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iCHEM™ ROC 107 USER MANUAL

1. 5 p Set the High Level Figure 3 11 njection Pressure Calibration 2 Click Update 3 Calculate Scale and Offset 4 Click Update The ROC 107 calculates the current Injection Pressure 3 0 Setting Up Cycles and Volume Once all data points are mapped the pump is ready for operation You can enter the necessary cycle and volume settings on the main ROC 107 screen in the Pump Status panel and Pump Program and Pump Cycles tabs NOTE Click Apply in ROCLINK 800 when any field is changed Connected ta Pump Default Pump Curent Mode DFF CAL Tank Level 38536 Cycle Timer Secs 4 Flow Aate 080 Daily Volume IN Injection Pressure 3600 Cycle Frequency Cycle Volume 10 0006944 Current Cycle Todays Volume 08 o Pump Pragram Pump Cycles Pump History Assignments Pump Operation OFF and Calibrate PO Meter Units Quarts Tank Level Units Inches Purp Contract Hour Figure 3 12 Pump Status Panel and Tabs on the 107 Interface 29 Setup and Calibration iChem ROC 107 User Manual 3 3 1 Setting Daily Volume In the Pump Status panel enter the required injection volume per day in the Daily Volume field 3 3 2 Setting Contract Hour The Pump Contract Hour determines the time of day that the pump cycle starts The clock uses a 24 hour format with a default value of 8 00 To change the default contract hour
2. 35 4 4 Pump Program 36 4 4 1 PD Meter Calibration 6 37 4 4 2 Tank Level Calibration sues oem 6665S ESSER REECE CERES SRR REESE TESS 38 44 3 INJ Pressure Calibration 38 4 5 Pump Cycles 39 4 6 Pump History 40 4 7 VO Assignments Tab 41 5 COMMON 185 5 42 5 1 Viewing History and 42 5 2 Clearing 5 43 5 3 Running Custom 43 5 4 Creating a User Defined 44 Appendix A Wiring Diagrams 45 iChem for FloBoss107 Standard JB 0 45 2 iChem for FloBoss107 Neptune JB Wiring 46 Appendix B Troubleshooting and Known 155 65 47 iChem ROC 107 User Manual Revision History Date Description Version september 2014 Initial Release July 2015 Dynamic Dosing tFactor and 2 0 Correctional Batch iChem ROC 107 User Manual 1 In
3. Automated Chemical Optimization ICHEM ROC 107 USER MANUAL INSTALLATION SETUP ano OPERATION FOR USE WITH THE FLOBOSS 107 AND ROCLINK 800 Patent Pending pcsFergusen iChem ROC 107 User Manual The iChem brand is trademarked by PCS Ferguson These documents and materials are copyrighted by PCS Ferguson 2015 All rights reserved The FloBoss and ROCLINK are licensed Emerson products For information contact PCS Ferguson 3771 Eureka Way Frederick CO 80516 Phone 720 407 3550 Fax 720 407 3540 Email information pcsferguson com Website www pcsferguson com iChem ROC 107 User Manual Table of Contents 1 5 1 1 Abbreviations 6 1 2 Safety Overview and Symbols 6 1 3 System i 1 3 1 FloBoss 4 1 3 2 ROCLINK 800 User UCT ACE eua stn Ss esa st cedo or e e 9 1 3 3 iChem ROC 107 0 H 2 Software Installation 12 2 1 Installing ROCLINK 800 12 2 1 1 Logging IN the First TIM 6 12 2 2 Loading
4. ROC 107 14 2 3 Licensing iChem ROC 107 16 2 4 Saving and Loading Configuration 05 18 2 4 1 Saving Points and 5 5 18 2 4 2 Loading Previously Saved 5 5 19 3 Setup and 20 3 1 Mapping 1 0 20 3 1 1 Tank Level TLP S aci ah do deu oko ob 3 cO Seg 3b 4 E CE b 3 OR GE EO b E E eae C HS 21 OU PD Fow Mel TLP S RR RRRGORRRRRRGREGAGRG ARARA ARALARA AAAA SA AAAA RARA RAE 22 3 1 3 Injection Pressure 23 3 1 4 Emergency Shutdown ESD 24 3 1 5 Pump Control DOUT TLP sgn eh ehh eh ed a ed a ae 26 O6 FOW CWNCN ILP propperer PSRSIJTESSSSISSSGG SIEGE SESS EE GEOP EHE dE 25 D EU DYNAMIC DOSO JEP a rcr nee oe Ge a e ay be an a t EEPE EERE EREE EEPE REER EREE 2 3 2 Calibrating the Flow 28 3 2 1 Calibrating the PD Meter sa ua aao opo deor dob ok dob OR GR EROR OE ORG OE GRO RE d d eg 26 3 2 2 Calibrating the Tank 26 3 2 3 Calibrating th
5. Det 13 20170833 0 Serial Humber jw48083 0022 0838384 Boot Revision 7 Boot Build Date Nov 17 2006 8 32 Integrity Uninstall Auto Scan B Update Apply _ 212 4 Figure 1 3 ROCLINK 800 User Interface Double click I O items or modules in the Configuration Tree Menu to manage types Use the Top Menu to set up your ROCLINK software for your system 9 Introduction iChem ROC 107 User Manual If necessary you can adjust the display of TLP points from text to numerical in the ROCLINK menu 1 Inthe Top Menu click Tools gt Options 2 Under Display TLP select As Number Display TLP As Test e a 6 1 ELI Scan Interval 1 000 Seconds TLP Selection Show All Point Types and Parameters ToolTip Popup Show source TLF of data when the cursor hovers over an object on a display OK Cancel Figure 1 4 ROCLINK 800 Options Dialog Box Introduction 10 iChem ROC 107 User Manual 1 3 3 iChem ROC 107 User Interface The ROC 107 application lets the user set chemical injection timing and volume Once in AUTO mode the application measures and monitors flow injection volumes and adjusts each cycle based on previous measurements iChem ROC 107 can be used with any pump However each ROC 107 version is custom built for the system and module slot Pump Status Panel Alarms Panel Current Alarm
6. Fill in the Observed TickDrop with the difference in fluid level before and after the test Click Apply Click the Calculate kFactor button Click Update E di di E 3 2 2 Calibrating the Tank Level 1 Setthe High and Low Voltage Points Isolate the tank Draw down the sight glass Enter the Low Level and click Set Establish a level to the sight glass Enter the High Level and click Set 2 Click Update 3 Calculate Scale and Offset 4 Click Update The ROC 107 calculates the current Tank Level Record the low point of the fluid after the test runs Meter Calibration Start Pump T est Calc kt Factors Test Time in Secs 15 Volume per Tick 10 0006944 Observed TickDrop 24 0 kFactor 9755 5 ComputedTickDrop 00 tFactor Timed Inj Cycles Figure 3 9 PD Meter Calibration Click Enable Disable button to use tFactor as emergency backup of PD meter Tank Level Calibration Low Level High Level 15 0 0 et Current Level 00 Calculate Scale and Offset Figure 3 10 7ank Level Calibration Setup and Calibration 28 iChem ROC 107 User Manual 3 2 3 Calibrating the Injection Pressure r Inp Press Calibration 1 Setthe High and Low Voltage Points LowLlevel foo Set Isolate the transducer High Level 310 Set Current Press 0 0 Bleed gas into the atmosphere Set the Low Level Calculate Scale and Offset Apply well pressure
7. 4 3 1 Alarm Messages and Meanings These alarms trigger Emergency Shut Down Message Abbreviation Meaning High Press HIPRES ESD Te low pressure through the transducer is high Manual ESD MANUALESD The user has clicked the Emergency Shut Down button Controls and Features 35 iChem ROC 107 User Manual 4 4 Pump Program Tab The Pump Program tab contains essential settings for operating and calibrating the system Pump Program Pump Cycles Pump History 1 0 Assignments Pump peration OFF and Calibrate PD Meter Units Quarts Tank Level Units Inches Pump Contract Hour 0 Batch Catch D Pump Off w Flow Alarm 5 0 E E Enabled Tank Low Warning D Disabled Tank Low Alarm Low Flw Alm Tmd Override Low Flow Time Limit secs 20 Low Flow Alarm 50 High Flow Alarm 000 0 Low Pressure Alarm foo High Pressure Alarm foo Alam Warming Flow Switch User Defined 1 lt v oo C User Defined 2 User Defined FLOAT 000 Figure 4 4 Pump Program Tab Field Function Pump Operation Defines the current mode of operation Select from AUTO Manual or OFF and Calibrate PD Meter Units Defines the units the ROC 107 uses to measure the flow Select from Quarts US Gallons or Liters Tank Level Units Defines the units the ROC 107 uses to measure the tank level Select from Inches or Centimeters Pump Contract H
8. type a new value in the Pump Contract Hour field on the Pump Program tab 3 3 3 Setting Pump Cycle Interval The Cycle Frequency field in the Pump Status panel automatically updates based on the selected Cycle Interval set on the Pump Cycles tab Purp Program Pump Cycles Purp History Assignments Min Cycle Interval Trigger Time 3 2 Hours 12 3n Der fie S fe Monh 1 pj 2 pl pl 4 5 8 3 p 8 ojn 12 p 13 pj Check All bli 18 18 bl 20 pl 2 Clear All 24 o 22 p 27 p 2 31 Figure 3 13 Cycle Interval in the Pump Cycles Tab On the Pump Cycles tab select the desired time between each pump cycle in the Cycle Interval drop down list Figure 3 12 shows a pump configured to run every two hours Set the cycle interval to Daily when you want the pump to run once at the Daily Trigger Time each day See Chapter 4 Controls and Features for descriptions of each data field Setup and Calibration 30 iChem ROC 107 User Manual 3 3 4 Dynamic Dosing Dose Input Multiplier This is a computation Dose to be injected Multiplier TLP Input Dose Minimum A constraint of the minimum allowed Dose to be injected Dose Maximum A constraint of the maximum allowed Dose to be injected Enable and Disable button of feature Enabling overrides user defined injection volume Dynamic Dosing Dose Minimum 10 0
9. 107 User Manual 3 1 7 Dynamic Dosing This is a User Defined input The input must be a Float data type Examples Analog measurement of transducer temperature H2S levels Point Type Logical Number Parameter Undefined HID Paint T ag ID Configurable E Logic Units Discrete Inputs Battery Scan Period Discrete Outputs Charge In Filter 3 Analog Inputs Unused Adjusted 4 0 0 Pulse Inputs Adjusted A D 100 AGA Flow Parameters Law Heading ELI History Parameters High Reading EU AGA Flow Calculation Values Low Alarm ELI Llack High Alarm Flags Low Low Alarm ELI Lamm Forts Hi Hi Alarm ELI System Variables Hate Alarm ELI FST Registers Alarm Deadband Soft Point Parameters Database Parameters Mode Module Information Alarm Code ro OO 7 CT CTI HE C0 oo Show All Point Types and Parameters 3 66 14 86 07648 v OK 2 Cancel Figure 3 8 Dynamic Dosing LTP Settings 27 Setup and Calibration 3 2 Calibrating the Flow Meter iChem ROC 107 User Manual The calibration controls are located on the Pump Program tab on the main iChem ROC 107 interface NOTE Click Apply in ROCLINK 800 when any field is changed 3 2 1 Calibrating the PD Meter Isolate the pump tank from the sight glass Mark the top of the fluid point on your sight glass Click the Start Pump Test button to run the test mo Ie gt and determine the difference
10. 107 User Manual The user must map the points on this tab prior to operation See 3 1 Mapping 1 0 Points Pump Program Pump Cycles Pump History m Tank Level TLP TankLvlRawAD 3 8 17 1 m Injection Pressure TLP Inj Press Raw4D 3 8 17 Es m Pump Control DOUT TLP DOUT Status 210 3 m Dynamic Dose Input TLP Dosing Input 0 0 0 mI Figure 4 10 0 TLP Assignments Tab Field Flow Meter TLP 5 12 17 ESD DIN TLP DIN Status Byte 0 0 0 A Flow Switch TLP DIN Status Byte 0 0 0 1 Function Tank Lvl RawAD TLP point selected for the Tank Level transducer Injection Pressure TLP TLP point selected for the Injection Pressure transducer Pump Control DOUT TLP point for Digital Output control of the pump TLP Controls and Features 41 iChem ROC 107 User Manual 5 Common Tasks The following activities facilitate operation and maintenance of the EFM through iChem ROC 107 5 1 Viewing History and Events To view the Event Log 1 Click View gt Alarms 2 Select From Device or From File to view the History Alarms or Events log ES File Edit ROC Configure Meter Utilities Tools Window D g Directory E HE EFM Report Calibration Report Connected to History Default Furg Alarms From Device Current Made i Ewents From File Cycle Timer Display Daily Volume VO Monitor 372 0 Cycle Freque
11. In order to license the ROC 107 application PCS Ferguson needs the serial number of the LCD controller Ensure that you send the LCD controller serial number and not the CPU serial number Software Installation 16 iChem ROC 107 User Manual Edit View ROC Configure Meter Utilities Tools Window Help Dot Rs m ge 9 EI T 5 E E 4 On Line Ethemet FB107 FB107 E Modules B 6 Foint Mat Installed Mat Installed Mat Installed Hat Installed Mat Installed Mat Installed History ABS User Program EEE User Display 52 General LED Advanced Installed Module LCD Controller 7 Actual Module LED Controller 00 Description Led ControllerApp 00 Build Date Sep 17 2007 358 2 Boot Revision Bv 10 Boot Build Date Sep 17 2007 98 2 mey Uninstall Figure 2 8 LCD Controller Serial Number PCS Ferguson will send you a 105 character string through email 1 Open ROCLINK 800 and click Utilities gt License Key Administrator gt Transfer Between DEVICE and KEY 2 Click Add License 3 Copy the 105 character string from your email and paste it into the text box Ensure you copy the entire string including the exclamation mark at the beginning 4 Click OK 17 Software Installation iChem ROC 107 User Manual Transfer Licenses Between a DEV
12. _ Q e e fe IOIO gt o Jg E Figure A 1 Standard Junction Box Wiring Example Wiring Diagrams 45 iChem ROC 107 User Manual A 2 iChem for FloBoss107 Neptune JB Wiring The following diagram shows an example wiring configuration using the Neptune Pump iChem for FloBoss 107 Junction Box for Neptune Pump ICHEM FB107 JB 2 1094750 FloBoss 107 Connections Descrption From Example Wiring Diagram s voz PH DIS GND ur Aud gt gt BLUE MOTOR PUMP BLACK RED 2 YELLOW FIELD WIRING Descrption From To PD Flow Meter 6 Tank Level HALL POWER HALLA HALLB ignal ignal C e 1 1 loo 1 Gio 9 WR ignal HALLGND VIN 10 15VDC Injection Pressure Motor PGOUT PHASEC 12 Volt lt DIRECTION Controller C Batter FREEWHEEL B 2 RUN STOP Flow Switch FAULT OUT VCONTROL 1B GND ESD Figure A 2 Example Junction Box Wiring for Neptune Pump WR ignal WR ignal WR 9 0 0 0 zB zB 20 20 79 46 Wiring Diagrams iChem ROC 107 User Manual Appendix B Troubleshooting and Known Issues Problem iChem will not license Sol
13. 10 0006944 Ti H Jb Current Cycle v pub Figure 5 1 View Alarms Menu Path ER ric Edit View ROC Configure Meter Utilities Tool Window Help D H hihi oe 4 Alarms 1652 FeO Uploaded 0770872014 14 54 40 Operator LOI DateTime Tag Set Clear Value Description 2014 12 09 04 LOWPRESSDON Alarm Clear 1996 167 OF 02014 12 09 04 OP CLEAR ALARM Alarm Clear 12024 ALARM Alarm Set OO 2014 2024 LOWPRESLMT Alarm Set ROC U OO 2014 120724 LOWwPRESSBMN Alarm Set 1 533205 0702014 12 05 48 HIPRESSSDON Alarm Clear 4000 0 1205 47 PUMPOFF_ALAR FI Alarm Set OF fOr 2014 1205 47 HIPRESSLMT Alarm Set 3000 0 12 05 47 HIFRESSSDON Alarm Set 4001 533 Save Print Preview ON LINE 25 2 3 4 B 4 Figure 5 2 Sample Alarms Log 42 Common Tasks iChem ROC 107 User Manual 5 2 Clearing Alarms To clear alarms and restart the pump 1 Click the Clear Alarms button in the Current Alarms panel Current Alarms MANUAL ESD Clear Alarms Current SV armings Figure 5 3 Alarms Panel 2 Then click Update NOTE Alarms can also clear automatically For example the alarm will trigger if the injection pressure dips below the low alarm level If the injection pressure then rises above the low alarm level the alarm will automatically clear 5 3 Running Custom Batches Emergency Shut Down 1 In AUTO or Manual mode enter the vol
14. 17 0 AC Cancel Ho 00 JC CT e oo Figure 3 4 nj Pressure Settings 23 Setup and Calibration iChem ROC 107 User Manual 3 1 4 Emergency Shutdown ESD DIN TLP The ESD is a discrete input Select TLP Pont Logical Number Parameter ndefined Configurable O Discrete Inputs Discrete Outputs Analog Inputs Analog Outputs Pulse Inputs AGA Flow Parameters History Parameters D Pulse Width AGA Flow Calculation Values 100 Pulse Width Clock Max Time Between Pulses Count Flags Units Comm Ports Scan Pernod System Variables Law Reading ELI FST Registers High Reading EU Soft Paint Parameters Low Alarm EU Database Parameters High Alarm EU Show All Point Types and Parameters Show Current Value 1 21 Y Cancel Filter Status Made Alarm Code Accumulated Value Counter OFF Counter ro OO JC On 4X Gi Figure 3 5 ESD DIN TLP Settings Setup and Calibration 24 iChem ROC 107 User Manual 3 1 5 Pump Control DOUT TLP The Pump Control point is a digital output Select TLP Point Type Logical Humber Parameter Undefined Point T ag ID Configurable maiU C3 Time On 2 Duzcrete Outputs DOU C4 3 Status Analog Inputs Analog Outputs 3 Alarm Code Pulse Input Accumulated Value AGA Flow Parameters Ly Units History Paramet
15. Dose Maximum 10 0 Doze Input Multiplier 1 li Dynamic Dose D Figure 3 14 Dynamic Dosing 31 Setup and Calibration iChem ROC 107 User Manual 4 Controls and Features This section details the functions of all data fields in the iChem ROC 107 interface 4 1 Operation Modes The iChem ROC 107 features three operation modes AUTO Manual and OFF and Calibrate The Operation Mode drop down menu is located on the Pump Program tab NOTE Click Apply in ROCLINK 800 when any field is changed Pump Operation AUTO FD Meter Units OFF and Calibrate Manual Tank Level Units AUTO Figure 4 1 Pump Operation Drop down Menu 4 1 1 AUTO Mode In Auto mode the iChem ROC 107 manages the measured injection of well chemicals The electronic flow meter detects the amount of fluid to seven digits of precision that is pumped into the well after each injection cycle iChem ROC 107 then adjusts the next pump cycle amount to account for inaccuracies over or under the set volume per cycle The flow meter causes the pump to skip cycles or simply revise the volume of the next cycle The PUMP ON and OFF buttons are not available in Auto mode Any Alarms cause the pump to shut off and switch the application to OFF Calibrate mode Warnings appear in the Warning box but will disappear after an Update The user can define the Warning and Alarm parameters in the Pump Program tab All Warnings and Alarms are recorded in the event a
16. ICE and a KEY Licenses on DEVICE Application Vendor App Version Quantity License Source Expiration Time Created 1 00 0 1 Ma Expiration 5 23 2014 02 51 31 PCS iChem 3 PCS 10228 0 02 4 1 File Expiration 0870772014 01 34 51 PM 1 00 0 Expiration 5 23 2014 02 51 37 PM No Expiration 0722922014 11 14 31 AM PCS Chem 2 File No Expiration 08 13 2014 11 55 17 AM Connect to KEY Moye to Add License Remove Figure 2 9 Licensing Screenshot Licenses on KEY Display The separate display file is not necessary to use the application The display is compiled into a single bin file for iChem ROC 107 in the FloBoss 107 and is included with the program load The display is under the User Program section of the tree 2 4 Saving and Loading Configuration Settings iChem ROC 107 s settings are not saved automatically and can be overwritten when updating your software version Follow these procedures to save your settings before you update and then reload the settings when the update is complete 2 4 1 Saving TLP Points and Settings 1 Click File gt Save Configuration EZ Edit View ROC Configure Meter New Ctrl N pen Ctrl O Download Close Save Configuration Print Configuration Print Ctrl P Print Setup Figure 2 10 Save Configuration Menu Path 2 Type aname for the file and click Save Software Installation 18 iC
17. O VZ 03 UPOS bin f Mame iChem AOC 107 v2 03 Download amp Stark Download Version Hev 2 03 Created 7 1 2015 9 25 49 SC DE Size 3b4 73 Figure 2 6 Download User Program File Software Installation iChem ROC 107 User Manual 6 Click Download to proceed After downloading iChem ROC 107 appears in the User Program slot with the application s properties displayed 7 Click Close to download the application to the FloBoss 107 and automatically start running the program 2 3 Licensing iChem ROC 107 To correctly license a user program slot PCS Ferguson needs to know which slot will be running the application You can have multiple iChem ROC 107 loads running simultaneously but each user program MUST have a license for each slot Utilities Tools Window Help Update Firmware License Key Administrator Transfer Between DEVICE and KEY Convert EFM File Transfer Between KEYS User Program Administrator ROCLINE 800 Security AI Calibration Values T PLIMPOFF OFF MVS Calibration Values MUN mergencu Shut Down FST Editor Custom Batch Start Custom Display Editor atch Vol 2 0 Custom EFM Report Editor Read File From Device Communications Monitor Figure 2 7 Menu Licensing Options PCS Ferguson needs two items to license a particular iChem ROC 107 firmware e FloBoss 107 serial number User Program slot or slots being activated
18. aily level Pump Program Pump Cycles Pump History Assignments Hour Cycle Interval 2 Haurs Daily Trigger Time 1 2 20 Check All Weekly Clear All Monthly Check All Clear All Figure 4 8 Pump Cycles Tab Field Function Cycle Interval Defines the amount of time between the start of pump cycles in minutes hours or daily Daily Trigger Time Defines the time the pump starts if the Cycle Interval is once Daily Weekly Alows the user to select specific days of week to pump For every day click Check All Allows the user to select specific days of the month to pump During months shorther than 31 days the application skips the extra days For every day click Check All D indicates Disabled S Controls and Features 39 iChem ROC 107 User Manual 4 6 Pump History Tab This tab displays statistics for chemical injection over time Today Vol Since Start 30 Day Volume 08 27 Yesterdays Volume 30 Day Target ol 00 Week Volume Err Volume 08 X Month Volurne 3l Day Batch Val 08 27 fear Volume 3l Manual sol 08 2 Forever Volume 30 Day Cycles 00 30 Day Skip Cycles 10 0 Batch Volume Today Batch Volume Day Clear History nee In OFFICAL Manual Volume Today 10 0 End DE D arce En ay Manual Volume 10 0 Figure 4 9 Pump History Tab Field Function 40 Controls and Features 4 7 1 0 Assignments Tab iChem ROC
19. e Injection 29 3 3 Setting Up Cycles and Volume 29 3 3 1 Setting Daily 30 3 3 2 Setting Contract 30 Table of Contents 2 iChem ROC 107 User Manual 3 3 3 Setting Pump Cycle 30 3 3 4 Dynamic 05 0 88 31 4 Controls and Eedl f6S 2222222234544244924544559333953249 2452452253343 32 4 1 Operation 32 AT TAU OMO0G ore 5 64555 32 4 1 2 Manual 8 8 32 4 1 3 OFF and Calibrate Mode ee eee 33 4 2 Pump Status 33 4 2 1 Pump Status Fields and Functions 33 4 2 2 Emergency Shut Down 34 4 2 3 ON OFF Buttons 1 34 4 2 4 Custom Batch RE 34 Aco IAMS PANG oa 2 2222 26 bien eeee sted eee 35 4 3 1 Alarm Messages and Meanings
20. e as measured by the PD meter for the current day starting at the Contract Hour time defined in the Pump Program tab 4 2 2 Emergency Shut Down Button Field Function Emergency Shut Down Turns off the pump and switches the application to the OFF CAL operation mode Button 4 2 3 ON OFF Buttons Field Function ON Button Turns ON Pump in MANUAL mode This button is disabled in other modes Pump State PUMPON or PUMPOFF shows the current state of the pump OFF Button Turns off pump in MANUAL or BATCH mode Disabled in other modes NOTE To turn off the pump in AUTO mode you must switch to MANUAL or OFF CAL 4 2 4 Custom Batch Fields Field Function Custom Batch Start Starts a custom Batch in AUTO or MANUAL mode Batch Vol Sets the volume for an instantaneous batch injection Correction Batch Start Starts a custom Batch in AUTO or MANUAL mode Batch Vol CPU computed volume for an instantaneous batch injection NOTE fa scheduled cycle occurs during batch mode the cycle is skipped If Correction Batch is Enabled in Pump Program Tab if unit stops injection due to alarm or user placing in OFF Cal mode CPU will compute volume during missed cycles due to stop condition 34 Controls and Features iChem ROC 107 User Manual 4 3 Alarms Panel This area of the iChem ROC 107 interface displays active Warnings and Alarms Current Alarms MANUAL ESD Clear Alarms Current V arings Figure 4 3 Alarms Panel
21. eck boxes 4 Click Download Your saved settings appear in your iChem ROC 107 user interface 19 Software Installation iChem ROC 107 User Manual 3 Setup and Calibration This section details the process for mapping and calibrating inputs and outputs for your system NOTE The same output slots can accommodate multiple output functions 3 1 Mapping 1 0 Points Before running your pump system with iChem ROC 107 you must properly map the TLP points based on your system configuration The user must define these TLP points For each TLP point 1 Click the button next to each TLP point to assign it to the corresponding slot based on your FloBoss setup Tank Level TLP Tank LvlRaw amp D 3 8 17 m Injection Pressure Inj Press Raw4D 9g 17 Pump Control DOUT TLP DOUT Status 2 10 3 2 1 Dynamic Dose Input Dosing Input 0 0 0 Figure 3 1 0 TLP Assignments Tab PD Flow Meter PCI Flow Rate 512 17 ESD DIN TLP DIN Status Byte 0 0 0 ES m Flow Switch DIN Status Byte 0 0 0 2 Select the correct I O type in the Point Type scrolling list 3 Select the corresponding Logical Number for the slot 4 Select the correct Parameter Setup and Calibration 20 iChem ROC 107 User Manual 3 1 1 Tank Level TLP The Tank Level point uses analog input 1 Select Analog Inputs in the Point Type scrolling list 2 Select t
22. ers Cycle Time 464 Flow Calculation Values 04 Count Clock 100 Court Flags Low Reading ELI Comm Ports High Reading ELI System Variables EU Value FST Registers Alarm Mode Soft Point Parameters Scanning Mode Database Parameters Manual Value Module Information Physical Value Show All Point Types and Parameters Show Current Value 2 18 3 HINTS Cancel Figure 3 6 Pump Control DOUT Settings 25 Setup and Calibration iChem ROC 107 User Manual 3 1 6 Flow Switch TLP The Flow Switch point is a digital input Flow Switch TLP DIN Status Byte 0 0 0 Select TLP Point Type Logical Number Parameter Undefined i Point T ag ID Configurable Filter Discrete Inputs Discrete Outputs Mode Analog Inputs Alarm Code Pulse Inputs Accumulated Value AGA Flow Parameters In Counter History Parameters OFF Counter AGA Flow Calculation values OF Pulse Width Clock 100 Pulse Width Flags Time Between Pulses Count Comm Ports Units System Variables Scan Period FST Registers Low Reading ELI Soft Point Parameters High Reading ELI Database Parameters Low Alarm EU Module Information High Alarm ELI Shaw All Point Types and Parameters Show Current Value 1 21 2 HINTS Y Cancel Figure 3 7 Flow Switch Settings Setup and Calibration 26 iChem ROC
23. ges shown in Figure 1 1 and Figure 1 2 are examples Your hardware setup may look different NP JN P ode ARTIS ac n AR D E p Lo c7 OX A a E Pa v XT P MED 222 Pict ra gest x UOTA a 95 0 Figure 1 1 Example of Standard Junction Box Wiring 7 Introduction iChem ROC 107 User Manual CURREN 3 LIMIT E i amp CL ADJ 10 C LOOP 2 CL1 1 EXTANT SPD 2FLTLATCH 3 RAMP 1 4 RAMP 2 5 607 120 Figure 1 2 Example Junction Box Wiring with a Motor Control Board See example wiring diagrams in Appendix A Introduction 8 iChem ROC 107 User Manual 1 3 2 ROCLINK 800 User Interface ROCLINK 800 configuration software allows a remote user to monitor configure and calibrate the FB107 ROCLINK also enables off line management of gas meters I O and Proportional Integral Derivative Feedback Control Loops PIDs The ROCLINK user interface displays the modules installed in the FB107 backplane File Edit View ROC Configure Meter Utilities Tools Window Help SX E Top Menu History ARS User Program User Display SEREG ER SABE RS Configuration Tree Menu General Advanced Paints Meter Paints Diagnostic Installed Module Actual Module CPU Description Application Firmware Revision 2 Part Number Build Date
24. he corresponding Logical Number for the slot 3 Select the correct Parameter select TLP Point Type Parameter Units Scan Period Filter Adjusted 4 D Adjusted 4 0 100 Law Reading EU High Heading ELI Undefined 10 Configurable Al 1 Slot 2 Discrete Outputs Al 2 Slot a Analog Inputs Al 1 Slots Analog Outputs Al 2 Slots Pulse Inputs Lagic AGA Flow Parameters E Battery History Parameters Charge In Low Alarm ELI AGA Flow Calculation Values Unused High Alarm ELI Clock Brd Temp Law Low Alarm ELI Flags Hi Hi Alarm ELI Lamm Parts Hate Alarm System Variables Alarm Deadband FST Registers Filtered ELI Value Soft Paint Parameters Made Database Parameters Alarm Code Module Information Haw A D Input mo cO CT CT Fe co p Figure 3 2 Tank Level TLP Settings 21 Setup and Calibration 3 1 2 PD Flow Meter TLP The PCI Flow Rate is always a pulse input iChem ROC 107 User Manual Select the correct Point Type Logical Number and Parameter for each point based on your system configuration select TLP Point Type Undefined Configurable Discrete Outputs Analog Inputs AGA Flow Parameters History Parameters AGA Flow Calculation Values Clock Flags Comm Forts System Variables FST Registers 5nft Point Parameters Database Parameters Module Information S
25. hem ROC 107 User Manual File name 107 AlG2 2014 07 08 Save as type Configuration File 800 Figure 2 11 Save File Dialog Box 3 Click Close 2 4 2 Loading Previously Saved Settings 1 Click File gt Download 2 Locate and Open your configuration file The Download Configuration dialog box appears Download Configuration Select Points ta Download System Variables Clock Parameters Configuration Module Parameters Control Modbus Function Tables v PCS Ferg PumpPragram Comm Port Parameters FST Code Modbus History Table Analog Inputs FST Parameters Modbus Master Table Analog Outputs User List Parameters Modbus Master Modem Discrete Inputs Meter Calibration Sampler ECM Parameters Discrete Dutputs Meter Configuration User Displays Pulse Inputs History Configuration 5 Parameters Soft Points 05800 Parameters Extended Soft Paints 05800 Resources Opeode Tables User Program Status Status Point Type Paint Number ST Select All Deselect All Download Close Figure 2 12 Chem ROC 107 Download Configuration 3 Inthe Download Configuration dialog box select PCS Ferg Pump Status and PCS Ferg Pump Program See Figure 2 12 CAUTION You can overwrite gas flow measurement settings by clicking the wrong check boxes when loading settings Use caution when selecting the ch
26. how All Point Types and Parameters 20 17 Figure 3 3 PD Meter Settings FIN BS Slot FIM BB FI 2 Slot FIM C5 Pl 1 Slots FIN CE PI 2 Slots Parameter Units Hate Flag Hate Pernod Filter Time Scan Period Conversion Low Alarm High Alarm ELI Low Low Alarm ELI HiHi Alarm ELI Hate Alarm ELI Alarm Deadband Rollover Maximum ELI Value Made Alarm Code Accumulated Value Curent Rate Show Current Value yY OK Cancel Setup and Calibration 22 iChem ROC 107 User Manual 3 1 3 Injection Pressure TLP Injection Pressure is an analog input Point Logical Number Parameter Undefined RATE Paint T ag ID Configurable Al 1 Slat Units 2 Discrete Outputs AIM Be 2 Slot Scan Pernod Analog Inputs Al 1 Slot Filter Analog Outputs Al 2 Slots Adjusted 4 0 Pulse Inputs Logic Adjusted 4 0 100 AGA Flow Parameters Battery Low Reading EU History Parameters Charge In High Reading EU AGA Flow Calculation values Unused Low Alarm Clock Brd Temp High Alarm ELI Flags Law Low Alarm ELI Comm Ports Hi Hi Alarm EU System Variables Hate Alarm ELI FST Registers Alarm D eadband Soft Paint Parameters Filtered ELI Value Database Parameters Mode Module Information Alarm Code Show All Point Types and Parameters Show Current value 3
27. igure 2 1 ROCLINK 800 Shortcut For more information on the ROCLINK 800 application visit the following link htto www2 emersonprocess com en US brands roc software roclink800 Pages roclink800 aspx Software Installation 12 iChem ROC 107 User Manual 2 Open the ROCLINK application ROCLINK 800 Configuration Software Password A E Cancel M Process Manna MER Figure 2 2 ROCLINK 800 Login Screen 3 When the login screen appears type your User ID and Password and then click OK If you do not have an individual user id and or password click the User ID text to automatically log in with the default credentials ID LOI and Password 1000 4 Locate the correct communication device for your FloBoss 107 configuration in the ROCLINK Device Directory 5 Right click on the device s corresponding PC port and click Properties od E Dee pe at ce DE a H 1 File Edit View ROC Configure Meter Utilities Tools Window Help 4 RS Eee PRO 2 Device Hoot Device Properties Connect Disconnect Rename 98 Delete Device ae Mew Groupi Figure 2 3 ROCLINK 800 Device Directory 13 Software Installation iChem ROC 107 User Manual 6 Define Communication Parameters as necessary for your system The green Online indicator will replace the red Offline field on the ROCLINK interface when
28. is OFF this field counts down the time until the next cycle starts When the pump is ON this field counts the amount of time that the pump has been running If the mode is switched from AUTO to another mode or Batch the count resumes when the next cycle begins Daily Volume Sets the total volume to be injected daily and displays the volume Cycle Frequency Displays the total number of pump cycles set to run on the current day This value is based on the Cycle Interval set in the Pump Program tab Current Cycle Displays the number of cycles that have occurred that day This count resets at the Contract Hour time defined in the Pump Program tab Tank Level Displays the Tank Level reading from the pressure transducer This entry requires calibration in the Pump Program tab and TLP definition in the I O TLP Assignments tab Flow Rate Displays the PD Meter reading This entry requires calibration in the Pump Program tab and TLP definition in the I O TLP Assignments tab Injection Pressure Displays the Injection Pressure reading from the Pressure Transducer This entry requires calibration in the Pump Program tab and TLP definition in the I O TLP Assignments tab Controls and Features 33 iChem ROC 107 User Manual Field Function Cycle Volume Displays the volume to be injected in the next cycle In AUTO and Batch modes this field counts down while pumping In Manual mode it counts up while pumping Todays Volume Displays the volum
29. kDrop 24 0 used in pump calibration kFactor 9755 5 Observed Tick Drop During pump calibration the user enters ComputedTickDrep 0 0 how many ticks the fluid dropped in this Factor field Timed Inj Cycles kFactor Displays the computed kFactor after a Calculate kFactor is clicked Figure 4 5 PD Meter Calibration Panel Computed Tick Drop Displays the computed fluid drop which should match the Observed Tick Drop This measurement is based off Test Time Volume per Tick and the kFactor Changing the Test Time in Secs and starting a pump test will compute a tick drop based on the calibrated factor Start Pump Test Button Starts the pump test Test Time and Volume per Tick must be entered before pressing this button The pump runs for time defined by the Test Time field Calculate kFactor Measures PD meter pulses during the Button pump test and calculates the kFactor for the injection system You must run the pump test before clicking this button to calculate When clicked this button computes the slope and offset of the calibration Controls and Features 37 iChem ROC 107 User Manual Field Function tFactor Button When Enabled after each successful cycle of PD meter a current tFactor is computed if PD meter fails to show flow unit after time will jump into tFactor mode If PD meter operates again will switch back to PD measurement mode 4 4 2 Tank Level Calibration Tank Level Calibration Low Leve
30. l oo Set High Level 15 0 Set Field Function Low Level Enables the user to set the low level entry for tank calibration Click the Set in tank High Level Enables the user to set the high level Calculate Scale and Offset entry for tank calibration Click the Set button when the fluid is at the high level Figure 4 6 Tank Level Calibration in tank Current Level Displays the current fluide level in the tank as measured eight 8 seconds after the pump stops Calculate Scale and Calculates the linear curve the Offset Button transducer will follow for a specific voltage based on the high and low levels 4 4 3 INJ Pressure Calibration Field Function Inj Press Calibration Low Level Enables the user to set the low level Low Level 00 Set entry during pressure transducer High Level 30 0 Sel calibration for injection pressure Curent Press 000 High Level Enables the user to set the high level entry during pressure transducer Calculate Scale and Offset calibration for injection pressure Displays the current injection pressure Figure 4 7 Injection Pressure Calibration Calculate Scale and Calculates the linear curve the Offset Button transducer will follow for a specific voltage based on the high and low levels 38 Controls and Features iChem ROC 107 User Manual 4 5 Pump Cycles Tab This tab enables the user to set the timing for pump cycles at a weekly monthly and d
31. me Unit TLP Point Type Logical number and Parameter 1 2 Safety Overview and Symbols This product and other chemical injection systems and components should only be operated by trained and experienced personnel Accidents can result in damage to equipment chemical spills loss of natural gas or other unintended consequences This manual contains Caution and Warning related text to alert the user to potential hazards CAUTION A Caution box indicates a potential for damage to equipment loss of data or interruption of essential processes WARNING A Warning box indicates likely damage to equipment or loss Introduction 6 iChem ROC 107 User Manual 1 3 System Overview The iChem ROC 107 application is designed to integrate with the Emerson ROCLINK 800 ROCLINK configuration software and the Emerson FloBoss 107 FB107 flow manager NOTE For more details regarding the FloBoss 107 or ROCLINK 800 refer to the appropriate Emerson documentation at http www 2 emersonprocess com en US brands roc software roclink800 Pages roclink800 aspx 1 3 1 FloBoss Hardware ROCLINK and iChem ROC 107 run with the FloBoss flow manager hardware The FloBoss 107 attaches to the outside of the pump and manages the injection volume and timing of the well The box has an LCD screen for basic operations The junction box wiring configuration determines the parameters for later mapping of the TLP points and other set up tasks The ima
32. nd history logs Custom batch injections can run in either Auto or Manual modes NOTE fa scheduled cycle occurs in manual mode or during a batch run the application skips that cycle 4 1 2 Manual Mode Manual mode allows the user to turn the pump ON or OFF and to run custom batches NOTE Manual mode the tank level will not update until eight 8 seconds after the pump stops 32 Controls and Features iChem ROC 107 User Manual 4 1 3 OFF and Calibrate Mode In OFF CAL mode the only function available is calibration The pump will not run ROC 107 switches to this mode when the Emergency Shut Down ESD button is activated 4 2 Pump Status Panel This area of the iChem ROC 107 interface displays live measurements and pump cycle timing data and contains the Emergency Shut Down and Batch functions 4 2 1 Pump Status Fields and Functions Connected to Pump 5 efault Pump Mame Current Made OFF CAL Tank Level 10 0 Emergency Shut Down Cycle Timer Secs 422 Flow Fate 10 0 ON PUMPOFF Daily S olume 1 440 Injection Pressure 10 0 Custom Batch Start Cycle Frequency 1 Cycle Volume Batch vol 20 Current Cycle 0 Todays Volume 10 0 Figure 4 2 Pump Status Panel Field Function Default Pump Name Allows the user to type a name for the pump Current Mode Shows which of the three operation modes OFF CAL Auto or Manual is currently set on the Pump Program Tab Cycle Timer Secs When the pump
33. ose D Figure 1 4 ROC 107 User Interface Click the Apply button to save your changes and click Update to refresh the screen and meter readings Clicking AutoScan updates all readings every second by default 11 Introduction iChem ROC 107 User Manual 2 Software Installation The ROCLINK 800 software must be installed and connected to a communication device NOTE Consult your FloBoss 107 ROCLINK 800 user documentation for additional information not included in this manual 2 1 Installing ROCLINK 800 To install ROCLINK from a CD ROM 1 2 Insert the disk into your PC and follow in the installation wizard instructions If any User Account Control messages appear click Yes to allow ROCLINK to install 3 Restart your PC when prompted to complete the installation To install ROCLINK 800 from a zip file 1 Extract all files in the zip folder and save the ROC folder in an appropriate location on your PC Open the ROC folder and ROCLINK sub folder Locate and open the setup file Follow the instructions in the Installation Wizard If any User Account Control messages appear click Yes to allow ROCLINK to install Restart your PC when prompted to complete the installation 2 1 1 Logging in the First Time ROCLINK automatically creates a shortcut on your desktop 1 To start ROCLINK double click the shortcut or locate the program in your Start menu F
34. our Defines the hour of the day when the pump restarts the Daily Volume measurement At the set hour Todays Volume clears to zero for the beginning of the new day This setting uses a 24 hour clock Batch Catch D E Pump Off W Flow Alarm Tank Low Warning Tank Low Alarm Low Flow Alarm Defines the level at which the low flow alarm activates and shuts off the pump This function checks the flow pressure every 20 seconds after the pump starts and continuously while pumping 36 Controls and Features iChem ROC 107 User Manual Field Function User Defined 1 Defines data point based on the User Defined setup The user can enable the point for an Alarm or Warning flag User Defined 2 Defines a data point based on the User Defined TLP setup The user can enable the point for an Alarm or Warning flag User Defined TLP Defines a TLP for dynamic definitions of alarms or warnings Enable Disable Buttons Allows the user to enable or disable any alarm or warning E enabled D Disabled Alarm Warning Buttons Lets the user set the Flow Switch and User Defined points as Alarms or Warnings 4 4 1 PD Meter Calibration Function PO Meter Calibration Test Time in Secs Defines the amount of time the pump start Pump Test Calc kt Factors runs during a positive displacement PD Test Time in Secs 15 meter calibration test Volume per Tick 00006944 Volume per Tick Lets the user set the volume per tick Observed Tic
35. s Connected Pump Default Pump Name 000000 Current Mode OFF CAL Tank Level oo Emergency Shut Down Cycle Timer Secs Flow Rate 0 Daily S elume Ho o Injection Pressure oo Cycle Frequency 1 440 Cycle Volume 10 0006944 Current Cycle In Todays Volume I Dynamic Dose Input rr Clear Alarms Pump Program Tab Current farnings PO Meter Calibration Pump Operation OFF and Calibrate Start Pump Test Calc kt Factors PE Meter Units Quarts Test Time Secs 15 Tank Level Units Volume per Tick 10 0006944 Observed TickDrop ao kF actor 37555 ComputedTickDrop oo tFactor oo D Disabled Timed Inj Cycles D Tank Level Calibration Low Level oo Set High Level 1 5 0 Set Current Level 10 0 Calculate Scale and Offset Alarm Warming Inj Press Calibration Flow Switch D Low Level oo Set High Level 30 0 Cet User Defined 1 vl s Current Press oo User Defined 2 D gt 0 0 D Calculate Scale and Offset User Defined TLP FLoaT Undefined El Pump Contract Hour Batch Catch Pump Flow Alarm E Enabled Tank Low arming Tank Low Alarm Low Flw Alm T md Override Low Flow Time Limit secs Low Flow Alarm High Flow Alarm Low Pressure Alarm High Pressure Alarm mA E E 5 5 5 Dynamic Dosing Dose Minimum 10 0 Dose Maximum 10 0 Dose Input Multiplier 1 O Dynamic D
36. troduction 5 This manual guides the user in installation setup calibration and operation of the iChem ROC 107 chemical well tending application Audience The iChem ROC 107 User Manual is intended for knowledgeable professionals in the natural gas well industry with flow management software experience Scope Chapter 1 Introduction Provides an overview of the system described in this manual Chapter 2 Software Installation Provides step by step installation instructions for the ROCLINK 800 and iChem ROC 107 software Chapter 3 Setup and Calibration Details the tasks required for customizing and testing your chemical injection system Chapter 4 Controls and Features Lists and describes each input field and function in the iChem ROC 107 application Chapter 5 Common Tasks Describes procedures for other useful options in the ROC 107 application Appendices Contains additional wiring diagrams and troubleshooting information Introduction iChem ROC 107 User Manual 1 1 Abbreviations and Acronyms DIN Digital Input DOUT Digital Output DP Differential Pressure EFM Electronic Flow Meter FB107 FloBoss 107 electronic flow computer iChem Intelligent Chemical Pump referring to the PCS Ferguson chemical injection system I O Input Output LOI Local Operator Interface PC Personal Computer PD Positive Displacement PID Proportional Integral Derivative PLC Programmable Logic Controller RTU Real Ti
37. ume be injected immediately in the Batch Vol field Custom Batch Start 2 Click the Custom Batch Start button to begin the batch injection Batch Vol 2 0 The Pump Status panel updates as the batch runs Conrection Batch Start 3 If Enabled Click Correction Batch Start button to begin the Figure 5 4 Custom Batch Functions Common Tasks 43 iChem ROC 107 User Manual 5 4 Creating a User Defined TLP Extended soft points allow users to define data types User Defined 1 D User Defined 2 00 D User Defined TLP FLAT Undefined Figure 5 5 User Defined TLP Functions Users can set alarms and shut down the pump using any TLP point defined in the FloBoss 107 1 Select and map the User Defined TLP point 2 Match the TLP point to its data type 3 Setup the warning or alarm levels as required 44 iChem ROC 107 User Manual Appendix A Wiring Diagrams A 1 iChem for FloBoss107 Standard JB Wiring The following diagram shows an example wiring configuration iChem for FloBoss 107 Standard Junction Box aaa aE ICHEM FB107 JB 1 1094749 ere PEE Vo Example Wiring Diagram wo mas 10A 001 11A not shown Relay13 PH DIS GND NL 1 FIELD WIRING Descrption To PD Flow Meter 6 Tank Level Injection Pressure B Flow Switch 12 Volt Pump Output 26 P P AC
38. ution Refer to Section 2 3 Problem Pump will not start Solution Check wiring and refer to Section 3 1 Solution Check operation and refer to Section 4 1 Problem Pump starts but no or Low Flow Detected Solution Check wiring and refer to Section 3 1 Solution Check PD meter sensor is installed correctly Solution Isolate the PD meter and examine inside the PD meter gears for blockage or flaws Troubleshooting and Known Issues 47
39. you are successfully connected 2 2 Loading iChem ROC 107 The FloBoss 107 allows up to six 6 user program slots Loading the iChem ROC 107 application requires the bin file To install iChem ROC 107 1 If necessary extract the bin and save it in an appropriate location on your PC 2 Start ROCLINK80O and connect to the FloBoss 107 3 In the configuration tree expand User Program and click Administrator Modules 20 Control E Meter System ES History User Program Administrator B S B B Figure 2 4 User Program Administrator Path Software Installation 14 15 iChem ROC 107 User Manual User Program Administrator User Programe Installed in Device IChemT ender V DID M No Fragram Pragram Program Version Library Version Program Created DAAM Used 0 Program CRC FLASH Used 0 Program Entry Pt Displays All Option Status Empty Download User Program File a isse Version Created gt gt Update Close Figure 2 5 User Program Administrator Dialog Box 4 Click the Browse button to locate and open the ROC 107 bin file on your PC 5 Ensure the Download User Program File path is correct and then click Download amp Start Download User Program File JOAROCTOAIChemROCT

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iCHEM™ ROC 107 USER MANUAL