Zenith User Manual Mk2 Sensor

Ar A r t i f i c i al L i f t Monitoring Systems

Zenith Oilfield Technology Ltd

Zenith down-hole Monitoring System User Manual - Part B ZSP Set up and Configuration (With SD Card)

Rev E September 2008

14460099000 User Manual Mk2 Sensor - Part B ZSP Rev E Page 1 of 56

www.zenithoilfield.com Tel: +44 (0) 1467 628866



Proprietary Information Information in this document is subject to change without notice and does not represent a commitment on the part of Zenith Oilfield Technology Limited. The software described in this document is furnished under a license agreement. The software may be copied only in accordance with the terms agreed in the license. The purchaser may make one copy of the software for backup purposes. No part of this manual may be reproduced of transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or information storage and retrieval systems, for any purpose other than the purchaser’s personal use, use, without the express express written written permission permission of Zenith Zenith Oilfield Oilfield Technology Technology Limited Limited . Trademarks Windows™ is a trademark of Microsoft Corporation. Modbus is a trademark or registered trademark of Schneider Automation Inc. All other trademarks acknowledged. Editions ZSP Mk2 Set up and Configuration User Manual Part B ECN 0330


Rev D August 2007 Rev E September 2008




Proprietary Information Information in this document is subject to change without notice and does not represent a commitment on the part of Zenith Oilfield Technology Limited. The software described in this document is furnished under a license agreement. The software may be copied only in accordance with the terms agreed in the license. The purchaser may make one copy of the software for backup purposes. No part of this manual may be reproduced of transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or information storage and retrieval systems, for any purpose other than the purchaser’s personal use, use, without the express express written written permission permission of Zenith Zenith Oilfield Oilfield Technology Technology Limited Limited . Trademarks Windows™ is a trademark of Microsoft Corporation. Modbus is a trademark or registered trademark of Schneider Automation Inc. All other trademarks acknowledged. Editions ZSP Mk2 Set up and Configuration User Manual Part B ECN 0330


Rev D August 2007 Rev E September 2008




WARNING VOLTAGES PRESENT CAN BE LETHAL

Parts of Zenith down-hole Sensor equipment are attached to the high voltage supply of the ESP. Personnel who have obtained the correct training and authorisation should only be allowed to have access to this equipment.

Before any work is carried out within the high voltage area or on any equipment, then the ESP drive or variable speed drive must be shut down and isolated, this is to ensure that the high voltage cannot be switched on accidentally or by a third party.

. Remove the 3 high voltage fuses from the Zenith high voltage surface choke before commencing any work that might be required to be carried out on the Zenith surface integral unit. This will ensure that the Zenith surface integral unit will be isolated from the high voltage side of the drive or VSD.

Remember Think Safe! Work Safe!





SECTION 1 - ZSP OVERVIEW.........................................................................................................................5 Zenith Surface Panel................ ................................................................ ..................................................... 6 Modbus Map – ZSP Mk 2 System........................................................... ....................................................... 7 ZSP Set up and Configuration ................................................................................. .....................................8 ZSP Units – Set up for Metric or Imperial Units ............................................................... ...........................8 ZKey and SD Card.................................................. Card .................................................. ........................................................... ...........................8 SECTION 2 - ZSP KEYPAD AND DISPLAY.................................................................................................10 ZSP K EYPAD EYPAD ....................................................................................................................................................11 ZSP BOOT UP SEQUENCE ..................................................................................................................................12 ZK EY EY AND SD CARD ........................................................................................................................................13 ZSP DISPLAY ...................................................................................................................................................14 Screen 1 – Config Screen............................................................................................................................14 Screen 2 – Data display screen (a) ...................................................... ....................................................... 14 Screen 3 – Trend Screen ........................................................... ............................................................... ...15 Screen 4 – Active Alarms Screen (a)...........................................................................................................15 Screen 5 – Modbus Table (a to s)................................................................................................................16 Screen 6 - Communications ........................................................................................................................16 Screen 7 – Data Logging ............................................................................................................................16 SECTION 3- BROWSER SET UP....................................................................................................................18 ZSP BROWSER SET UP. ................................................... ........................................................... ......................19 PC to ZSP E-Net Connection. .................................................................... .................................................19 PC to ZSP Local Area Connection Set Up..................................................................................................20 Confirming a PC Local Area Connection................... ................................................................ ................22 Opening the ZSP Browser...........................................................................................................................22 Browser Menu Navigation ........................................................ .............................................................. ....23 SECTION 4- ZSP SET UP AND CONFIGURATION CONFIGURATION - KEYPAD OR OR BROWSER ..................................24 ZSP CONFIGURATION.......................................................................................................................................24 ZSP CONFIGURATION MENU ............................................................................................................................24 K EYPAD EYPAD MODE CONFIGURATION .....................................................................................................................24 BROWSER MODE CONFIGURATION ...................................................................................................................24 ZSP CONFIGURATION.......................................................................................................................................24 Port 1 Menu ............................................................ .............................................................. ......................24 Port 2 Menu ............................................................ .............................................................. ......................24 Parameters Menu........................................................................................................................................24 Alarms Menu......... ........................................................... ............................................................... ............24 Analogue Menu .......................................................... .................................................................... .............24 Data Menu ................................................................................................... ............................................... 24 ZKey Menu (SD Card Removal and Re-install) ................................................................. .........................24 Date / Time Menu............................................................. .............................................................. .............24 Screen Menu ...............................................................................................................................................24 SECTION 5– LOG DOWNLOAD....................................................................................................................24 Log download via browser..................................................................... ..................................................... 24 Log download from SD card....................................................................... card....... ................................................................ ................................................24 Clearing Flash Memory Logs ..................................................... ............................................................ ....24 SECTION 6 – APPENDIX A.............................................................................................................................24 STANDARD OPERATING PROCEDURE.....................................................................................................24 EY – SD EMOVAL, DATA LOG TRANSFER AND CARD R E-INSTALL........................24 SOP : ZSP WITH ZK EY – SD CARD R EMOVAL





Section 1 - ZSP Overview



Artificial Lift Monitoring Systems


Zenith Surface Panel This manual should be used in conjunction with the User Manual - Part A which covers the equipment installation and field wiring arrangements in detail The Zenith Surface Panel (ZSP) provides an interface, via the Zenith Surface Choke, with the Zenith down hole Sensor. The ZSP provided  Real time monitoring of Zenith Sensor data via the LCD screen display Data and status logging to the on-board Flash Memory  Alarm and Trip set up from any (Logged) parameter  Third party Modbus communications port (RS232 or RS485)  Accept up to an additional eight parameters as Analogue Input (4 – 20mA)   Can provide up to eight parameters as Analogue Output (4 – 20mA) on request The ZSP is supplied with 24 V PSU, ESP Interface Board, Display Terminal Board, Analogue Input/Output Board, Alarm and Trip relays and Engineers E-Net port. The ZSP is supplied pre-wired and ready for field installation Field wiring requirements consist of Power supply (110-220VAC) – Cable and ZSP gland provided  Signal cable from Zenith Surface Choke – Cable and ZSP gland provided  Alarm and Trip wiring to appropriate field wiring terminal board   Modbus wiring to appropriate DT Board Port 2 connection Analogue input/output wiring to field wiring terminal board  The ZSP is supplied with two fitted cable glands (Power and signal cable). An additional four gland holes (0.813” dia) allow for additional cable glands to be fitted. Blanking plugs are fitted to these holes The client will supply any additional cabling, glands etc required Field installation and wiring arrangements are covered in detail in User Manual – Part A





Modbus Map – ZSP Mk 2 System Description Intake Pressure – Pi (Bara)

Modbus Address 40001

Data Type

Units and Scaling

Signed Integer

40002

Signed Integer

Bar * 10 (10.2 Bar is represented by 102) Bar * 10

40003

Signed Integer

Degrees C * 10

Discharge Pressure – Pd (Bara) Intake Temperature - Ti (deg C) Motor Temperature - Tm (deg C) Vibration X - Vx

40004

Signed Integer

Degrees C * 10

40005

Signed Integer

g* 1000

Vibration Z - Vz

40006

Signed Integer

g * 1000

Tool Current - Ct

40007

Signed Integer

mA * 10

Tool Voltage - Vt

40008

Signed Integer

V * 10

Intake Pressure – Pi2 (Psia)

40009

Signed Integer

Psia * 10

Discharge Pressure – Pd 2 (Psia) Intake Temperature - Ti2 (deg F) Motor Temperature - Tm2 (deg F)

40010

Signed Integer

Psia * 10

40011

Signed Integer

Deg F * 10

40012

Signed Integer

Deg F * 10

Modbus Map – ZSP Mk 2 System Note Note The Zenith Mk2 system Modbus output operates in MMIC mode (ZSP Port 1 and 2 Mode should both be set to MMICmode In earlier versions of software, parameters 1 to 4 (Pi, Pd, Ti and Tm – Modbus registers 40001 to 40004) output was in metric units (Bar/Deg C with Parameter 9 to 12 (Pi2 Pd2, Ti2 and Tm2 – Modbus registers 40009 to 400012) output is in imperial units (Psi/Deg F)

In later versions software parameters 1 to 4 can be set to metric or imperial units by changing the “Units” name (Config Parameters Units) – See User Manual Part B – Set up and Configuration – However Modbus output from registers 40001 to 40004 remains in metric units Except for software version 1.56.1 which will provide register 40001to 40004 output in imperial units





ZSP Set up and Configuration ZSP configuration can be done from either keypad or by using the web browser Note however that SD card removal can only be done from Keypad – the safe removal of the SD card CONNOT be done from the browser interface

ZSP Units – Set up for Metric or Imperial Units In earliest versions of software, parameters 1 to 4 (Pi, Pd, Ti and Tm ) output was in metric units (Bar/Deg C) Parameter 9 to 12 (Pi2 Pd2, Ti2 and Tm2 ) output was in imperial units (Psi/Deg F) – With this early version software access to port 1 menu was required to allow parameters 1 to 4 to output in imperial units In Latest versions software parameters 1 to 4 can be set to metric or imperial units by changing the “Units” name (Config Parameters Units) – See section 4 – Set up and Configuration Setting units name for parameters 1 and 2 (Pi and Pd) to Bar will output metric parameter values – setting units name to Psi will output imperial parameter values Similarly for parameters 3 and 4 (Ti and Tm) naming units as DegC outputs metric values, DegF outputs imperial values (See Parameter Units Menu – P32) Note However even if parameters 1 to 4 display out put is changed to imperial units, modbus register 40001 to 40004 output units remains as metric - To view Modbus in imperial units (psi and deg F) modbus registers 40009 to 40012 must be polled Software version 1.56.1 however provides an exception and this version allows for registers 40001 to 40004 to ‘follow’ the displayed units

ZKey and SD Card Software version 1.56 or above is recommended for use with SD card system The ZSP ZKey (flash memory) with removable SD card is mounted internally on the back plate of the display and analogue board The Zkey is a 4mb flash memory capable of storing around 22 days of data logged at 1 minute intervals. This ZKey memory DOES NOT overwrite when full and should therefore be cleared (after saving logs) on a regular basis Data and status logs from the ZKey is copied to SD card for ease of download (note data is not transferred directly to SD card – The SD card merely copies the contents of the Flash memory) The appropriate procedure MUST be followed for removal of SD card from the ZSP The SD card must be removed via the ZKey menu option – This menu option is available from keypad Config menu only On selecting ZKey Remove SD Card data transfer from Flash memory to SD card is updated and stopped A message is then displayed when it is safe to remove the SD card When the ZSP restarts without SD card an error message is displayed – This message can be ignored When the ZSP is started without SD card data will automatically be logged to ZKey memory. 14460099000 User Manual Mk2 Sensor - Part B ZSP Rev E Page 8 of 56




When the SD card is later inserted, the ZSP will detect the card and run through a housekeeping sequence of updating the card. The SD card is inserted with the card label facing towards the panel door.. It is recommended that good quality SD cards are used – Cards should be formatted before first use





Section 2 - ZSP Keypad and Display





ZSP Keypad The ZSP front plate display section houses the LCD screen along with the 9 soft key pad The keypad can be split into four distinct sections

2

LCD Display

1

3 4

5 8 6

9 (Enter/Select Key)

7

Keys 1 and 2 – These two keys allow access to various menu options and additional display screens (e.g. Config, Trend, Fast Log, More etc) In each case a ‘legend’ on the LCD screen bottom row will indicate the function of the appropriate key Keys 3 and 4 – These 2 keys allow for scrolling through various display screens (Back/Next) In each case a ‘legend’ on the LCD screen bottom row will indicate the function of the appropriate key Keys 5, 6, 7 and 8 – These four keys allow navigation through the various menu screens to scroll up or down, or in the case of the alphanumeric configuration screens, left or right Key 9 – The Enter (Select) key – This key selects or enters a request, instruction or data to the ZSP

The ZSP offers 7 main display screens – Select Next (Key 4) to scroll through the 7 available main screens





ZSP Boot up Sequence On power up the ZSP runs through a boot up sequence and automatically cycles through five screens as shown below. The first screen (ZSP Surface Panel….) will only be displayed during the boot up sequence if the Flash Screen option is set to On (from the Configuration Screen menu) The second screen displayed indicates that the data logging Flash Memory with SD Card (ZKey) has been detected whilst screens 3 and 4 confirm the presence of the SD card before settling to data display screen- Screen 2 (a) Engineers should monitor the panel boot up sequence, noting software version, confirming data logging medium (RAM, Flash or ZKey) and where applicable confirming the presence of the SD card

Zenit h Surf ace Panel

Flash Memory Found Logging to ZKey

Version 1.57. Zenith Oilfield Technology Ltd www.zenithoilfield.com

Copying to SD Card Please wait

SD Card Inserted

Well Name 1 28 / 07 / 06 15 : 28 : 00 Parameter Pi 0.0 Pd 0.0 Ti 0.00 Tm 0.00 Vx 0.000 Vz 0.000 Vt 121.3 Ct 0.00 TREND MORE

XX XX XX XX XX XX XX XX

Bar Bar Deg C Deg C G G V mA BACK

SCREEN 2 (a) Data Display screen – Display defaults to this screen on panel boot up (also and panel re-boot when exiting configuration mode

NEXT





When the ZSP is powered up (or on re-boot as panel exits configuration mode) the display will run through the boot up sequence and will automatically default to data display screen SCREEN 2 (a) On boot up the first values to be displayed on screen will be Vt (120V approx) and Ct (10mA approx) Ct may be seen to hunt 9 – 15mA as communications is established with the Sensor before settling back to 10mA It may then take 1 – 2 minutes before a full set of down hole parameters is updated on screen. If the ZSP is powered up without a Sensor connected then all parameters will display zero with the exception of the Tool Voltage (VT) (approx 120V) If Vt shows 0V then link 3-4 on the signal cable terminal block is not in place

ZKey and SD Card The ZSP ZKey (flash memory) with removable SD card is mounted internally on the back plate of the display and analogue board The Zkey is a 4mb flash memory capable of storing around 22 days of data logged at 1 minute intervals. This ZKey memory DOES NOT overwrite when full and should therefore be cleared (after saving logs) on a regular basis Data and status logs from the ZKey is copied to SD card for ease of download (note data is not transferred directly to SD card – The SD card merely copies the contents of the Flash memory) The appropriate procedure MUST be followed for removal of SD card from the ZSP

The SD card must be removed via the ZKey menu option – This menu option is available from keypad Config menu only On selecting ZKey Remove SD Card data transfer from Flash memory to SD card is updated and stopped A message is then displayed when it is safe to remove the SD card When the ZSP restarts without SD card an error message is displayed – This message can be ignored When the ZSP is started without SD card data will automatically be logged to ZKey memory. When the SD card is later inserted, the ZSP will detect the card and run through a housekeeping sequence of updating the card. The SD card is inserted with the card label facing towards the panel door.. It is recommended that good quality SD cards are used – Cards should be formatted before first use





ZSP Display The ZSP displays 7 main level screens. – Data Display covers up to four screens (screen 2a to 2d) to allow all (logged) data to be displayed – Note that where logging has been disabled for a specific parameter then that parameter will not be displayed on screen – Underlying screens (2b, c and d) will only be accessible if a sufficient number of parameters is being logged The number of underlying screens accessible will depend on the number of parameters being logged – For example if only 12 parameters are logged then data display will cover two screens – If all 32 parameters are logged then data display will cover all four screens (a to d)

Screen 1 – Config Screen The main screen displays current date and time along with Zenith Oilfield Technology contact details (Address, telephone fax and e mail details) The contacts screen offers 3 keypad options Config Press key 1 - Allows access to configuration mode Back Press key 3 – Scrolls back one screen Next Press key 4 – Scrolls forward one screen •

•

•

Screen 2 – Data display screen (a) The data display screen shows well name on row 1 (see Screens Well Name Menu) along with current date and time on row 2 Rows 4 to 11 shows the first 8 parameters where logging is currently enabled, displaying parameter names, values, units and alarm and trip status – Note that only parameters where logging facility has been enabled will be displayed on screen (See Parameters Logged menu) – Where a specific parameter is not logged then next parameter will be moved up 1 row Current ZSP software (ver 1.57) will allow up to 32 parameters to be displayed over four individual screens (a to d) – Some of these parameters apply to different applications (PCP Sensor torque and positioning tools) and do not apply for E series Sensor systems – Logging should be disabled on all irrelevant parameters – These parameters will not then be shown on the display screen. Disabling logging on all irrelevant parameters will also save on data logger log space The data display screen offers 4 keypad options Trend Press key 1 – Moves directly to Trend screen (Next serves the same purpose) More Press key 2 – Scrolls to a second level data display screen (b) – Screen b displays next 8 parameters. Use More to scroll through display screens (c) and (d) and back to screen (a) Back •

•

•



Artificial Lift Monitoring Systems •


Press key 3 – Scrolls back one screen Next Press key 4 – Scrolls forward one screen

Screen 3 – Trend Screen The trend screen allows trends to be displayed for any two (logged) parameters The Trend display screen offers 4 keypad options – Note the Trend screen can also be accessed from Screens 1 or 2) Note if there is no logged data in memory or if the parameter has remained constant over the selected time frame then a trend will not be displayed and the message No Data will be shown The Trend screen offers 4 keypad options Time Frame Press key 1 – allows a time frame of 1, 4, 8, 12, 24 or 84hours Param Press key 2 – Allows any two logged parameters to be selected for trending purposes. Parameters are selected through a sub menu as P1 (parameter one) and P2 (parameter two) Back Press key 3 – Scrolls back one screen Next Press key 4 – Scrolls forward one screen •

•

•

•

Screen 4 – Active Alarms Screen (a) The Active Alarms screen displays Lo and Hi trip and alarm status for the (logged) parameters. – The display shows if alarms and trips are enabled or disabled and if the alarm or trip has been activated If the alarm or trip is disabled – or has been set with invalid levels then the appropriate box will display X If the alarm or trip has been enabled but has not been activated then the appropriate box will remain blank If the alarm or trip is enabled and has been activated then the appropriate box will display YES The Active Alarms screen offers 4 keypad options More Press key 1 – Scrolls through four Active Alarm screens (a to d) allowing alarm and trip status to be monitored for all active parameters Level Press key 2 – Displays parameter current value along with alarm and trip set points – On screen message will also advise if invalid levels are set Back Press key 3 – Scrolls back one screen Next Press key 4 – Scrolls forward one screen •

•

•

•





Screen 5 – Modbus Table (a to s) Modbus table screen displays parameter name, assigned Modbus (address) register and modbus output value. Modbus Table covers 19 screens (More key) and covers modbus registers 40001 to 40028, 40101 to 40106, 41001 to 41056 and 41101 to 41156 – Most of these registers are for specific Zenith applications and normally only registers 40001 to 40012 will be of interest to the operator Note Modbus register assignment is fixed and cannot be changed The Modbus Table screen offers 3 keypad options More Press key 1 – Scrolls through 19 Modbus Table screens (a to s) allowing modbus output to be monitored – Normally only modbus registers 40001 to 40028 will be of interest to the operator Back Press key 3 – Scrolls back one screen Next Press key 4 – Scrolls forward one screen •

•

•

Screen 6 - Communications This screen offers a trouble shooting guide tracking ports 1 and 2 communications and errors The Communications screen offers 2 keypad options Back Press key 3 – Scrolls back one screen Next Press key 4 – Scrolls forward one screen •

•

Screen 7 – Data Logging The data logging screen provides a useful guide to logging status. This screen confirms Logging to Zkey (Flash) – Also listed is the date and time of last log, the percentage of memory used and the logging time remaining. This screen also indicates if the SD card has been detected It is recommended that engineers use this screen as part of their checks before leaving location The Data Logging screen offers 2 keypad options Back Press key 3 – Scrolls back one screen Next Press key 4 – Scrolls forward one screen (Back to screen 1) •

•





Note The Zkey incorporates a 4Mb flash memory is capable of holding approximately 22 days of data with the ZSP logging at 1 minute intervals - Data stored on the Flash is copied to SD card – Data is not written directly to SD card The Flash memory does not overwrite when full and must be cleared on a regular basis – If Flash memory is full then data will be lost - ie WILL NOT be written directly to SD card





Section 3- Browser Set Up





ZSP Browser Set Up. Browser configuration is carried out via the ZSP ‘Engineers Port’ 6 pin military style connector located on the bottom left of the ZSP enclosure (Figure 3.1) An ‘Engineers Cable’ (14460077000 – Figure 3.2) is supplied with the cable installation pack for connection from the ZSP to PC.

Figure 3.1 Engineers Port.

Figure 3.2 Engineers Port Cable (14460077000)

PC to ZSP E-Net Connection. The Engineers Port cable (P.No14460077000) connects from the PC network port (RJ45) to the ZSP ‘Engineers Port’ (6 pin military) connector located on the bottom left of the ZSP housing. The Engineers port is connected internally to the ZSP Display Terminal Board. E-Net port In the unlikely event that this cable should ever be disconnected then care must be taken when re-connecting, ensuring the connection is made to the E-Net port E-Net Port connection MUST NOT be made to the R-Net Port. The E-Net port is located beneath the 32 way cable ribbon connecting the Display Terminal Board to the field wiring terminal block.

In order for the ZSP and PC to communicate, the appropriate PC Local Area Connection must first be set up. In many cases the PC used for ZSP configuration and down load will also be used to connect to an office LAN. It will therefore be necessary to set up the Local Area Connection each time a connection to ZSP is to be made and to reverse these changes after disconnecting from the ZSP. If the set up is not reversed then it will not then be possible to reconnect to the office LAN





PC to ZSP Local Area Connection Set Up To allow communications with the ZSP the PC network connection must first be configured, setting the ZSP IP address (See Browser Connection – Figures 3.3 – 3.6 ) From the Start Menu

Select -Control Panel Select - Network connections Right click - Local Area connection Select - Properties Select - Highlight Internet Protocol (TCP/IP) Select - Properties Select - Internet Protocol (TCP/IP) Properties screen Highlight - “Use the following IP address” Set up the connection IP address as shown below IP Address

192. 168. 0 . 1

Subnet Mask

255. 255. 255. 0

Default Gateway

192. 168. 0

.100

Select “OK” to save the property changes

Figures E, F, G and H below show the appropriate PC screens for setting the ZSP IP address. Note - After disconnecting from the ZSP it will then be necessary to return the PC to default status to allow connections to other networks (e.g. office LAN) Repeat the steps above to get to the Internet Protocol (TCP/IP) Properties screen and highlight “Select Obtain an IP address automatically” Select OK to save the configuration

Failure to reset the Internet Protocol (TCP/IP) properties will mean the PC will be unable to re-connect to other local networks (e.g. office LAN)





Browser Configuration – PC set up

Figure 3.3

Figure 3.4

Figure 3.5

Figure 3.6





Confirming a PC Local Area Connection Any computer running Windows 2000 or XP should normally show a Local Area Connection icon on the bottom right taskbar – If the LAN icon is not visible then open the adapter Properties dialog box (through control panel) and select the option to display the taskbar icon. With no cable connected a red cross will be displayed over the LAN icon (may also show an error balloon – “Network cable unplugged”) • • •

Connect the Engineers Port E-Net cable from PC to ZSP Switch on ZSP (if not already on) The Local Area Connection icon should now show the Local Area Connection open at 10mbs

•

If the icon does not show a connection then check the PC set up and Engineers Port cable. If this does not solve the problem then check that the Engineers port cable is securely plugged into the correct (E-Net) port on the Display Terminal board.

Opening the ZSP Browser Open a standard web browser (Internet Explorer, Mozilla Firefox etc) Enter web address as http://192.168.0.100/ The ZSP login screen ( Figure 3.7 ) will then open If the Login screen is not displayed then a connection has not been established between the ZSP and PC. Check both Local Area Connection Properties and cabling to locate the problem

Figure 3.7 – Browser Log in screen





Browser Menu Navigation A user name and password are required to open the ZSP browser User Name: Password:

zenith (lower case) AB51 (UPPER case)

Type in the user name and password and select the SUBMIT to enter the configuration mode. – In browser mode the Submit option serves the same purpose as keying Return in keypad mode whilst Back (browser) and Exit(keypad) perform the same function When the ZSP enters the configuration mode, the ZSP stops communication with the down hole Sensor, the data display disappears from screen and is replaced with an on screen message – “System halted whilst configuration is modified” The browser main menu screen (Top Menu) will then be displayed (on PC) The ‘System halted….’ message remains on (ZSP) screen until the panel is brought out of the edit (configuration) mode and returned to operational status. During this period the ZSP does not display data, communicate with or log data from the down hole Sensor Selecting the ‘Save Changes” or “Discard Changes’ options will exit the edit mode. After 5 minutes of inactivity the edit mode is automatically exited – Any changes not saved will be lost Figures I and J show the Log-in and Main (Top) Menu PC screens The SUBMIT button is used to enter data, information or request to the ZSP. Highlighting Submit may open an underlying menu level or may accept a value level entered from PC (e.g. an alarm level). In other cases the Submit may return to the previous menu level Changes are then stored in a buffer memory until either the SAVE CHANGES or DISCARD CHANGES option (Top Menu screen) is selected Keying Submit uploads the changes to the ZSP buffer but does not save the changes.

When the SAVE CHANGES option is selected, the ZSP then runs through a re-boot sequence and updates the (new) configuration before returning to the normal data display screen (screen 2) If Discard Changes is selected then the ZSP display returns directly to the data screen without re-boot. In this case no changes are made to the panel configuration. 14460099000 User Manual Mk2 Sensor - Part B ZSP Rev E Page 23 of 56




Only after Save Changes has been accepted is the ZSP configuration updated. The browser page BACK option will return to the previous (browser) page Continue to select BACK to return to the Top menu screen where the Save Changes/ Discard Changes option can then be selected and accepted. In some cases, in some underlying menus, the BACK option may not be available and selecting an item will return to the previous level. Note that if the ZSP times out (after 5 minutes of inactivity) and returns to operational mode then any changes not saved will be lost

Figure 3.7 - ZSP Browser Log in Screen





On entering the correct user name and password the browser configuration screen (figure 3.8) will then be displayed

Figure 3.8 – ZSP Browser Main (Top) Menu Screen





Section 4- ZSP Set Up and Configuration - Keypad or Browser





ZSP Configuration ZSP configuration and set up can be carried out from either keypad or from PC via the web browser (Engineers E-Net cable 14460077000 required to interface to ZSP) Keypad configuration mode is accessed from screen 1 by selecting Config (key 1) option The menu structures for both keypad and browser configuration are generally very similar. Note however SD card removal can only be carried out from keypad – this action cannot be accessed from browser. The browser option on the other hand offers an option to down load (and upload) ZSP configuration files to (from) PC – This option is useful where several panels are required to be set up with exactly the same configuration. Note the configuration menu can only be entered from one option at a time – i.e. If the configuration menu is entered from the ZSP browser then the keypad will be disabled until the configuration menu is exited (from browser). - Likewise if the configuration mode is entered from the keypad then the ZSP browser cannot be opened until the configuration menu is exited (from keypad)

When the ZSP enters configuration mode (by either method) then communications between the ZSP and Sensor is halted and the screen display is replaced by the message “System halted whilst configuration is modified”

When the configuration mode is entered from PC via the ZSP browser, the ‘System halted…..’ message will remain on screen until the configuration mode is exited (from browser) Where the configuration mode was entered from keypad then the ‘System halted…..’ message will display for approximately 5-10 seconds before being replaced by the Configuration (Main) Menu There is no password required to enter the configuration mode from the ZSP key pad. However the password AB51 is required to clear data and/or status logs There is no special software required for configuration via the ZSP browser. However it is necessary to establish the PC to ZSP LAN connection via the Engineers Port E-Net cable Access to the ZSP browser menu requires a user name and password to be entered in the home page User Name zenith (lower case) Password AB51 (UPPER CASE) The password AB51 is also required to clear data and/or status logs Port 1 menu is no longer accessible to field operators - A password is now required to enter this menu from both browser and keypad options





ZSP Configuration Menu ZSP menu configuration is very similar from both keypad or browser options and in most cases differences are merely in screen layout The main differences are the ZKey option in keypad mode – This option does not exist in the browser – SD card removal can only be initiated from the keypad The keypad Analogues menu offers an option – analogue calibration – This is a factory set up menu and is not required for field operatorions The Configuration Interface Menu screen provides a selection of 8 menu options plus the save changes and discard changes options Port 1 –

This menu is factory configured and MUST NOT be altered A password is required in software ver 1.57 to access this menu

Port 2 –

Configures Port 2 for third party comms systems (Modbus)

Parameters –

Allows selection of parameters to be logged This menu also allows for parameter units to be changed (Parameter Units option)

Alarms -

Allows set up of Alarm and trip levels

Analogs -

Allows set up of analogue input/outputs

Data -

Allows logging rate to be set, logs download and clearing etc

Zkey-

Allows SD card removal in approved manner – This menu option is available in keypad mode only

Date/Time

Allows set up of Date and Time – Uses European Format

Screen -

To set up display screen – Well Name is entered from this menu

View Param and Alarm Config-

Displays Configuration file This menu option is available in Browser mode only

Configuration File-

Allows for configuration file down load to PC or upload from PC

Save Changes -

Saves Changes made in configuration mode This option is available in Browser mode only

Discard Changes –

Discards changes and returns ZSP to previous configuration This option is available in Browser mode only

ZKey Menu option is available on Keypad configuration mode only Menu options shown in red are available through browser configuration mode only





Keypad Mode Configuration In keypad mode menus are selected by highlighting the appropriate option and selecting by the Return key (key 9) – This may select a particular option or may open an underlying menu Most menu levels include the EXIT option – selecting EXIT will return to previous screen Where there is no EXIT option then the display will return to previous screen by highlighting the appropriate option and pressing key 9 On touchpad keyboard screens the Ret option will return to previous screen On completion the EXIT option should be selected to scroll bay to Save Changes Screen On the save changes screen highlight YES (or NO) to save the changes (or discard) changes. All configuration changes are saved in buffer memory until the save changes option is exercised If NO is selected then all changes are discarded and the ZSP immediately leaves configuration mode returning directly to screen 2(a) If YES is selected then the changes are applied to the configuration fileand the ZSP then runs through a re-boot sequence (see ZSP Boot up sequence – P11) before returning to screen 2a In many cases selecting a specific option will open a drop down menu listing some but usually not all parameters – These drop down menus will also include a More and Exit option The Exit option will return to the previous screen The More option will list additional parameters The ZSP by default lists 32 parameters – these parameters are covered by four separate screens or lists – The More option scrolls through these screens (lists)

Browser Mode Configuration In Browser mode menus are selected by highlighting the appropriate option or parameter and keying return or selecting SUBMIT (where available) to move to the next level Where a value has been entered for a specific parameter then select the SUBMIT option to store the value in buffer and return to the previous level Most menu levels include the BACK option – selecting this option will return to previous menu level Where there is no BACK option then select SUBMIT to the previous level When configuration in browser mode is complete select BACK to return to the main menu (ZSP Configuration Interface screen) In the ZSP Configuration Interface screen select Save Changes or Discard Changes As with keypad configuration if discard changes is selected then the ZSP will immediately exit configuration mode returning to screen 2(a)- data display screen and all changes will be lost If the save changes option is selected then any changes made will be applied to the configuration file after which the ZSP will run through a re-boot sequence returning to the default data display screen (see ZSP Boot up sequence – P11)





NOTE - Changes made in configuration mode are saved in buffer memory – Changes are not applied to the configuration file until the Save Changes option has been selected If the Discard Changes option is selected then any changes made in configuration mode will be discarded NOTE – If the ZSP browser configuration mode remains inactive for 5 minutes the ZSP will automatically exit the configuration mode and the display will revert to data display screen 2a – Any changes made to the configuration prior to the 5 minutes of inactivity will be lost. Changes are only applied when the Save Changes option is selected

ZSP Configuration. Port 1 Menu In older versions software access to port 1 menu was necessary to allow output units to be set. Output units are now set through Parameters Units menu Port 1 menu is now restricted to internal communications set up between Interface card and ZSP display terminal and is no longer required for field purposes Accesss to Port 1 menu is now restricted Zenith personnel only.

Port 2 Menu Port 2 is the third party communications port linking between the ZSP and the external system (e.g. client SCADA, PC running HyperTerminal etc). Configuration will depend on the external device set up ZSP Mk2 system Modbus Map is shown in section 1 – page 7 Port 2 menu offers six second level menu options required to set up manage the communications link between the ZSP and third party device •

Output Port

•

Mode

•

Baud Rate

•

Data Bits

•

Parity

•

Modbus

Output Port:

This menu offers two options – •

RS232

•

RS485





•

The ZSP provides for two different Modbus communications levels. However, only one converter can be used at any one time. Probably one of the most common causes of Modbus problems is where the output port is set to one level (e.g. RS232) whilst the Display Terminal Board is wired for the alternative mode (RS485) For an RS232 connection, Display Terminal Board terminal J10, connections 8, 9 and 12 (Gnd) are required For an RS485 connection, Display Terminal Board terminal J10, connections 10 and 11 are required – Normally RS485 will not require the ground connection See User Manual part 1 for Modbus field wiring connections Mode:

This menu offers 3 second level menu options •

Port 1 Echo

•

Modbus Slave

MMIC MMIC is the standard mode for third party output interface (e.g. SCADA). •

Baud Rate:

This menu offers a selection of baud rate options from 1200 to 38400bps Baud rate should match the third party Modbus Master configuration. Data Bits:

This menu offers an option of 7 or 8 data bits from the drop down menu. (normally 8) Selection should match third party Modbus Master configuration. Parity:

This menu offers an option of None, Odd or Even parity from the drop down menu (normally None). Selection should match third party Modbus Master configuration. Modbus:

Port 2 Modbus option is used to set the Modbus slave number (address) and can be in the range 0 to 255. The default slave number is 1. The Modbus slave number must match that set to that to be polled by the third party Modbus master.

Use the Back (browser) or Exit (Keypad) to return to the save changes screen





Parameters Menu The Parameters menu allows for changing parameter names and units. It also allows the selection of parameters to be logged to memory Changing a parameter name does not re-assign a parameter to a different channel Changing parameter units on pressure and temperature parameters does however change output value from metric to imperial units (or vice versa) – Pressure values may be expressed in Bar or Psi and temperature units in Deg C or Deg F – In older versions software the option to change units used to be done through port 1 menu – However with version 1.57 this is now accessible through this parameters menu The Parameters menu also now includes an additional three options – Decimal places and Filter Coeff and Filter passes. Decimal Places menu is not applicable for ESP E series sensors Filter Coeff and Filter Passes menus have been introduced to overcome issues related to motor winding temperature systems Because motor winding temperature thermocouple is located close to motor windings, this parameter is very susceptible to noise pick up and can result in ‘spikey data’ being observed. Traditionally most ESP monitoring systems have handled this issue by incorporating a fixed rate filter in the down hole sensor. Zenith feel that this approach is somewhat suspect and have opted to incorporate an adjustable filtering facility in the surface package -

The parameters menu provides six second level menus •

Names

•

Units

•

Logged

•

Decimal Places

•

Pilter Coeff

•

Filter Passes

•

Exit

Names :

Select the required parameter from the drop down menu and select Return (Submit) to edit the parameter name In keypad mode use the touch screen to edit the parameter name – Select RET to exit touch screen Note: This only changes the parameter name – It does not re-assign a parameter from a different channel





Unit:

Select the required parameter from the drop down menu and select Return (Submit)to edit the parameter units This menu is now used to change between imperial and metric units – Unit names are changed via the touchpad screen For pressure enter unit name as Bar or Psi. For temperature units enter name as DegF or DegC By making the appropriate name changes the ZSP will then output parameter nos 1 to 4 in either imperial or metric units dependant on units name Pressures and temperatures are the only parameters where units may be changed (Bar or Psi and Centigrade or Fahrenheit). – Default names should remain unchanged for all other parameters Note – Changing unit names will not alter the modbus register output Logged:

This menu allows the selection of which parameters to be logged to the Flash Memory (ZKey/SD card) for data log storage and trending purposes. It is advised that only relevant parameters are logged - Normally Pi, Pd, Ti, Tm, Vx, Vz, Vt and Ct with possibly dP, dT and Clp - Note however this is not a definitive list and logged parameters will depend on client requirements It is recommended that logging is disabled (off) on all parameters where no data (zeros) is being returned Select the required parameter from the drop down menu and select Return (Submit) to edit which parameters are logged (Yes) or not logged (No) NOTE - Changes to the selection of logged data can only be made after the data log has been cleared and before a fresh log has started (i.e. before exiting the configuration mode).

Where a parameter is not selected for logging then that parameter WILL NOT be displayed on the data display screen (screen 2 a to d) Logging status can also be checked via the Browser – View Parameters ans Alarm Configuration menu option Selecting only required parameters for logging purposes will greatly increase logging capacity of Flash memory or Zkey/SD card Decimal Places:

This is a special applications menu and normally should not be altered (1 for pressures, temperatures and tool voltage – 2 for tool current and 3 for vibrations. Filter Coeff:

This menu allows filtering to be set on motor temperature to compensate for ‘noise’ (spiking) on motor windings temperature data Under normal conditions Filter Coefficient is normally set to 150-200 Filter Passes: This menu is used in conjunction with the Filter Coeff menu. The Filter Passes menu allows for smoothing of motor winding temperature by averaging out the data Under normal conditions Filter Coefficient is usually set to 2 or 3 14460099000 User Manual Mk2 Sensor - Part B ZSP Rev E Page 33 of 56




Note:- Filter passes option is not available from browser menu Note that in Keypad option, the screens to enter Filter Coeff and Filter Passes values are not touch screens. – Values are entered using keypad. The RET option is used to return to main menu

Use the Back (browser) or Exit (Keypad) to return to the save changes screen

Alarms Menu The Alarms menu allows for configuration and activation of Alarm and Trip facility. Alarm and Trips can be set on any parameter and the respective relay activated or inhibited. Wherever a trip value is set, it is recommended that a corresponding alarm level is also set up. It is also recommended that appropriate levels are set on both Hi and Lo relays (Low Trip, Lo Alarm, Hi Alarm and Hi Trip). Values must be chosen appropriately and with care to avoid spurious Trips The Alarms menu provides five second level menus •

Alarm Level

•

Parameter Enabled

•

Deadband

•

Holddown

•

Global Enable

Each option provides a drop down menu – Select the required option and key Return (Submit) to enter edit mode. Alarm Level:

This menu allows alarm and trip levels to be set Selecting the Alarm Level option opens an additional drop down menu allowing specific parameters to be selected – a further menu level allows alarm and trip levels to be set on the specific parameter Alarm and trip set points should be entered on all four levels LO TRIP LO ALARM HIGH ALARM HIGH TRIP

Enter the required set points and key Return (Submit) to return to the drop-down menu. The Trip/Alarm levels entered are then buffered until the Save Changes option is selected from the Main Menu





Repeat for each Parameter – Ensure that no parameter setting is liable to accidentally trip the VSD when the parameter is accidentally enabled Set up the appropriate Trip and Alarm levels on each parameter as required Where a Trip Level is set up then the corresponding alarm level should also be set Even although only one relay is wired it is essential that both Trip and Alarm Levels are set up (see User Manual Part B Section 4 Alarms Menu) – If both trip and Alarm Levels are not set then the relay WILL NOT activate Parameters Enabled:

Where a Trip (Alarm) facility is required on a specific parameter then the Enable option must be turned ON for that parameter (in addition to setting Trip and Alarm Levels) Select the required parameter from the drop down menu and key Return (Submit)). A second level drop down menu opens to allow for the alarm and trip to be enabled (YES) or disabled (NO) Repeat for each parameter – Ensure that only the relevant parameters Trip/Alarms are activated Avoid setting alarm and trip levels or enabling alarms and trips on parameter which may cause spurious VSD trips It is recommended that the Global Enable facility is ignored – Use the Alarms/Parameters Enable facility to select the applicable parameters Alarms/Deadband:

Deadband is set to prevent nuisance alarms and trips. Deadband is set as a percentage of the Trip (or Alarm) value the parameter has to drop below the Trip (or Alarm) set point (Level) before the system will come out of a Trip (or Alarm) situation. Select the required parameter from the drop down menu Return (Submit) In the dialogue box enter the required Deadband (as a percentage of the Trip /Alarm set Level)> Key Return (Submit) to enter the value Repeat for each Parameter that alarms and trips have been set up on Remember for each parameter that a Trip Level is set up on, the corresponding Alarm Level must also be set 2 (percent) is a common Deadband setting but will depend on the individual situation Alarms Holddown:

Holddown, like Deadband is set to prevent nuisance alarms and trips Holddown is the number of consecutive data points (from the down hole Sensor) required after an Alarm or Trip level has been breached before the Alarm (Trip) relay will activate. Setting Holddown to 1 disables this function – ie 1 data point over the set Level will activate the Trip (Alarm) – This means a data spike would activate the Trip (Alarm). Note that with the Zenith Sensor, parameters are updated from the Downhole sensor at differing time intervals.





Intake pressure is the most frequently updated parameter (approximately every 7-9 sec). Vibrations are the least frequently updated parameter (approximately every 22-25 sec) Therefore if Holddown is set to 3 then 3 consecutive data points above the Trip (Alarm) Level before the relay will activate. If a Trip was then set on Pi the system could trip within 3 x 9 = 27sec after the level was breached. If a Trip was set on Tm then the system could take up to 3 x 15 = 45 sec after the set Level was breached Select the required parameter from the drop down menu and key Return (Submit). In the dialogue box enter the required Holddown Key Submit (Return from Keypad) to return Repeat for each Parameter that alarms and trips have been set up on Remember for each parameter that a Trip Level is set up on, the corresponding Alarm Level must also be set Holddown is normally set to 2 or 3 but will depend on the individual situation Alarms/Global Enable

This Option provides a shortcut to enabling either all Lo or Hi Alarms /Trips where appropriate Levels have been set. Ensure the appropriate Trip/Alarms have been properly configured before exercising this option to prevent accidental tripping of the ESP This option should only be exercised with extreme caution and it recommended that it be disregarded (use the Alarm/Parameter enable menu to set enable/disable specific parameters)

Once the appropriate Trip (Alarm) Levels have been set, the appropriate parameters enabled and the conditions (Holddown and Deadband) applied then exit the Alarms to apply the new configuration Use the Back (browser) or Exit (Keypad) to return to the save changes screen Select Save Changes - Yes to apply the new configuration to the ZSP Selecting Save Changes – No (or Discard Changes) will be discarded any changes made and re-apply the previous set up





Checking Alarm and Trip Set Up from the Display Screens

Whenever alarms and trip levels are set on a specific parameter, set up and levels should be checked on the display screen after exiting the Configuration mode. Alarm and trip set up can be confirmed from two display screens The Data display screen Where a parameter displays XX at the end of the line, this indicates Alarm and Trips for that parameter is disabled. Where AT is displayed confirma alarms and trip values have been set is The Active Alarms screen Where X is displayed on the Active alarms screen indicates that alarms and trips have not been set (Levels invalid) - These parameters will not trip the VSD Where a blank space is shown in the respective column indicates the trip or alarm is Enabled (ON) – These parameters will trip the VSD if the trip set point is breached (and dead band and hold down conditions are met) Where YES is shown in a respective column indicates that a set point has been breached and the trip or alarm is Active –If YES is shown on the trip level then the level has been breached, the relay has been activated and the VSD should be stopped

Where X is shown this indicates that the alarm and trip level settings are invalid – This will Selecting the Levels option on the Active Alarms screen will display the current value of the parameter, along with to alarm and trip level settings (where the settings are invalid - eg all four levels set to zero) then the message Alarm Levels Invalid will be displayed – where this message is present then the relay will not trip the VSD The ZSP works on a Normally Closed Relay – the relay will open when an alarm or trip activates





Analogue Menu The ZSP can accept up to eight analogue outputs and can (if requested) provide up to eight analogue inputs Analogue input requires factory set up and this facility should be requested prior to shipping the ZSP. The source of the analogue inputs can be down hole tool parameters or surface analogue inputs. Analogue output can be any of the ZSP parameters (surface or down hole) Both analogue input and output systems both operate on a 4 – 20mA mode The Analogs menu provides five second level menus

Output source Scaling Input Scaling Output Calibrate Inputs View Inputs

Each option provides a drop down menu Select the required option and key Return (Submit) to enter edit mode. Calibrate inputs and View Inputs options are only available in keypad configuration mode Output Source

From the drop-down menu, select the desired analogue output (e.g. A1) From the next level drop down menu select the required parameter (e.g. Pi) This assigns that parameter (Pi) to the selected analogue output (A1) Key Return (Submit) assign the parameter and return to the Analogue menu. Repeat for each required parameter Scaling Inputs

From the drop-down menu, select the desired analogue input. The dialogue box then allows for the required min and max scaling values to be entered Key Return (Submit) to enter changes and return to the Analogue menu. Repeat for each required parameter Normally the scaling range should be that of the analogue input transducer Scaling Outputs

From the drop-down menu, select the desired analogue output. The dialogue box then allows for the required min and max scaling values to be entered Key Return (Submit) to enter changes and return to the Analogue menu. Repeat for each required parameter Normally the scaling range will be chosen to match the ZSP parameter range





Calibrate Inputs

This menu is for factory use only This option is only available in keypad mode View Inputs

Lists the values on the eight analogue input channels (A1 to A8) – This screen is for information only This option is only available in keypad mode Select Continue (key 1) to return to the main analogues menu screen

Use the Back (browser) or Exit (Keypad) to return to the save changes screen Select Save Changes - Yes to apply the new configuration to the ZSP Selecting Save Changes – No (or Discard Changes) will be discarded any changes made and re-apply the previous set up





Data Menu The Data Menu allows for configuration of data update and storage rate This menu also allows data and events logs to be downloaded and/or cleared. It is strongly advised that the Password Reset Option is disregarded

Where a ZSP has been locked out with a forgotten password, the reset can normally only be done by Zenith Engineering in UK. Where a password is changed by the client from default ( AB51) it is the client’s responsibility to ensure that a safe and secure record of the password change is retained

Data Menu -Keyboard Option

The Keyboard option provides ten second level menus – Of these ten options only the first four and last options are relevant for E series applications Data Fetching DataSaving Rate Delete Logged Data Delete Status Log Password reset Pump Lobes Flux Reset Ts Reset Td Reset Clp Data Menu – Browser Option

The Browser option provides twelve options It provides all options as for keyboard except Reset Clp – This option is only available from keypad mode The Browser option does however include an additional three options Output Data Log Output Status Log Flush Logged Data The Output Data and status log options allow for logs to be the flash memory log to be downloaded to PC – The SD card option has now replaced the need for log downloads – however these options remain in the browser menu as a back up facility -It should be remembered that the logs are stored to Flash memory then copied to SD card – In the event of a corrupted SD card the log could still be ownloaded via the browser





Data Fetching Rate:

This is the rate at which data is updated from the ESP interface board. This rate can be set to between 1 to 3600 seconds Normally this value will be set to 5 or 10 seconds – Data update from down hole sensor is roughly once every 6-7 seconds for Pi with other parameters taking up to 25-30 seconds for full update – It is therefore somewhat pointless to have an fetching rate faster that the tool update rate Enter the required time on screen and select Ret to return to the main menu screen (select Submit in browser)

Data Saving Rate:

This is the rate at which data is saved in the internal data logger. This rate can be set to between 1 to 3660 seconds





As above it is somewhat pointless to set a data logging rate at a value faster than tool update rate. Enter the required time on screen and select Ret to return to the main menu screen (select Submit in browser) Note The data logger does not overwrite when full and therefore should be cleared on a regular basis Delete Logged Data: This option deletes the data log from the Flash memory. Confirmation of the request is required (YES) From keypad, the password AB51 must then be entered before the log and Ret selected before the log is cleared From the Browser menu the user name (zenith) and password ( AB51) must then be entered before the log will be cleared When the log has been successfully deleted, a massage Data Log Deleted will be displayed before the screen returns to the data menu In Browser mode the message SUCCESS will be displayed on screen when the log has been deleted The data log should only be deleted after the log has been downloaded and the download checked – Where an SD card is available the card should be removed and the data log transferred to PC (and checked) before the Falsh memory is erased

Delete Status Log: This option deletes the status log from the Flash memory. Confirmation of the request is required (YES) From keypad, the password AB51 must then be entered before the log and Ret selected before the log is cleared From the Browser menu the user name (zenith) and password ( AB51) must then be entered before the log will be cleared When the log has been successfully deleted, a massage Status Log Deleted will be displayed before the screen returns to the data menu In Browser mode the message SUCCESS will be displayed on screen when the log has been deleted The status log should only be deleted after the log has been downloaded and the download checked – Where an SD card is available the card should be removed and the log transferred to PC (and checked) before the Falsh memory is erased.





Password Reset

It is recommended that this option be ignored The DATA Menu screen also allows for the password to be changed – Entry of the old password (AB51) and new password (twice) is required. It is the client’s responsibility to ensure that any password change is recorded and kept safe and secure for future reference Pump Lobes Flux Reset Ts Reset Td

These four options are not applicable to E series sensor applications

Reset Clp

The Zenith E series sensor records a tool current – This value is normally around 10.0mA Historically ESP monitoring systems have tended to show a ‘Passive Current Leakage’ as opposed to a tool current. This Passive leakage current was basically a calculated value of the change in current between ESP system running and ESP system off Selecting Reset Clp on the Zenith system stores a reference tool current value - this reference value is then used to calculate the change in tool current being drawn when the ESP system is running The Reset Clp option should be exercised after the system has been landed and down hole conditions have been allowed to stabilise It is normal practice to select the Reset Clp option just before initial start up of the ESP (Clp(REF)) Current Leakage is then calculated from (Clp (ESP Off) - Clp(REF)) Confirmation is requested ( YES/NO) before the reference value is stored – display then returns to the main data menu






Data and Events Log Overview

Logging is set up from two different menus Parameters Menu Parameters Logged This Menu option selects which parameters are to be logged to memory – All parameters that are shown on the data display screens (Screen 2 a to d) will be logged to memory Data Menu Data Saving Rate This Menu option sets the rate at which data is to be logged (1 – 3600 seconds It is recommended that the minimum rate set is 10 seconds to give a regular update of the fastest parameter).

Data and events logs should be down loaded (and cleared) on a regular basis. Data and events logs must be down loaded and cleared before any editing changes are made to the ZSP configuration. This is of particular importance if a date/time change is to be made to the ZSP Parameters Logged option cannot be changed until after the log has been down loaded (and cleared) It is good practice to download (and clear) both data and events logs at the same time. Logs must always be down loaded before clearing Log Down Load via Browser

There are two options for downloading ZSP logs – The most convenient being the removal of the SD card and subsequent transfer from SD card to PC (see ZKey menu option) However logs can also be downloaded (direct from Flash memory to PC) via the web browser. Selecting the Output Data (Status) Log allows for the Flash memory log to be downloaded to PC Log donnload from browser is covered in detail in section 5





Figure O – Down load Pop Up

Clear Data and Status Log Data and Status logs should be cleared after download and checking. The logs are cleared via the two options Delete Logged Data Delete Status Log

ZKey Menu (SD Card Removal and Re-install) The SD card copies data from Flash memory to provide a faster, simplified method of data transfer from ZSP to PC The SD card must NOT be removed directly from the ZKey The appropriate removal procedure must be followed – Removal can only be done via keypad configuration – See Section 6 – Appendix - Procedure for the specific procedure for SD card removal, copying logs and SD card re-installation There is no facility in browser menu to allow for SD card removal From the main configuration menu select Zkey Selecting the ZKey option provides two second level menus Remove SD Card Max lines per file Remove SD Card Highlight the remove SD card option and key return The message -Copying to SD card - XX% Complete is displayed as data is transferred to SD card. 14460099000 User Manual Mk2 Sensor - Part B ZSP Rev E Page 45 of 56




When data transfer is complete the message - Remove SD Card is displayed – The card must not be removed until this message is displayed On removal of the SD card and the display then returns to the ZKey menu screen. Select Exit option to return to Save Changes screen – Select YES to save changes The ZSP will then run through the re-boot sequence to the screen displaying the message Unsafe SD card removal Reinsert SD card Goto Config/Zkey/Remove SD card Press any key to continue

A back up SD card could be installed at this point or the message could simply be ignored By pressing any key the display then returns to the data screen (screen 2a) and even although an SD card has not been installed the ZSP will still continue to log to ZKey (Flash Memory) When an SD card is re-installed this data will then be copied to card Max Lines per file This option allows operator to set file size by specifying the maximum number of lines (X 1000) for the SD card file When the maximum number of lines is reached a second SD card file is created

The SD card can be re-inserted at any time – There is no specific menu or house keeping procedure required for re-installing – Simply insert the SD card (label should face towards the ZSP door) into the ZKey After a few seconds a message – Copying to SD Card – Please Wait is displayed before the display again returns to data display screen 2a SD card data and status log is covered in more detail in section 5 of this manual

Use the Exit (Keypad) to return to the save changes screen Select Save Changes - Yes to apply the new configuration to the ZSP Selecting Save Changes – No will be discarded any changes made and re-apply the previous set up





Date / Time Menu Date MUST be set in European format DD-MM-YYYY with the time set as HH-MM-SS Date and time must only be reset after the data and events logs have been down loaded and cleared and before logging is re-started. The Date & Time option provides two second level menus Set Time Set Date

Set Time

Select Time to open the time set up screen Enter the current time as HH-MM-SS Select Return (Submit)) to return to the Date/Time menu screen Set Date

Select Date to open the date set up screen Enter the current time as DD-MM-YYYY Select Return (Submit|)to return to the Date/Time menu screen






Screen Menu The screen menu offers five lower level options Flash Screen Contrast Backlight Invert screen Well Name Flash Screen

The Flash screen drop down menu allows for the flash screen to be turned on or off – The Flash screen is the Zenith Logo screen seen for a short period as the ZSP is first powered up Contrast

Allows screen contrast to be adjusted (on a scale of 1 to 31) Backlight

The drop down menu allows the back light to be turned on or off Invert Screen

Sets screen to reverse video Well Name

Allows the appropriate well name to be entered via the alpha numeric touch screen The well name should always be entered - The name entered here will be attached to all down loaded logs helping to identify logs and minimise the potential for errors Use the Back (browser) or Exit (Keypad) to return to the save changes screen Select Save Changes - Yes to apply the new configuration to the ZSP Selecting Save Changes – No (or Discard Changes) will be discarded any changes made and re-apply the previous set up





Section 5– Log Download





Log download via browser Data and status logs are downloaded from ZSP to PC with the Engineers E-Net cable The ZSP data log can only be accessed through the Configuration Data menu, and hence the system operation will then be halted whilst in configuration mode. This means that a small section of down hole date will not be logged during the download period Data logging will re-start when the ZSP exits the Configuration mode. Download time will depend on the size of data log – however a large log may take 20 minutes or more to download – Down hole data will be lost during this download period •

• • • •

•

• •

• •

Open the PC browser (User name – zenith and password AB51 required – Note the user name is lower case, the password is UPPER case) Select the Data menu Select Output Logged Data option A File Download dialogue box will then be displayed on screen Select Save on the File Download dialogue box and select a suitable location for the download The file name proposed is date and time and Well name stamped for identification purposes and is best left unchanged – the down load file will be saved as a .csv file Select Save from the Save As screen – The file download will then proceed When the download has finished open the download file and check that the download was successful Change the file name extension from .csv to .xls and save The ZSP Data log can then be safely deleted

It is recommended that the download file is then checked before proceeding to clear the log. Status log is downloaded in exactly the same manner – However for the status log download file this is usually saved as a text file Screen shots of the log download process are given below





Data Log down load via browser





Log download from SD card Data and status log are copied to SD from the ZSP Flash memory (ZKey) The SD card provided a far simpler and faster method of collecting panel logs The SD card can be removed from the ZSP at any time following a simple housekeeping procedure as specified in section 6 The SD card data log download file is then be converted to csv file and copied from SD Card to PC where the data log file is then saved as an excel file The Status log file is saved directly to PC as a text file Section 6 details the specific procedure for removal of SD card, - converting and copying down load files and the re-install of SD card

Clearing Flash Memory Logs It is recommended that the ZSP Flash memory logs are not cleared until the SD card files have been saved to PC Note the Flash memory must not be cleared whilst SD card is installed as this may also clear data still to be uploaded from Flash to SD card





Section 6 – Appendix A Standard Operating Procedure



SOP: 1XXXXXXXX Rev ‘A’ Pages 1 to 3 ECN No: Date: Sept 2008 Approved By: ZSP SD Card


SOP : ZSP with ZKey – SD Card Removal, Data log transfer and Card Re-install 1.

General

1.1

1.2

2.

This procedure details the Procedure for the use of a removable data storage medium to capture the Zenith Surface Interface Panel (ZSP) data log. The removable data storage medium, referred to as the Z-Key, is a standard 256MB SD card. It is recommended that only good quality SD cards are used. SD Cards must be formatted before first time use.

Overview

2.1

2.2

2.3

2.4

2.5

2.6

The SD Card is located inside the ZSP. This entails opening of the panel door for install and removal of the SD Card. This operation must only be carried out by suitably competent personnel It is recommended that the SD Card is only inserted with ZSP power on. Monitoring the red and green LED’s immediately above the card holder will confirm the card detection To ensure the data log capture to SD Card, and to prevent possible software corruption the SD Card MUST BE REMOVED AS PER SECTION 3 PROCEDURE The SD card copies the data and status logs as they are written to the ZSP Flash memory. When the SD card is removed (via the appropriate procedure) data continues to be written to the Flash memory. When the SD card is then re-instated, the Flash memory content is then automatically copied (flushed) to the SD card. This procedure means there should be minimum data loss over the period when SD card has been pulled. It also means that in addition to logs being saved on the SD card a back up copy exists on the ZSP Flash memory which could if required be downloaded by conventional methods It must be stressed however that the Flash memory log must be cleared on a regular basis. The Flash memory DOES NOT overwrite when full and hence no further data will be transferred to SD card until the Flash Memory has then been cleared ZSP logs can be cleared at any time with SD card in or out. However it is recommended that logs should only be cleared after the data has been transferred, checked and saved on PC. ZSP logs are cleared, as per normal procedures, via the ZSP Keypad through the Config Data Delete logged Data menu options – A password ( AB51) is required to clear the data log



SOP: 1XXXXXXXX Rev ‘A’ Pages 1 to 3 ECN No: Date: Sept 2008 Approved By: ZSP SD Card

3.


Removal of the SD Card

Select Config menu option Select Data option Select Remove SD Card option. The screen display then switches to the message - COPYING TO SD CARD - ----100% COMPLETE. – This process should take around 1 minute maximum 3.4 When Data transfer is complete then the screen then displays REMOVE SD CARD 3.5 If the data transfer to SD card is not successful then the message: COPYING TO SD CARD -0% COMPLETE. Will be displayed. - REMOVE SD CARD message will not be displayed. In this case exit the Config menu. (Select BACK to return to the Config menu and exit as per steps 3.7 to 3.9 – Remember to select YES from the Save Changes selection) - Then repeat procedure from step 3.1 NOTE The SD card must NOT be removed before the ‘REMOVE SD CARD’ message is displayed The SD Card must not be ejected whilst the red LED D2 is illuminated or whilst either message is displayed 3.6 Open the ZSP door and remove the SD card (Press to eject) 3.7 Once the SD card has been ejected the screen display then returns to the data menu screen Select Exit to return to the Config Menu screen – NOTE: the system will not display or log data whilst in Configuration mode 3.8 Select Exit to return to the Save changes screen 3.9 Select Yes to acknowledge the changes and exit the configuration mode. 3.10 The ZSP will then run through the re-boot sequence and will display the message – FLASH MEMORY FOUND - LOGGING TO ZKEY before returning to the data display screen 3.11 An error message will then be displayed 3.1 3.2 3.3

Unsafe SD Card Removal Reinsert SDCard Go to Config/ZKey/Remove SD Card Press any key to continue

3.12 A second SD card may be inserted or the message may simply be ignored pressing any key (twice) to return to the data display screen (screen 2a) 3.13 Note that it is recommended the ZSP is not in configuration mode when the SD card is inserted (see section 5)



Zenith User Manual Mk2 Sensor

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