Creating an intuitive user interface and Data Acquisition System
NORSOK (Norwegian Sector) nitrogen pumping units.
I was tasked with designing and installing a replacement Data Acquisition System (DAS) that could display primary instrumentation and provide engine and pump electronic protection. This system would become part of the company product line.
The DAS would be HMI and PLC based, with all engine controls and safety shutdown systems utilising field serviceable electro-mechanical relays and intrinsically safe temperature and pressure switches.
Engine Protection
Electro-mechanical relays were used to protect the engine from high temperatures, low oil pressures and and over speed. I designed these in such a way that when a shutdown was activated, an indicator lamp was illuminated on the control panel and the relay latched. The operator had to acknowledge the fault by pressing a reset button once it had cleared.
The use of electro-mechanical relays enabled fast troubleshooting and end user repair in the field compared to software controlled shutdown systems.
Data Acquisition and primary instrumentation
The pump screen was reworked to provide an accurate and clearer view of critical pump data at a glance. I programmed the system to be able to switch between bar graphs and numbers at the push of a button.
Data Trending and History
The further introduction of a line graph screen added the benefit of seeing data trend history. This became valuable during troubleshooting of the nitrogen unit, as it allowed a clearer view of what was happening up to the moment of any particular occurrence.
Remote Pressure Monitoring and Over Pressure Protection
The lack of a remote pressure channel on the older system meant that additional pressure monitoring equipment had to be on site at the remote location. Hardware and software was added to allow remote pressure monitoring with no additional equipment needed. I included a new screen and programmed the software to allow for a full user selectable pressure range to suit application and transmitter value.
Pump Protection
The nitrogen pump was electronically protected with user adjustable shutdown values. Over pressure (local and remote), high/low temperature alarms, hydraulic oil temperature and exhaust temperature are all monitored in real time and can be set to shut down the pump and/or engine at user defined values.
The Data Acquisition and Engine Protection System has now been installed on 16 Norwegian units and has been in service for over 2 years. No issues have been reported and feedback is positive.
