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Project Members:Joey Philippi – Project ManagerBryan Roby – Hardware EngineerBrad Swallow – Test EngineerAlex Shaffer – Software Engineer

Advisor: Dr. Wei Zhan Sponsor: Russel Treat

Background

• In 1980, the world consumed 62 mb/d of oil

• Today the world consumes more than 85 mb/d of oil

• Strong push to be less dependant on foreign oil

• Beam pumping consists of nearly 60% of oil production in U.S.

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How it Works

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Beam Pump Action

Plunger Mechanism

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Ideal Pump Action Low Pressure System

Objective

• Develop a pump control system, JAB2, that will maximize production and minimize costs

• Reduce damage to the pump system from previous methods of control

• Incorporate CIGCOM and SCADA to enhance the overall functionality potential

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Justification

• Need for Oil

• Increase in Production

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• Reduction in Downtime

• Reduce Maintenance Costs

Source: Energy Information Administration

Problem Statement

“Legendary Applications is moving forwardto expand in three key areas in beam pumping future: communications, sensing, and enhanced recovery, by introducing JAB2”

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Functional Requirements

• Variable Speed Drive Motor Control• Old Measurement Devices

– Strain, Pressure, Voltage, Amperage, Transducer

• New Measurement Devices– Accelerometer, Tachometer, Thermocouple

• Emergency Shutdown• CIGCOM Integration• Data Storage• SCADA-Pack Communication• HMI (Human Machine Interface)• Bluetooth Interface• GUI Data Presentation

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Conceptual Diagram

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PIC μ Controller

Signal Conditioning

On-Board Indicators

Data Storage

RS485

I/O Board

VSD

Power Regulator

Power In

CIGCOM

Functional Block Diagram

Laptop GUI - Bluetooth

Communication Bluetooth Communication

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Programming Provided HardwareDeveloped HardwarePartial Programming

Feedback

Sensor Inputs

Pressure Sensor

Accelero-meter

Strain Gauge

Volt Meter

Ammeter

Temperature

Frequency counter

Tachometer

Beam-Pump System

Motor

Modbus

SCADA Pack

Bluetooth Module

Wireless Comm.

Data Storage

HMI

LCD TactileInterface

Work Breakdown

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Research

• Protocols• Measurement Devices• VSD• SCADA Pack• Production• Placement• System

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Hardware

• Schematic Design– Breadboard–Multisim/Ultiboard– Sensor Inputs

• Multiple Revisions• Prototype– Enclosure– Final

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Software

• Sensor Inputs• Signal Processing– Bluetooth– ModBus

• Data Acquisition and Storage• Outputs– VSD– Emergency Shutoff– Data

• User Interface

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Procurement

• Components– PIC24– Sensors– Housing

• Equipment– Measurement Devices– CIGCOM– SCADA Pack– Programming Environment– Motor

• Funding

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Testing

• Test Plan– Breadboard– PCB

• Components– Functionality– Calibration

• Software– User Interface– Data– Control

• Prototype

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Finalization

• Demonstration– Working Prototype– Communication with SCADA Pack– Communication with Laptop– User Interface

• Documentation– User Manual– Schematics– Source Code– Test Report– Final Report

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Milestones

• Selecting Components for JAB2

• Develop PCB Design– Approval of Schematics– Approval of PCB Layout

• Design User Interface– Laptop– HMI

• Communication Software Design

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• Test of Prototype• Design of Motor

Control• Demonstration of

Source Code

• Working Prototype

Milestones

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Deliverables

• Pseudo Code• User Interface Flow

Chart• Software

Demonstration• Schematic Design and

Alterations• Bill of Materials• Critical Design Review• User Manual

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• Final Report– Final Test Report– Final Documented

Source Code• Fully Functional Prototype

Deliverables

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Resources

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Hardware Rate - - - - - - Total

Components, Housing, PCB, etc

650   $650

SCADA Package 275   $275

Software Rate - - - - - - Total

Software Packages

8,500   $8,500

Computers 1,050  2 $2,100

Equipment Rate - - - - - - Total

Measurement Devices

1,100   $1,100

Labor Rate per Hour Hours Total

4 x Engineers 30 1,600 $48,000

Space Rate per month Duration Total

Work Space 1,100 4 months $4,400

Combined Total:    $65,025

Task Breakdown

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Joey Philippi

• Several years of managerial experience at a PC repair company

• Software experience in C, Visual Basic, Assembly, VHDL, & Java

• Training with the FLEX testing equipment

• Four years of logo and animation design

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Project Manager

Bryan Roby

• One year experience with automation and control systems.

• Two years experience with various sensors and filtering.

• Three years experience in general hardware design and applications

• Two years experience with communications networks.

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Hardware Engineer

Alex Shaffer

• Four years experience in hardware design and development

• Three years experience in software design and embedded software programming

• FLEX Semiconductor Tester Training

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Software Engineer

Brad Swallow

• Extensive knowledge in hardware and software design and test

• Website design for personal and professional use

• Leadership and management experience

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Test Engineer

Technical Merit

Technical Merit FactorWeight

Contains a clearly described and completely understood technical challenge 0.1

Contains a requirement for system integration 0.2

Contains a requirement for system testing 0.2

Contains a requirement for analysis 0.2

Contains hardware design, development and test 0.3

Contains software design, development and test 0.3

Contains a hardware fabrication requirement, typically a prototype 0.2

Contains a requirement for documentation other than the project report 0.0

Contains a requirement for intellectual property protection 0.0

Total 1.5

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QUESTIONS?

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