfunction Well States

A well state that includes the word Downtime (DT) in a well state, with two exceptions, tells the user that the SAM PCP Controller will automatically start the pumping unit when the programmed downtime elapses. The two exceptions to this general rule are:

• Downtime Global Off Command well state — When the SAM PCP Controller receives a Global Off command, it keeps the pumping unit shut down until told to do otherwise.

• Downtime Peak Energy Management well state — The SAM PCP Controller keeps the pumping unit in a downtime state for the entire period programmed for Peak Energy Management.

The word Malfunction (MALF) in a well state means that the SAM PCP Controller detected a malfunction with equipment and that an operator must take action to return the unit to a pumping condition.

A.3.1 Violation Conditions and Types Violation Run well states occur after a violation is detected. Once it is detected, the SAM PCP CONTROLLER will go into the Power Off Delay well state. After Power Off Delay expires, if the action selected by the user for the particular violation is to Run Minimum, the SAM PCP CONTROLLER will go into the appropriate Violation Run well state. If the action for the violation is to shut down, the SAM PCP CONTROLLER will go to the Stopping well state after Power Off Delay and then into the appropriate Downtime well state.

Below are the types of violations that can occur to trigger a Downtime or Malfunction well state.



• Low RPM — Occurs after the measured RPM value violates the user-programmable low RPM threshold.

• Torque Violation — Occurs after the torque value violates the critical torque limit.

• No RPM — Occurs after the SAM PCP CONTROLLER determines that the rods are not turning during a running well state.

• Low Production — Occurs when the measured production rate violates the user programmable low production threshold.

• Torque Limiting — Occurs when the torque value violates the torque limiting threshold and the rods reach minimum speed.

• High Production — Occurs when the measured production rate violates the high production threshold.

A.3.2 Violation Run Well States VR - Low RPM

VR - Torque Violation

VR - No RPM

VR - Low Production

VR - Torque Limiting

VR - High Production

Duration: User-programmed Downtime.

A.3.3 Violation Downtime Well States DT - Low RPM

DT - Torque Violation

DT - No RPM

DT - Low Production

DT - Torque Limiting

DT - High Production



Duration: User-programmed Downtime.

A.3.4 Malfunction Run Well States MALF RUN - Low RPM

MALF RUN - Critical Torque

MALF RUN - No RPM

MALF RUN - Low Production

MALF RUN - Torque Limiting

MALF RUN - High Production

Duration: Until a Reset Malfunction is issued through HMI or by HOST communications.

A.3.5 Malfunction Shutdown Well States MALF SD - Low RPM

MALF SD - Critical Torque

MALF SD - No RPM

MALF SD - Low Production

MALF SD - Torque Limiting

MALF SD - High Production


A.3.6 Logic Expression Violation Well States The logic expression feature can be programmed in the SAM PCP CONTROLLER to affect control similar to a violation. However, the logic expression does not have a run minimum selection. When the logic expression is violated, the SAM PCP CONTROLLER stops the motor. The user also selects whether the SAM PCP CONTROLLER will go into a malfunction well state, or go continually into a downtime state when the violation occurs.

A logic expression violation occurs when all of the following are true:



• A logic expression is defined to act on MO2 (Motor Control Digital)

• The action for the logic expression acting on MO2 is STOP or MALF

• The logic expression is true for longer than the Logic Time Delay

If the action for the logic expression is set to MALF (Malfunction), and the number of consecutive violations exceeds the consecutive violations allowed, then the SAM PCP CONTROLLER will go into the MALF SD – Logic Expression well state.

DT - Logic Expression

Duration: User-programmed downtime.

MALF SD - Logic Expression


A.3.7 Malfunction - Drive Fault The SAM PCP CONTROLLER can monitor the VSD for a drive fault. If a fault is detected, then the SAM PCP CONTROLLER will enter a Malfunction – Drive Fault well state.

A.3.8 Miscellaneous Downtime States DT - Peak Energy Mgmt Occurs when the current time of day enters

the user programmable Peak Energy Management window.

Duration: Until the current time of day exits the user programmable Peak Energy Management window.

DT - Global Off Occurs when a broadcast message from the host signals an entire field shutdown.

Duration: Until a Start command is issued through HMI or a Host communication.

SD - Operator Stop Occurs when a stop command is issued through the HMI.

Duration: Until a Start command is issued through HMI or a Host communication.



A.4 HOA Well States If a HOA switch is wired into the SAM PCP CONTROLLER, the feature is enabled, and when the switch is turned to the ON or OFF setting, the well state will reflect the change.

HOA OFF The SAM PCP CONTROLLER has detected that the HOA switch has been turned to the OFF position.

Duration: Until the HOA switch is changed

HOA HAND The SAM PCP CONTROLLER has detected that the HOA switch has been turned to the HAND position.

Duration: Until the HOA switch position is changed.

A.5 Quick-Start Well States When the user initiates a Quick-Start for configuration, the SAM PCP CONTROLLER will enters into one of two states. For more information about the Quick-Start feature, see section 15, “Quick Programming Using the Well State List Feature.”

Quick Start – Run Quick-Start is initiated and the motor is turned on.

Quick Start – Stopped Quick-Start is initiated and the motor is turned off.

A.6 Timed Mode Well States When the SAM PCP CONTROLLER is operating in the Timed Mode, the user can configure the control mode to be either HI – LO or ON – OFF. The well states indicate which control method is in use.

TIMED MODE – HI The SAM PCP CONTROLLER is operating in the HI – LO method, and is currently running at the HI Speed.

Duration: For the programmable Timer Mode Hi period.

TIMED MODE – LO The SAM PCP CONTROLLER is operating in the HI – LO method, and is currently running at the LO Speed.



Duration: For the programmable Timer Mode Lo period.

TIMED MODE – ON The SAM PCP CONTROLLER is operating in the ON – OFF method, and is currently running.

Duration: For the programmable Timer Mode On period.

TIMED MODE – OFF The SAM PCP CONTROLLER is operating in the ON – OFF method, and is currently shut down.

Duration: For the programmable Timer Mode Off period.

A.7 Host Mode Well States When the SAM PCP CONTROLLER is operating in the Host mode, the control mode can be configured as HI-LOW or ON-OFF. The well states indicates which control method is presently in use.

HOST MODE – HI The SAM PCP CONTROLLER is operating in the HI – LOW method, and is currently running at HI Speed. This speed is programmed by the user.

Duration: Remains in this state unless operation mode is changed or Host switch is changed.

HOST MODE – LOW The SAM PCP CONTROLLER is operating in the HI – LOW method, and is currently running at LOW Speed. This speed is programmed by the user.


HOST MODE – ON The SAM PCP CONTROLLER is operating in the ON – OFF method, and is the unit is currently running.


HOST MODE – OFF The SAM PCP CONTROLLER is operating in the ON – OFF method, and is the unit is currently stopped.




A.8 Monitor Mode Well States When the SAM PCP CONTROLLER is operating in the Monitor mode, no control decisions are being made. Also the SAM PCP Controller is not controlling the speed at which the motor is running.

Monitor Mode The SAM PCP CONTROLLER is currently operating in the Monitor mode.

Duration: Remains in this state unless the operation mode is changed.

A.9 Speed Control Well States When the SAM PCP CONTROLLER is operating in the Speed Control method, the motor is set to run at a constant speed. In this mode, violation checking can be enabled and the appropriate actions to take when a violation occurs can also be configured.

Speed Control – ON The SAM PCP CONTROLLER is operating in the Speed Control method.

Duration: Remains in this state unless operation mode is changed or due to a reaction to a violation.

A.10 Sand Blowout Well States SBO:Ramp Down Period The pump is being slowed down to allow a

fluid to build up for the sand blow-out process.

Duration: Predetermined in the configuration of the SBO feature.

SBO:Speed Increase The pump speed is being increased to blow out the sand.

Duration: Predetermined in the configuration of the SBO feature.

A.11 Power Fail Lockout SD - Power Failure Lockout When enabled, the SAM PCP Controller

will not restart the well after a power failure.



Duration: Until a start command is issued through HMI or a Host communication.

A.12 Error Well States Invalid State This well state should never be reached.

Loss of Programming SAM PCP CONTROLLER has lost the programmed parameters and has therefore returned to default conditions.

Duration: Until reset by user.

Programming Fault SAM PCP CONTROLLER has reached an internal error that can not be recovered from. Most of the tasks including the control task have been terminated.

Duration: Until reset by user.

Issue Date: 1/18/08 Revision 1.00 B-1

Appendix B

AGA 3 Definitions

This appendix describes the formulas used by the SAM PCP Controller to calculate gas flow rate and accumulate gas production volume data.

The topics covered in this appendix include:

B.1 AGA 3 Formulas ............................................................................B-2 B.1.1 AGA-3 1992 Tap Type Factors Method..........................B-2 B.1.2 Pressure Measured at Upstream Tap Pf1 ..........................B-4 B.1.3 Orifice Flow Constant C’.................................................B-4 B.1.4 Numeric Conversion Factor — Fn ...................................B-5 B.1.5 Velocity Approach Factor — Ev .....................................B-5 B.1.6 Orifice Calculation Factor — Fc ......................................B-6 B.1.7 Reynolds Number — ReD ................................................B-7 B.1.8 Orifice Slope Factor – Fsl.................................................B-8 B.1.9 Expansion Factor – Y ......................................................B-8 B.1.10 Pressure Base Factor — Fpb .............................................B-9 B.1.11 Temperature Base Factor — Ftb ......................................B-9 B.1.12 Flowing Temperature Factor — Ftf..................................B-9 B.1.13 Real Gas Relative Density (Specific Gravity)

Factor — Fgr...................................................................B-10 B.1.14 Supercompressibility Factor — Fpv ...............................B-10 B.1.15 AGA-3 1985 Formula — Pipe Taps ..............................B-11

B.2 Orifice Flow Constant — C’ ........................................................B-12 B.2.1 Basic Orifice Factor — Fb .............................................B-12 B.2.2 Reynolds Number Factor — Fr ......................................B-13 B.2.3 Pressure Base Factor — Fpb ...........................................B-15 B.2.4 Temperature Base Factor — Ftb ....................................B-15 B.2.5 Flowing Temperature Factor — Ftf................................B-15 B.2.6 Real Gas Relative Density (Specific Gravity)

Factor – Fgr.....................................................................B-16 B.2.7 Supercompressibility Factor — Fpv ...............................B-16

B.3 NX-19 Formulas...........................................................................B-16


B-2 Revision 1.00 Issue Date: 1/18/08

B.3.1 Adjusted Pressure And Temperature Calculations ........B-17 B.3.2 Pressure and Temperature Correlation Parameters........B-19 B.3.3 NX-19 Natural Gas Regions and E Equations...............B-19 B.3.4 Flowing Compressibility — Zf ......................................B-21 B.3.5 Base Compressibility — Zb...........................................B-21

B.4 Calibration Factors .......................................................................B-21 B.4.1 Orifice Thermal Expansion Factor — Fa .......................B-22 B.4.2 Water Manometer Correction Factor — Fam................B-22 B.4.3 Local Gravitational Correction Factor For U-Tube

Manonmeters — Fwl.......................................................B-23 B.4.4 Water Manometer Temperature Correction Factor — FwtB-24 B.4.5 Local Gravitational Correction Factor For Weight

Standards — Fpwl ...........................................................B-24 B.4.6 Correction for Gas Column in Mercury Manometer

Instruments – Fhgm..........................................................B-25 B.4.7 Mercury Manometer Temperature Factor — Fhgt ..........B-26

B.1 AGA 3 Formulas

B.1.1 AGA-3 1992 Tap Type Factors Method In 1992 AGA released a new version of Report 3. The new version addressed improvements made in gas flow measurement utilizing flange taps. The new formulas introduced in the report offer two methods for calculating flow with flange taps. For the SAM PCP Controller AGA implementation we use the Factors method.

Appendix B: AGA 3 Definitions


The general equation using the Factors method is:

The SAM PCP Controller uses a modified version of the general equation, which is:

taporificedownstreamtheatmeasuredispressurestaticabsolute thewhen2subscriptortaporificeupstreamtheatmeasuredispressure staticabsolute

thewhen1subscriptuseabsolute,inchsquareperpoundsinpressurestaticabsolutePF60atwaterofinchesinpressurealdifferentih

n)calibratioafterchange etemperaturinstrumentforcorrection(spanfactoretemperaturmanometermercuryF

manometersmercuryincolumngasforcorrectionfactor,manometerF

standardpressurestatictesterweightdeadforcorrectionnalgravitatiolocalFstandardncalibratiocolumnwaterforre)(temperatucorrectionweightwaterF

standardncalibratiocolumnwaterforcorrectionnalgravitatiolocalFncalibratioinstrument

aldifferentitheduringmanometerwatertheinwateroverairforcorrectionFfactorexpansionthermalorificeF

constantfloworificeC'conditionsbaseathourperfeetcubicinflowvolumebaseofratequantityQ

:WherePhFFFFFFFCQ

f

Ow

hgt

hgm

pwl

wt

wl

am

a

v

fwhgthgmpwlwtwlamav

==

=

=

===

====

= 5.0]['

taporificeupstreamtheat

measuredabsolute,inchsquareperpoundsinpressurestaticabsolutePF60atwaterofinchesinpressurealdifferentih

factors these calculate to how for B Appendix seeF and ,F ,F ,F ,F

F ,F :factors following for correct to factor ncalibratio entered serUFconstantfloworificeC'

conditionsbaseathourperfeetcubicinflowvolumebaseofratequantityQ:Where

PhFCQ

f1

Ow

hgthgmpwlwtwl

amacal

v

fwcalv

==

===

= 5.01 ]['



B.1.2 Pressure Measured at Upstream Tap Pf1 Since the pressure can be measured at either the upstream or downstream, the tap downstream measurement needs to be converted to an upstream pressure for all calculations. The conversion is as follows:

B.1.3 Orifice Flow Constant C’ In the 1992 formula C’ becomes:

The terms (Fc+Fsl) combined are called the discharge coefficient Cd(FT). factorlityompressibisupercF

factordensityrelativegasrealF

factoretemperaturflowingFfactorbaseetemperaturF

factorbasesurepresFupstream to referenced factorxpansionEY

factorSlopeOrificeFfactornCalculatioOrificeF

factorconversionNumericFWhere

FFFFFYFFFC

pv

gr

tf

tb

pb

1

sl

c

n

pvgrtftbpbslcn

=

=

==

====

=

+=

:

)(' 1

taporificestreamdowntheat

measuredabsolute,inchsquareperpoundsinpressurestaticabsolutePF60atwaterofinchesinpressurealdifferentih

taporificeupstreamtheat

measuredabsolute,inchsquareperpoundsinpressurestaticabsoluteP:Where

Ph

P

f2

Ow

f1

fw

f

==

=

+= 21 707.27



B.1.4 Numeric Conversion Factor — Fn

The numeric conversion factor is calculated as:

B.1.5 Velocity Approach Factor — Ev The velocity approach factor is calculated as:

α1 and α2 are as follows:

Material Linear Coefficient (in/in-OF) Type 304 and 316 stainless steel 0.00000925 Monel 0.00000795 Carbon Steel 0.00000620

conditions base at air of essibilitySupercomprZmaterial tube meter the of expansion thermal of tcoefficien linear

material plate orifice the of expansion thermal of tcoefficien linearT at diameter bore plate orifice referenced

TTddfacor approachvelocity the E

:Where

ZdEF

air

air

b

rr

rfr

v

bvn

====

−+==

=

2

1

1

22

)](1[

265.338

αα

α

material tube meter the of expansion thermal of tcoefficien linearmaterial plate orifice the of expansion thermal of tcoefficien linear

T at diameter internal tube meter referenceDT at diameter bore plate orifice referenced

TTDD

TTddd/D

:Where

E

rr

rr

rfr

rfr

v

====

−+=

−+==

−=

2

1

2

1

4

)](1[

)](1[

11

αα

α

αβ

β



B.1.6 Orifice Calculation Factor — Fc The orifice calculation factor is calculated as:

For meter tubes whose internal diameter is less than 2.8 inches, Fc is modified by an additional term such that:

number ReynoldsRematerial tube meter the of expansion thermal of tcoefficien linear

material plate orifice the of expansion thermal of tcoefficien linearT at diameter internal tube meter referenceD

T at diameter bore plate orifice referenced

TTDD

TTddd/D

Where

DD

ee

F

d

rr

rr

rfr

rfr

D

D

DD

c

=====

−+=

−+==

⎥⎥⎦

⎤

⎢⎢⎣

⎡⎟⎟⎠

⎞⎜⎜⎝

⎛−

⎥⎥⎦

⎤

⎢⎢⎣

⎡⎟⎟⎠

⎞⎜⎜⎝

⎛−

−−

−

−⎥⎥⎦

⎤

⎢⎢⎣

⎡⎟⎟⎠

⎞⎜⎜⎝

⎛−−++

−+=

−−

2

1

2

1

8.01.1

3.1

4

48.00.65.8

82

)](1[

)](1[

Re000,1914.01

)1(252.0

)1(2116.0

1Re000,1923.01)1145.00712.00433.0(

2290.00291.05961.0

αα

α

αβ

ββββ

βββ

ββ

)8.2)(1(003.0' DFF cc −−+= β



B.1.7 Reynolds Number — ReD

The Reynolds number can be calculated by assuming an initial value and iterating the following equation:

The initial value can be assumed from the table below.

Nominal Tube Diameter (inches)

Assumed Reynolds Number ReD

2 500,000 3 750,000 4 1,000,000 6 1,500,000 8 2,000,000 10 2,500,000 12 3,000,000 16 4,000,000 20 5,000,000 24 6,000,000 30 8,000,000

After calculating ReD, the calculated ReD can be reused in the equations and a new Qv calculated. From this new Qv, ReD can be calculated. After three to five iterations, the calculated values should be acceptable.

bb

rr

rfr

b

r

b

v

bb

rbvD

T at air of essibilitySupercomprZViscoscity

material tube meter the of expansion thermal of tcoefficien linearT at diameter internal tube meter referenceD

TTDDeTemperatur BaseT

gravity SpecificGPressure BaseP

rate flow Volume Q:Where

ZDTGPQRe

air

air

====

−+=====

⎟⎟⎠

⎞⎜⎜⎝

⎛=

μα

α

μ

2

2 )](1[

0114541.0



B.1.8 Orifice Slope Factor – Fsl The orifice slope factor is calculated as:

B.1.9 Expansion Factor – Y The expansion factor is calculated as:

number ReynoldsRematerial tube meter the of expansion thermal of tcoefficien linear

material plate orifice the of expansion thermal of tcoefficien linearT at diameter internal tube meter referenceD

T at diameter bore plate orifice referenced

TTDD

TTddd/D

Where

ReF

d

rr

rr

rfr

rfr

DDDsl

=====

−+=

−+==

⎟⎟⎠

⎞⎜⎜⎝

⎛

⎥⎥⎦

⎤

⎢⎢⎣

⎡⎟⎟⎠

⎞⎜⎜⎝

⎛++⎟⎟

⎠

⎞⎜⎜⎝

⎛=

2

1

2

1

35.04

8.07.0

)](1[

)](1[

Re000,000,1000,19049.0210.0

Re000,000,1000511.0

αα

α

αβ

ββββ

tables. lookup AGA of generation the in used was1.3 of value A exponent. isentorpic k

absolute inch squareper

pounds in tap, pressure upstream the at pressure staticabsolute PF60 at waterof inches in pressure, aldifferenti h

tap. upstream the at pressure staticabsolute to pressure aldifferenti of ratio the x

tap. upstream the at measured pressure staticabsolute the on based factor expansion theY

Where

Ph

x and

kxY

f

Ow

1

f

w

1

=

==

=

=

=

+−=

1

1

11

14

.

:

707.27:

)35.041.0(1 β



B.1.10 Pressure Base Factor — Fpb The pressure base factor is applied to change the base pressure from 14.73 psi absolute and is calculated as:

B.1.11 Temperature Base Factor — Ftb The temperature base factor is applied to change the base temperature from 60° F and is calculated as:

B.1.12 Flowing Temperature Factor — Ftf The flowing temperature factor is applied to change from the assumed flowing temperature of 60° F to the actual flowing temperature Tf and is calculated as:

absolute inch squareper pounds pressure, base (contract) required the P:Where

PF

b

bpb

=

=73,14

Rankine degreees in etemperatur (contract) required the T:Where

TF

b

btb

=

=67.519

Rankine degrees in gas the of temperatur flowing acutal T:Where

TF

f

ftf

=

⎥⎥⎦

⎤

⎢⎢⎣

⎡=

5.067.519



B.1.13 Real Gas Relative Density (Specific Gravity) Factor — Fgr

The real gas relative density (specific gravity) factor is used to change from a real gas relative density of 1.0 to the actual real gas density of the gas flowing, and is calculated as:

B.1.14 Supercompressibility Factor — Fpv The basic supercompressibility equation is:

For the MPC implementation of AGA-3, the supercompressibility factor will be calculated using NX-19.

gas flowing the ofdensity gas real acutal G:Where

GF

r

rgr

=

⎥⎦

⎤⎢⎣

⎡=

5.01

conditions flowing atility compressib gasZconditions base atility compressib gasZ

Where

ZZF

f

b

f

bpv

==

=

:



B.1.15 AGA-3 1985 Formula — Pipe Taps The AGA-3 1985 formula is given as:

The SAM PCP Controller uses a modified version of the 1985 formula, which is:



n)calibratioafterchange

etemperaturinstrumentforcorrection(spanfactoretemperaturmanometermercuryF

manometersmercuryincolumngasforcorrectionfactor,manometerF

standardpressurestatictesterweightdeadforcorrectionnalgravitatiolocalFstandardncalibratiocolumnwaterforre)(temperatucorrectionweightwaterF

standardncalibratiocolumnwaterforcorrectionnalgravitatiolocalFncalibratioinstrument

aldifferentitheduringmanometerwatertheinwateroverairforcorrectionFfactorexpansionthermalorificeF

constantfloworificeC'conditionsbaseathourperfeetcubicinflowvolumebaseofratequantityQ

:Where

PhFFFFFFFCQ

f

Ow

hgt

hgm

pwl

wt

wl

am

a

v

fwhgthgmpwlwtwlamav

==

=

=

===

====

= 5.0]['



factors these calculate to how for B Appendix seeF and ,F ,F ,F ,F

F Fa, :factors following for correct to factor ncalibratio entered serUFconstantfloworificeC'

conditionsbaseathourperfeetcubicinflowvolumebaseofratequantityQ:Where

PhFFCQ

f

Ow

hgthgmpwlwtwl

amcal

v

fwcalav

==

===

= 5.0]['



B.2 Orifice Flow Constant — C’ The orifice flow constant is given as:

B.2.1 Basic Orifice Factor — Fb The basic orifice factor is given as:

Calculating Ko Ko is calculated using the following formulas:

factorlityompressibisupercF

factordensityrelativegasrealF

factoretemperaturflowingFfactorbaseetemperaturF

factorbasesurepresFfactorexpansionY

factorNumberReynoldsF

factororificebasicFWhere

FFFFYFFFC

pv

gr

tf

tb

pb

r

b

pvgrtftbpbrb

=

=

==

===

=

=

:

'

( )

A Term drop then If

D

DDDK

:taps pipe For :as gcalculatin isK

)/15disRwhentcoefficienflowK

tapspipeforD

BtapsflangeforD

B

DddiametertubemetermeasuredtodiameterorificeofratioBdE

diametertubemetermeasuredDdiameterorificed

Whered

EKK

A Term

e

e

de

eo

25.0

25.043.1

35.1225.0935.006.0440.00182.05925.0

10(

,75875,530)/(

)420090005000830(

:)10(

151

25

5.0

1452

6

5.0

32

6

>

−+

+⎥⎦

⎤⎢⎣

⎡ −+⎥⎦

⎤⎢⎣

⎡ +++=

=

+==

=+−+−=

==

+=

β

β

βββ

ββββ

444 3444 21



B.2.2 Reynolds Number Factor — Fr The Reynolds number factor is given as:

988.0700.0943.0675.0904.0650.0869.0625.0837.0600.0

810.0575.0785.0550.0763.0525.0742.0500.0724.0475.0

707.0450.0692.0425.0680.0400.0668.0375.0658.0350.0

650.0325.0641.0300.0634.0275.0628.0250.0623.0225.0

618.0200.0614.0175.0611.0150.0608.0125.0607.0100.0

,)1(

604.0

,75875

,530

)/()420090005000830(

)(

:

1

5.04

5.0

32

KKKKK:table from determined be must K taps pipe for

tapsflangeforK

tapspipeforD

BtapsflangeforD

B

DddiametertubemetermeasuredtodiameterorificeofratioBdE

diameter orificed12835dK

E b

flowingpressurestaticabsolutePpressurealdifferentih

Where

Ph

bF

f

w

fw

r

βββββ

β

ββββ

−=

+==

=+−+−=

=

=

==

+=



Expansion Factor — Y The Expansion factor is calculated based on whether measurement is referenced to upstream or downstream pressure, and the type of tap being used. Calculations are as follows:

tap. downstream the at pressure staticabsolute to pressure aldifferenti of ratio the x

tap. downtream the at measured pressure staticabsolute the on based factor expansion theYWhere

Ph

PPP

x and

xkx

xY :taps pipe For

Pressure Downstream to Referenced

tables. lookup AGA of generation the in used was1.3 of value A ts.)measuremen phase gas most for conditions

standardat ratio the use to is practice (accepted conditions flowing at volume constant at gas

the of heat specificthe to pressure constant at gas the of heat specificthe of ratio the ,cc k:Where

ratio acoustic the kx

absolute inch squareper pounds in tap, pressure downstream the at pressure staticabsolute P

absolute inch squareper pounds in tap, pressure upstream the at pressure staticabsolute PF60 at waterof inches in pressure, aldifferenti h

tap. upstream the at pressure staticabsolute to pressure aldifferenti of ratio the x0.70. to 0.10

from range a over used bemay taps pipe for that while0.80, to 0.10 from ratios beta of range a for used bemay taps flange for equation The expected. bemay y uncertaint larger

somewhata x, of values larger For 0.20. x whenpercent, 0.5 minus or plus to 0, x n whe 0, from varying tolerance a to subjectare equations theseby computed Y of values The

tap. upstream the at measured pressure staticabsolute the on based factor expansion theYWhere

Ph

PPP

x and

kx

Y :taps pipe For

Pressure Upstream to Referenced

2

f

w

f

ff

2

vp

1

f

f

Ow

1

1

f

w

f

ff

1

==

=−

=

++++−+=

=

=

=

==

=

==

=

=−

=

+++−=

2

22

212

5.02

213525.02

2

1

1

11

211

11352

:

707.27:

)1()]127.0(145.1333.0[1]1[

/

/

.

:

707.27:

)]127.0(145.1333.0[1

βββ

βββ



B.2.3 Pressure Base Factor — Fpb The pressure base factor is applied to change the base pressure from 14.73 psi absolute and is calculated as:

B.2.4 Temperature Base Factor — Ftb The temperature base factor is applied to change the base temperature from 60° F and is calculated as:

B.2.5 Flowing Temperature Factor — Ftf The flowing temperature factor is applied to change from the assumed flowing temperature of 60° F to the actual flowing temperature Tf and is calculated as:

absolute inch squareper pounds pressure, base (contract) required the P:Where

PF

b

bpb

=

=73,14

Rankine degreees in etemperatur (contract) required the T:Where

TF

b

btb

=

=67.519

Rankine degrees in gas the of temperatur flowing acutal T:Where

TF

f

ftf

=

⎥⎥⎦

⎤

⎢⎢⎣

⎡=

5.067.519



B.2.6 Real Gas Relative Density (Specific Gravity) Factor – Fgr The real gas relative density (specific gravity) factor is used to change from a real gas relative density of 1.0 to the actual real gas density of the gas flowing, and is calculated as:

B.2.7 Supercompressibility Factor — Fpv Supercompressibility can be calculated using the NX-19 Manual equations or the AGA-8 method. This section will describe the NX-19 Manual derivation. Over most normal measurement ranges, 500 to 1500 psia (3.5 to 10.4 MPa ) and –10 to 100OF (-23 to 38OC), the NX-19 will compute the gas compressibility factor to within 0.2% of the values computed by the AGA-8 method. The basic supercompressibility equation is:

B.3 NX-19 Formulas The ranges over which the NX-19 method of calculation are valid are:

• Pressure pg To 5000 psig (10.34 MPa, gauge)

• Temperature Tf -40º to 240º F (-40º to 116º C)

• Specific Gravity 0.554 to 1.0

• CO2 and N2 0 to 15%

gas flowing the ofdensity gas real acutal G:Where

GF

r

rgr

=

⎥⎦

⎤⎢⎣

⎡=

5.01

f

bpv Z

ZF =



B.3.1 Adjusted Pressure And Temperature Calculations Four methods are use to obtain the adjusted temperature and pressure:

Method 1 — Specific Gravity Method Calculates adjusted pressure and temperature from the mole fractions of carbon dioxide and nitrogen as:

Method 2 — Analysis Method Recommended for high specific gravity gas (G > 0.75). Calculate adjusted pressure and temperature as:

tFahrenehei degrees in flowing eTemperatur T

nitrogen of fraction mole x

dioxide carbon of fraction mole xGravity SpecificG

pressure Gauge pWhere

xxGT

T

xxGp

P

F

N

CO

g

NCO

Fadj

NCO

gadj

=

=

==

=

−−++

=

−+−=

2

2

22

22

:

1.1681009.21115.99)460(29.226

2.3910022.78.16047.156

component each of pressure Critical pcomponent each of etemperatur Critical T

component each of fraction mole xtFahrenehei degrees in flowing eTemperatur T


TxTT

px

pP

ci

ci

i

F

g

cii

Fadj

cii

gadj

====

=

+=

=

∑

∑

:

)460(46.359

4.671



Method 3 — Methane Method Recommended for high specific gravity gas (G > 0.75). Requires methane mole fraction and the two inert mole fractions of carbon dioxide and nitrogen. Calculates adjusted pressure and temperature as:

Method 4 — Heating Value Method Uses the measured heating value [wet basis, Btu/(std ft3) at 14.73 psia and 60º F] and the mole fractions of nitrogen and carbon dioxide. Calculates adjusted pressure and temperature as:

methane of fraction mole x


dioxide carbon of fraction mole xtFahrenehei degrees in flowing eTemperatur T


xxxG

TT

xxxG

pP

CH

N

CO

F

g

CHNCO

Fadj

CHNCO

gadj

=

=

==

=

−−−+

+=

−−+−=

4

2

2

422

422

:

78.10252.31912.14482.21477.327

)460(46.359

52.12223.23204.44356.17211.891

4.671

value heating H


dioxide carbon of fraction mole xtFahrenehei degrees in flowing eTemperatur T


xxH

TT

xxH

pP

wtBtu

N

CO

F

g

NCOwetBtu

Fadj

NCOwetBtu

gadj

=

=

==

=

+++

+=

−+−=

,

,

,

2

2

22

22

:

11.9199.3842203.07.124

)460(46.359

2013790209.0693

4.671



B.3.2 Pressure and Temperature Correlation Parameters Once the adjusted temperature and pressure are calculated, the mixtures pressure and temperature correlation parameters are calculated as:

B.3.3 NX-19 Natural Gas Regions and E Equations With the calculated pressure and temperature correlation parameters, the user can find the appropriate E equation by matching the corresponding region as follows:

Ranges p T E Equation 0 to 2 1.09 to 1.40 E1 0 to 1.3 0.84 to 1.09 E2 1.3 to 2.0 0.88 to 1.09 E3 1.3 to 2.0 0.84 to 0.88 E4 2.0 to 5.0 0.84 to 0.88 E5 2.0 to 5.0 0.88 to 1.09 E6 2.0 to 5.0 1.09 to 1.32 E7 2.0 to 5.0 1.32 to 1.40 E8

500

T T

pp

adjadj=

+=

1000

7.14



The E equations are calculated as follows:

4323

4322

4321

432

3221

43

32

21

178

17

36

45

2)88.0(8025.143

263.24

225.143

263.23

243.22

25.025.03.21

054533.014416.0058598.010573.0075255.0

19687.052216.016453.051419.035978.0

27839.078221.048782.0028094.0016299.0

28603.178221.056796.133123.27172.1

])2(0833.0)2(1.0)2(483.13)[2()32.1(

)2()2()2()2(

])2(69.1)[3.1)(844.42028.18

0167.203249.0200(455.0)]20exp(2[00075.01

])2(69.1)[3.1)(844.42028.18

0167.203249.0200(455.0)]20exp(2[00075.01

)69.1(317.1)]20exp(2[00075.01

]4.117.2[0011.0)20exp(00075.01

09.109.1

2

TTTTA

TTTTA

TTTTA

TTTTA

pppppX

pApApApAX

XEEXEEXEEXEE

ppTT

TTTTpE

ppTT

TTTTpE

ppTTpE

pTpTTpE

TTTT

Tbb

bbbb

bb

bbbb

bb

aaa

ba

−+−−=

+−++−=

+−+−=

−−−−=

−+−−−−−−=

−+−+−+−=

−=−=−=−=

−−+

−+−+−−−=

−−+

−+−+−−−=

−−−−−=

−+−−−=

−=−=

−+



B.3.4 Flowing Compressibility — Zf

The flowing compressibility is calculated as follows:

B.3.5 Base Compressibility — Zb The base compressibility is calculated as follows:

B.4 Calibration Factors The following factors can be calculated to calibrate readings closer to actual conditions on site. The factors should be combined and entered in the AGA-3 Calibration Factors field.

parameter ncorrelatio etemperatur Tparameter ncorrelatio pressure p

above calculated equations E from comes EBbbD

mpE

mpmnnb

mpmnB

mTTTn

TTTm

Wherep

nDDB

Z f

===

++=

−−

=

−=

−+=

+−=

+−=

−−−−

−−−

31

5.032

23

3

2

2

1142

532

])([

25429

93

)133185.00457697.0265827.0(

0161353.00221323.00330378.0

:3

1

parameter ncorrelatio etemperatur TWhere

TZ b

=

⎟⎠⎞

⎜⎝⎛ +=

−

:

00132.012

25.3



B.4.1 Orifice Thermal Expansion Factor — Fa The orifice thermal expansion factor is used to correct for the error associated with the expansion or contraction of the orifice plate due to the operating temperature differing from the temperature at which the orifice was measured. The orifice thermal expansion factor is given as:

B.4.2 Water Manometer Correction Factor — Fam This factor is used to correct for the gas leg over water when a water manometer calibration standard is used to calibrate a differential pressure gage. The factor is calculated as:

The real gas density of air ( ρw ) is calculated for any hw pressure above atmospheric pressure as:

air ofdensity ftlb 62.3663 is F60 at waterofdensity

Where

F

a

mwO

w

w

awam

==

−=

ρρρ

ρρρ

3/

:

pressure aldifferentihabsolute inch squareper pounds in pressure catmospheri localP

Where

hP

w

atm

watm

a

==

+=

:4.192

707.27ρ

measured is plate orifice the whenplate orifice the of Fahrenheit degrees in etemperaturt

Fahrenheit degrees in orifice the at flowing fluid the of etemperaturtWhere

ttF: MonelFor

ttF: steel stainless316 and 304 For

meas

f

measfa

measfa

=

=

−+=

−+=

:

)](0000159.0[1

)](0000185.0[1



The local atmospheric pressure can be calculated using the following equation from the Smithsonian Meteorological Tables:

B.4.3 Local Gravitational Correction Factor For U-Tube Manonmeters — Fwl This factor is used to correct for local gravity effect on manometer fluids and is calculated as:

The ambient value of gravity at any location is most accurately obtained from a U.S. Coast and Geodetic Survey reference to aeronautical data or from the Smithsonian Meteorological Tables. In the absence of better data, practical values of g can be obtained from the following equations:

54.14*)361,(55096)361,(55096

−+−−

=ftElevationftElevationPatm

squared. secondper feet ingravity to due onaccelerati localgWhere

gF wl

=

=

:17405.32

level seaabove feet in elevationHdegrees in latitudeL

WhereHL

0.0020299L0.0028247L-78.018550.032808(9g

:equation fit curve a 90 to 0 fron latitudes For

HLg 60 and 30 between latitudes,-mid For

2

OO

OO

==

−

−+=

−−+=

:)000094.0000015058.0

)000094.0)]45(087.0[665.980(032808.0:

3



B.4.4 Water Manometer Temperature Correction Factor — Fwt This factor is used to correct for variations in the density of water used for calibration due to temperature or other reasons. The factor can be calculated as follows:

B.4.5 Local Gravitational Correction Factor For Weight Standards — Fpwl This factor is used to correct for the local gravity effect on the weights of the dead weight calibrator and can be calculated as follows:

n.calibratio instrument the during manoometer tube-U the in existing etemperatur and pressure the at samplefluid the of vacuo in

weightas definedusually ( excluded is air catmospheri of effect The foot. cubic per pounds savoirdupoi U.S. in manometer tube-U ncalibratio the in waterthe ofdensity

Where

F

w

wwt

=

=

ρ

ρ

:3663.62

tester weightdead or weightsthe calibrate to usedgravity of onaccelerati gforce nalgravitatio local to due onaccelerati g

WhereggF pwl

==

=

0

0

:



B.4.6 Correction for Gas Column in Mercury Manometer Instruments – Fhgm This factor is used to correct for the gas vapor leg of fluid at Pf1 static pressure and the temperature of the manometer or instrument. This factor is used to correct for the effect of the gas column above the mercury during the flow measurements and can be calculated as follows:

Rankine degrees in etemperatur ambient T

:Where

T

:as calculated be can t).measuremen flow the for defined etemperatur and pressure base the at mplemercury sa the of vacuo in weightas defined(usually excluded is air catmospheri of effect The foot. cubic per

pounds savoirdupoi U.S in instrument pressure aldifferenti the inmercury the ofdensity t).measuremen flow the for defined etemperatur

and pressure base the at mplemercury sa the of vacuo in weightas defined(usually excluded is air catmospheri of effect The foot. cubic per pounds savoirdupoi

U.S in instrument pressure aldifferenti the in vapoir or gas the ofdensity gas real Where

F

a

ahg

hg

hg

g

hg

ghghgm

=

−−=

=

=

−=

)]67.519(000101.01[324.846

:

ρ

ρ

ρ

ρ

ρρρ



B.4.7 Mercury Manometer Temperature Factor — Fhgt This factor is used to correct for the change in mercury density in the mercury manometer due to the temperature change from the temperature at the time of instrument calibration and can be calculated as follows:

t).measuremen flow the for defined etemperatur and pressure base the at mplemercury sa the of vacuo in weightas defined(usually

excluded is air catmospheri of effect The n.calibratio its of time the at foot cubic per

pounds savoirdupoi U.S in instrument pressure aldifferenti the inmercury the ofdensity gage).

mercury the of etemperatur the and tmeasuremen flow the for defined etemperatur and pressure base the at mplemercury sa the of vacuo in weightas defined(usually excluded is air catmospheri of effect The .conditions operating gagemercury he at foot cubic per

pounds savoirdupoi U.S in instrument pressure aldifferenti the inmercury the ofdensity Where

F

hgc

hgo

hgc

hgohgt

=

=

=

ρ

ρ

ρ

ρ

:

Issue Date: 1/18/08 Revision 1.00 Index-1

Index

12-volt power supplies features, 2-4

24-hour AGA 3 gas flow historical data, 10-11

60 Day Coil Tracking option, 10-10

60-day AGA 3 gas flow, 10-12 alarm coil tracking, 10-10 daily production, 10-8 peak rod speed historical data, 10-8 peak rod speed output historical data, 10-8 register log activity, 10-9 rod peak torque historical data, 10-8

accumulators engineering units used, 8-50 programming, 8-48 resetting totals, 8-52 status, 9-14

Additional Configuration option, 8-31

AGA 3 24-hour historical data for gas flow, 10-11 60-day historical data for gas flow, 10-12 analog channel configuration, 8-68 enabling and disabling gas calculations, 8-78 formulas, B-2 gas calculation programming, 8-68 implementing definitions, 8-68 parameter configuration, 8-70 temperature and pressure programming, 8-76

alarms 60-day coil track history, 10-10 coil tracking (alarm condition accumulation) configuration, 8-97 configuring for auxiliary analog inputs, 8-39 history of last 100 recorded logs, 10-14 register alarm configuration, 8-80 status screens, 9-23

AUX I/O board status screen, 9-15

auxiliary accumulators programming, 8-48 status, 9-14

auxiliary analog inputs alarm and alert configuration, 8-39 configuration, 8-37 engineering units used, 8-38 status, 9-10

auxiliary analog outputs configuration, 8-41 engineering units used, 8-43 status, 9-11

auxiliary I/O configuration, 8-36 status, 9-9

backup protection for RAM, 7-3 battery

backup protection for RAM, 7-3 disconnect jumper pin configuration, 6-2

baud rate (for flash upgrade) specifying for laptop, 16-5 specifying for SAM PCP Controller, 16-6 specifying in controller, 16-11


Index-2 Revision 1.00 Issue Date: 1/18/08

baud rate configuration for controller communications, 8-8

brownout/blackout protection, 3-3

calendar setting, 8-5 changing passwords, 8-28 checking power-up voltage, 5-18 checksum

for *.sam firmware file, 16-4 for App firmware component, 16-4 for code versions, 13-1 for LL firmware component, 16-4 location where displayed on screens, 9-3

clearing a logic expression state, 8-65

clock setting, 8-5 coil tracking

definition, 8-97 displaying data for last 60 days, 10-10 enabling and disabling, 8-98 setting alarm flags, 8-97

Coil Tracking option, 8-97 coldfire microporcessors, 3-3 communication diagnostics, 14-6 communication parameters

for communicating with laptops, 8-8 for flash upgrade, 16-5 for SAM communications, 8-8

Communication Parameters option, 8-7, 8-8

communication port configuration, 8-8

communication protocol used for SAM PCP Controller, 2-3

Communications option, 14-6 communications port

configuration for radios, 6-4 component (internal) layout of

SAM PCP Controller, 3-2 configuration. See also

programming AGA 3 gas calculation, 8-68 alerts for analog inputs, 8-39 auxiliary accumulators, 8-48 auxiliary analog inputs, 8-37 auxiliary analog outputs, 8-41

auxiliary digital inputs and outputs, 8-45 battery disconnect jumper pins, 6-2 baud rate, 8-8 coil tracking (alarm condition accumulation), 8-97 end devices for meters and scaled flow, 7-19 expansion comm port mode and baud for Modbus, 8-10 gauge off time (GOT), 8-33 keying properties, 8-8 logic expressions, 8-53 Modbus slave device to be used, 8-17 Modbus transmission mode, 8-12 Modbus transmission rate, 8-8 NX-19 design parameters, 8-73 parameter violations, 7-13 passwords, 8-28 peak energy management, 8-33 power on delay, 7-4 register alarms, 8-80 register log calculations, 8-88 register logs, 8-84 RTU address, 8-8 SAM fundamental RTU operating parameters, 8-4 sand blowout (SBO), 7-26 smart devices, 8-14, 8-17 temperature and pressure for AGA 3, 8-76 VSD parameters, 8-99

configuring PCP system hardware. See hardware configuration

Controller Date and Time option, 8-5

current operating status, 9-2 current transmitter input

configuration, 6-3 custody transfer and EFM, 8-79 customer technical support, 1-4 data transmission rate

configuration, 8-8 date and time setting, 8-5 daylight savings time (DST)

configuration, 8-5 default parameter resetting, 8-30 default screen specified to

display, 8-31

Index


diagnostics tools for troubleshooting, 14-1

digital input status, 9-12 digital input/output programming

auxiliary inputs and outputs, 8-45 programmed as accumulators, 8-48

dipswitch configuration for RS-485 board, 6-8

disable and enable AGA 3 calculations, 8-78 alarm coil tracking, 8-98 HOA switch, 8-95 logic expressions, 8-67 peak energy management, 8-34 violation operation, 7-13

displaying historical data as tables and plots, 10-2

DST (daylight savings time) configuration, 8-5

EFM and custody transfer, 8-79 elapsed time in current well state,

9-4 electric prime mover specifying,

7-24 electro-mechanical relay

wiring, 5-17 e-mail address for technical

support, 1-4 enable and disable

AGA 3 calculations, 8-78 alarm coil tracking, 8-98 HOA switch, 8-95 logic expressions, 8-67 peak energy management, 8-34 violation operation, 7-13

end device configuration for meters and scaled flow, 7-19

engineering units for accumulators, 8-50 for analog inputs, 8-38 for analog outputs, 8-43 for production status, 8-31

event log historical data, 10-13 last 200 significant events, 14-2

expansion auxiliary I/O programming, 8-36

expansion board assembly #520.5003A (I/O), 6-3 assembly #520.5012 (RS-485), 6-6

grounding, 6-4 termination resistor jumper configuration, 6-3

expansion comm port configuration for Modbus, 8-10

factory-default parameter values, 8-30

field wiring diagram, 5-8 firmware

upgrading, 16-18 version number displayed, 9-3 versions installed in SAM PCP Controller, 13-1

Firmware Versions option, 13-1 flash utility and flash upgrade.

See SAM Flash Upgrade Utility software

flow rate meter installation, 5-6 formulas used for AGA 3

definitions, B-2 gauge off time

configuring, 8-33 time of day buffers updated, 9-4

general RPC parameter programming, 7-1

GOT. See gauge off time ground rod installation, 5-4 grounding

expansion board, 6-4 SAM PCP Controller, 5-13 turbine meter board, 6-10

Hall-Effect transducers installing for RPM, 5-7 wiring, 5-16

handshake protocol configuration, 8-8

hardware configuration battery disconnect jumper pins, 6-2 expansion board termination resistor jumpers, 6-3 MDS radio transmission cable, 6-5 overview, 6-1 radio communications port, 6-4 turbine meter board, 6-9 voltage and current transmitter inputs, 6-3 VSD, 6-10

historical data 60-day coil tracking, 10-10



60-day polished rod activity, 10-7, 10-8 60-day pump efficiency, 10-8 AGA 3 24-hour gas flow, 10-11 AGA 3 60-day gas flow, 10-12 configuring gauge off time (GOT), 8-33 data display formats, 10-2 displaying multiple plots simultaneously, 10-6 event log of last 200 significant events, 14-2 last 100 alarms, 10-14 overview of features available, 10-2 PCP activity, 10-5 PCP-specific event log plots, 10-13 register log plots, 10-9 SAM PCP Controller activity, 10-9 toggling between tables and plots, 10-2

Historical option, 10-2 HOA switch enabling/disabling,

8-95 Host mode, 7-10 hydraulic prime mover

specifying, 7-24 I/O expansion programming,

8-36, 8-48 installation. See also wiring

flow rate meters, 5-6 mounting post and ground rod, 5-4 personnel required, 5-2 process variable transmitters, 5-6 recommended tools for system wiring, 5-11 RPM Hall-Effect transducer, 5-7 RS-485 communication expansion board, 6-6 Sam Flash Upgrade Utility software, 16-9 SAM PCP Controller, 5-6 selecting a site for the system, 5-2 specifications for system wiring, 5-10 stepdown transformer, 5-5 typical components in PCP system, 5-2 typical system drawing, 5-3 wiring the system, 5-8 Yagi antenna, 5-2

interface board assembly expansion board, 6-3

main board dipswitches and jumpers, 6-1

jumper pins configuration for battery connect/disconnect, 6-2 configurations for 4–20 MA transmitters, 6-3

key up and down time configuration for SAM communications, 8-9

keypad description of key functions, 2-5 overview, 2-5 testing keys, 14-9

keystrokes used on operator interface, 2-6

K-factor configuration, 7-23 LCD graphics display

overview, 2-5 specifications, 3-2

logic expression action programming, 8-62 alarm and special section entry code group, 8-57 channel selection entry code group, 8-56 clearing a latched output, 8-65 clearing one or all, 8-65 detailed overview, 8-53 enabling and disabling, 8-67 expression example, 8-59 I/O and logic selection entry code group, 8-56 procedure for writing, 8-60 programming, 8-54 requirements before using, 8-53 resetting, 8-65 syntax and programming rules, 8-57 syntax error messages, 8-58 viewing status of programmed expressions, 9-19

Main Board I/O Diagnostics option, 14-3

Main Board I/O Status option, 14-4, 14-5

Main Menu screen, 2-6 maintenance event log, 14-2 Maintenance Log option, 14-2 malfunction (MALF) allowed

and action taken, 7-17 malfunctions resetting, 12-1

Index


maximum production allowed, 7-16

MB Register Map Check option, 14-8

MDS radio transmission cable configuration, 6-5

measurement units for accumulators, 8-50 for analog inputs, 8-38 for analog outputs, 8-43 for production status, 8-31

memory backup, 7-3 menu map for operator interface,

2-6 microprocessor and memory

technical specifications, 3-3 minimum production allowed,

7-16 Modbus communications

protocol, 2-3, 3-4 Modbus Master CFG option,

8-14, 8-17 Modbus Master feature

assigning a numbers to slave devices, 8-15 associating addresses to indices, 8-19 configuring communication expansion port, 8-26 configuring register logs, 8-84 configuring salve device communication parameters, 8-15 expansion comm port mode and baud configuration, 8-10 overview, 2-7 retrieveing current status of slave devices, 9-26 slave device type to be used, 8-17 specifying a polling routine, 8-24

Modbus Transmission Mode CFG option, 8-12

Modbus transmission rate configuration, 8-8

Monitor mode, 7-10 motor control relay wiring, 5-17 motor starter panel wiring to

stepdown transformer, 5-14 motor type configuration, 7-23 mounting post

installation, 5-4 maximum weight supported, 5-4

mounting the equipment. See installation

NX-19 design parameter configuration, 8-73 formulas and calculations, B-16

obtaining firmware upgrade files for upload, 16-18

operating environmental range for SAM PCP Controller, 3-2

operation modes for startup, 7-6 operator interface

keypad button descriptions, 2-5 keypad overview, 2-5 keys used for navigation, 2-6 Main Menu screen, 2-6 menu map, 2-6 overview, 2-4 part numbers for interface systems, 4-2 programming methods, 2-6 shorthand access method for selecting options, 1-3 systems used with SAM PCP Controller, 4-2 troubleshooting keypad, 14-9

ordering replacement parts and accessories, 4-3

parameters reset to defaults, 8-30 parts lists

hardware components, 4-1 how to order parts, 4-3 operator interface systems, 4-2 optional hardware, 4-2 spare parts, 4-1 VSD optional hardware, 4-2

password setting and changing, 8-28

PCP historical data, 10-5 activity since startup, 10-6 displaying multiple plots simultaneously, 10-6 normal operation for previous 25 hours, 10-7 normal operation since ramp down, 10-7 torsional effects since power down, 10-7



PCP parameter programming, 7-1

PCP status screens, 9-2 peak energy management

configuring, 8-33 toggling between enable and disable, 8-34

polished rod speed historical data, 10-8

polling routine for Modbus Master feature, 8-24

power off delay for pump, 7-9 power on delay configuration,

7-4 power-up voltage checks, 5-18 pressure configuration for AGA

3, 8-76 primary speed control algorithm

process, 2-2 prime mover type specifying,

7-23 process variable transmitter

installation, 5-6 production (minimum and

maximum) allowed programming, 7-16 status, 9-6

Production Control mode, 7-9 production historical data, 10-8 production status measurement

units, 8-31 programming. See also

configuration auxiliary accumulators, 8-48 auxiliary analog inputs, 8-37 auxiliary analog outputs, 8-41 auxiliary digital inputs and outputs, 8-45 enable/disable violation, 7-13 K-factor using programming screen, 7-23 logic expression actions, 8-62 logic expressions, 8-54 NX-19 design parameters, 8-73 optional AGA 3 gas calculations, 8-68 PCP configuration parameters, 7-1 SAM configuration parameters, 8-1

temperature and pressure values, 8-76

pump 60-day efficiency historical data, 10-8 efficiency status, 9-7 power off delay configuration, 7-9 starting and stopping, 11-1

Quick Start feature benefits, 15-1 methods for navigating programming screens, 15-2 starting, 15-3

radio communications port configuration, 6-4 network troubleshooting tool, 14-7 transmission cable configuration for MDS, 6-5

RAM backup protection, 7-3 ramp down historical data, 10-7 ramp up steps and rate, 7-5 recommended tools for system

wiring, 5-11 Register Digital Output option,

8-80 register log

configuring, 8-84 displaying historical data, 10-9 displaying the status of combined values, 9-22

Register Log Configuration option, 8-84

registers alarm configuration, 8-80 log configuration, 8-84 register log calculation configuration, 8-88

Reset Malfunctions option, 12-1 Reset to Defaults option, 8-30 resetting accumulator totals, 8-52 resetting malfunctions, 12-1 rod speed

configuring full and minimum scale, 7-7 configuring min and max operating ranges, 7-7 displaying 60-day peak historical data, 10-8

rod torque allowed, 7-15

Index


RS-485 communication expansion board, 6-6

configuring data line polarity, 6-8 configuring dipswitches, 6-8 configuring for use with SAM PCP Controller, 6-6 configuring for use with SAM Well Manager, 6-6 configuring to be recognized by SAM PCP Controller, 8-26 description and features, 6-6 installing, 6-6 overview, 6-6

RTU address configuring, 8-8 displayed on status screen, 9-4

RTU Level option, 8-4 RX/TX Messages option, 14-7 RX/TX troubleshooting, 14-7 Sam Flash Upgrade Utility

software checksums for App and LL, 16-4 command button descriptions, 16-8 communication parameter settings, 16-5 connecting laptop to SAM PCP Controller, 16-13 disconnecting communications between SAM PCP Controller and laptop, 16-20 establishing communications between SAM PCP Controller and laptop, 16-14 installing upgrade utility software on laptop, 16-9 obtaining configuration files for upgrade, 16-18 overview about each screen component and feature, 16-2 saving controller configuration to a file, 16-14 specifying baud rate in controller, 16-11 specifying communication parameters in laptop, 16-12 upload saved configuration file to controller, 16-16

SAM PCP Controller 12-VDC primary power supply, 2-4 brownout/blackout protection, 3-3 communication protocol, 2-3 connecting to laptop for flash upgrade, 16-13

current operating status, 9-2 enclosure specifications and dimensions, 3-1 environmental operating range, 3-2 expansion board assembly, 6-3 firmware versions used, 13-1 hardware configuration, 6-1 historical data of controller activity, 10-9 installing the controller, 5-6 installing the system, 5-1 internal component layout, 3-2 LCD graphics display, 2-5 menu map of operator interface, 2-6 microprocessor and memory, 3-3 Modbus communications protocol, 3-4 Modbus Master feature, 2-7 operator interface, 2-4 optional hardware, 4-2 overview, 2-1 parts lists, 4-1 power specifications, 3-3 programming accumulators, 8-48 programming for auxiliary accumulators, 8-48 programming for auxiliary analog inputs, 8-37 programming for auxiliary analog outputs, 8-41 programming for auxiliary digital inputs and outputs, 8-45 programming methods, 2-6 proper grounding, 5-13 Quick Start feature, 15-1 resetting malfunctions, 12-1 serial communications, 3-3 spare parts, 4-1 starting and stopping PCP system, 11-1 status screens, 9-2 terminal blocks, 2-4 transmitter device types used, 5-6 troubleshooting diagnostics, 14-1 typical components in system, 5-2 wiring the system, 5-8

SAM Status option, 9-7 sampling period time allowed,

7-10 SamScreen Terminal emulator

interface program, 2-5 sand blowout (SBO)

configuration, 7-26



serial communications technical specifications, 3-3

setting clock and calendar, 8-5 setting passwords, 8-28 setting the default screen

displayed, 8-31 settling period time allowed,

7-10 sheave ratio, 7-24 shielded cables, 5-11 shorthand access method for

selecting options, 1-3 signal wiring and shielding, 5-10 site selection for system

installation, 5-2 slave devices

assigning numbers for Modbus Master feature, 8-15 configuring a register addresses and values, 8-19 configuring parameters for Modbus Master feature, 8-15 retrieving current status using Modbus Master feature, 9-26 specifying a type for Modbus Master feature, 8-17

software Sam Flash Upgrade Utility, 16-2 SamScreen Terminal emulator interface program, 2-5

spare parts. See parts lists specifications

120-VAC power supply, 3-3 enclosure dimensions, 3-1 environmental operating range, 3-2 internal components, 3-2 LCD graphics display, 3-2 microprocessor and memory, 3-3 serial communications, 3-3 wiring PCP system, 5-10

speed control algorithms primary, 2-2 secondary, 2-2

Speed Control mode, 7-9 starting and stopping PCP

system, 11-1 startup operation modes, 7-6 status screens

AGA 3 calculation status, 9-17 alarm and alert conditions, 9-23

auxiliary accumulators, 9-14 auxiliary analog inputs, 9-10 auxiliary analog output, 9-11 auxiliary board status, 9-15 digital inputs, 9-12 main board DIO, 14-5 main board I/O, 14-4 overview, 9-2 PCP control parameters, 9-7 PCP functions, 9-2 RPC current operating values, 9-2 SAM functions, 9-7 slave devices and level sensors using Modbus Master feature, 9-26

stepdown transformer installing, 5-5 wiring to motor starter panel, 5-14 wiring to SAM PCP Controller, 5-15

stop protection override, 7-12 supervisory password setting,

8-28 SUPV (supervisor)

configuration, 8-29 System Tools option, 14-1 technical specifications. See

specifications technical support, 1-4 temperature configuration for

AGA 3, 8-76 terminal strip wiring, 5-11 time and date setting, 8-5 Timed mode, 7-9 torque limiting for rod

operating status, 9-6 programming, 7-15

transmitter devices used, 5-6 transmitter jumper configuration,

6-3 troubleshooting

communication diagnostics, 14-6 diagnostic tools available, 14-1 keypad testing, 14-9 locating memory register locations in Modbus register map, 14-8 radio network communication problems, 14-7 RX/TX messages, 14-7

turbine meter board grounding, 6-10 hardware configuration, 6-9

Index


turbine meter parameter configuration, 7-20

types of transmitter devices used, 5-6

typical components in PCP system, 5-2

units of measurement used for accumulators, 8-50 for analog inputs, 8-38 for analog outputs, 8-43 for production status, 8-31

upgrading firmware version, 16-18

user password setting, 8-28 using the operator interface

menus, 2-6 violation enable/disable

operation, 7-13 voltage power-up checking, 5-18 voltage transmitter input

configuration, 6-3 VSD

generic drive configuration requirements, 6-10 optional hardware parts, 4-2 parameter configuration, 8-99 reference speed input programming, 6-10 typical wiring diagram, 5-8

wedge meter parameter configuration, 7-20

well states elapsed time in current state, 9-4 state currently displayed, 9-4 states involved in downtime, A-4 states involved in malfunctions, A-4 states not observed, A-2

wiring conduit, 5-12 electro mechanical relay, 5-17 Hall-Effect transducers, 5-16 motor control relay, 5-17 powerup-voltage checking, 5-18 proper cable shielding, 5-10 proper grounding, 5-13 recommended tools, 5-11 shielded cables, 5-11 stepdown transformer, 5-14 stepdown transformer to motor starter panel, 5-14 stepdown transformer to SAM PCP Controller, 5-15 terminals and terminal strips, 5-11 typical field wiring diagram, 5-8 wiring specifications, 5-10

writing logic expressions, 8-60 Yagi antenna site selection and

positioning, 5-2

Part No. 099.5028 Rev. 1.00 1/08

Lufkin Automation 11375 W. Sam Houston Parkway South, Suite 800Houston, Texas 77031 Tel: 281.495.1100 Fax: 281.495.6333 www.lufkinautomation.com

Documents

Sam Pcp Manual v1.00