COMOC-V. Operational and Technical Overview

Transcription

1 May 5, 2003 COMOC-V Operational and Technical Overview REFINERY SYSTEMS DIVISION, USA 19 Roszel Road Princeton, NJ Phone (609) Fax (609)

2 CONTENTS 1.0 Introduction Features System Overview COMOC-V Computer System COMOC-V CFR Engine Hardware COMOC-V Upgrade - Migration from COMOC-III Systems COMOC-V Specifications Site Requirements...13 Core Lab Refinery Systems 2

3 1.0 Introduction This document is intended to give managers and users a brief overview of the Refinery Systems Division COMOC-V System. It summarizes the system s features, the different computer technologies leveraged, the operator interface, and security issues. For additional information please consult the COMOC-V Operators Guide (document T- EIOW.8192A) and the COMOC-V Technical Reference Guide (document T-EIOW.8192B). 2.0 Features The COMOC-V System is the successor to the industry standard COMOC-III System. COMOC-V when used in conjunction with ASTM Research and Motor Method engines automatically determines the quality of in-line blended gasoline s. COMOC-V is capable of handling simultaneously up to 10 engines and 3 in-line blenders. Octane analysis can be performed by either the knock intensity or the compression ratio approach as defined by ASTM D2885. Compliant with the latest ASTM D2885 Method - Since Core Laboratories Refinery Systems Division is an active member in ASTM, the COMOC-V System is continually updated as the ASTM D2885 method evolves. Provides an Open PC Architecture - Since COMOC-V utilizes personal computers and Microsoft Windows operating systems, COMOC-V is able to leverage the power of technologies such as Open Database Connectivity (ODBC) and Dynamic Data Exchange (DDE). In addition, new technologies will be added to COMOC-V as the software industry develops and adopts them. Simple User Friendly Computer Operations - Utilizes the Microsoft Windows Graphical User Interface. This interface is known throughout the computer industry and eliminates the need for specialized training. Provides Necessary Engine/Analyzer Functions - COMOC-V includes ASTM compliant D2885 Blending, Prototype Tank Calibration, System Qualification Checkout, and Analyzer Calibration procedures. Includes Rugged Engine Hardware - Provides a modern analyzer enclosure, digital KI recorder, LVDT CR sensor, fuel position verification and easy access to calibration points. Also included are a re-designed spill type carburetor, heat exchanger and fuel junction assembly. Core Lab Refinery Systems 3

4 Supports Unattended Automation - Utilizing ODBC or DDE technology, the blender control system can propagate blend recipe parameters to the COMOC-V System to provide unattended automation. In addition, COMOC-V provides octane deviation parameters through the same interface to provide a closed-loop control. Expandable Analyzer Network - Add additional COMOC-V engine analyzers at any time by connecting to the 4 wire RS-422 network. Expandable User Network - Add additional COMOC-V control and viewer consoles by connecting a desktop computer to the in-house or vendor provided TCP/IP network hub. The COMOC-V client software is designed to be compatible with the latest internet browsers. Secure Analyzer Network - The COMOC-V Data Server software runs on the Windows Server operating system and utilizes the extensive security features built into the operating system. Remote Access - With an optional router and Internet connection the COMOC-V network can be connected to the Internet for secure remote access. Core Lab Refinery Systems 4

5 3.0 System Overview Core Lab Refinery Systems 5

6 4.0 COMOC-V Computer System 4.1 Description The COMOC-V system components consist of the COMOC-V Data Server, Blender Console, Maintenance Console, and network interconnection hardware. These devices are tied together via Ethernet cables and a network hub to form the COMOC-V network. 4.2 COMOC-V Data Server The COMOC-V Data Server (C5DataServer) is the heart of the COMOC-V System. C5DataServer is a 32 bit multi-threaded Windows service application. COMOC-V Data Server Model Data Acquisition and Control C5DataServer scans the digital and analog channels in the engine area via the 4- wire RS-422 network utilizing the OPTOMUX protocol. This protocol supports up to 255 devices on the RS-422 network. The I/O scan rate is configured via the COMOC-V database. The data acquisition and control logic provides control of the compression ratio, fuel to air ratio control, prototype to product fuel switching, and alarm monitoring while the CFR engines are physically running Historical and Real-Time Data Storage The COMOC-V data is housed in the Microsoft SQL Server database format. The database consists of tables for real-time data, historical data, command queue processing, I/O devices and channel assignments, system configuration parameters, engine calibration data, blender control system interfacing, and user configuration. The real-time data tables are updated periodically as configured by the system configuration. Historical data is stored by engine number and by blend identifiers. The following engine functions are historized by date and engine number; fuel air search, engine calibration, proto calibration, and system checkout. All blending data is historized by the blend identifiers (maximum of 50 character). Limits to the number of historical entries are defined by the system administrator. Core Lab Refinery Systems 6

7 4.2.3 Web Server Interface The C5DataServer software resides on a Windows based server with the Microsoft Internet Information Server (IIS) software along with Microsoft Data Access Components (MDAC). The IIS provides the COMOC-V consoles with the appropriate COMOC-V client data via the HTTP (world-wide web) protocol. Data is acquired through the ADO interface included with MDAC. IIS has built-in security which require each client to log in to the web server before allowing access to the site. The C5DataServer Service uses Object Linking and Embedding for Database (OLE DB) for database access Blender Control System Interface Just as the traditional COMOC-III System, COMOC-V supports hard-wired analog and digital I/O communication to blender control systems. Signals supported are; delta octane number, absolute octane number, optional volatility trims, analyzer hold/resume, and an analyzer alarm output. In addition to the above mentioned interfacing, COMOC-V additionally supports a purely digital interface to blender control systems. This digital communication takes place over the Ethernet network hardware installed in the C5DataServer computer. This interface eliminates calibration errors that can occur in digital to analog and analog to digital conversions. Since COMOC-V data is accessible with Transact SQL commands, other tasks running on the C5DataServer computer or other computers on the network can read and write to the database. This open architecture permits a blender control system to store blend recipe data needed by the COMOC system in to the COMOC database. Some of the different technologies available for accessing the database include; DDE, NetDDE, OLEDB, DCOM. Once the data is stored in the correct database table, COMOC simply reads the data and launches the blend monitoring feature of the COMOC system. To close the loop, when new octane number data becomes available the COMOC system updates the database and the blender control system reads the data to perform recipe control. 4.3 COMOC-V Client Consoles Description Two consoles are supplied with a typical COMOC-V System, a blender console, and maintenance console. The blender console is usually installed in the blender control room and the maintenance console is typically installed in the engine room or close proximity. Each console consists of a desktop computer running the Windows operating system and a web browser. The user logs in to the COMOC-V Data Server with a user name and password. At this point the browser is configured to invoke a web page or URL (uniform resource locator) which displays the COMOC-V system. Core Lab Refinery Systems 7

8 4.3.2 Site Map Once the user has pointed their browser to the COMOC-V URL, the COMOC-V home page will be displayed in their browser. At this point the COMOC-V logo page is displayed which contains version information, a user name field, and a password field. An operator is required to login to the COMOC System before proceeding. Once logged in, the System Status page is displayed with real-time engine and blend data. In addition, a menu bar enables navigation throughout the COMOC system. The menu bar contains 8 top level selections; COMOC-V Login, Blend Details, Commands, Configuration, Engine Status, Reports, System Status, and Help. Some users may not have access to all areas of the site. For instance, a laboratory technician may not have a need to access the blend definition page. Therefore this page will not be accessible by this user COMOC-V Home Page COMOC-V Logon Page (displayed in Intenet Explorer) Core Lab Refinery Systems 8

9 4.3.4 System Status System Status Page (displayed in Internet Explorer) Blend Details Blend Detail Page (displayed in Internet Explorer) Core Lab Refinery Systems 9

10 4.3.6 Security Access to the COMOC-V System is gained by entering a user name and password in to the login page. The COMOC system verifies the name and password with the user database. Upon verification of the login information a cookie is generated and sent to the browser. From this point forward any access to the COMOC system is granted through use of this browser cookie. Access is granted until the user logs off the system or until the cookie expires. The default expiration of the cookie is 30 minutes. This expiration is a configurable parameter. If a more secure environment is desired, the Secure Sockets Layer (SSL) interface can be set up to enable data encryption between the client and the server. Core Lab Refinery Systems 10

11 5.0 COMOC-V CFR Engine Hardware 5.1 Description The COMOC-V System comes with complete engine hardware and accessories. The system requires valid working CFR Research and Motor method engines with compression ratio motor control. The system also requires engine coolant from a Core Lab Intake Air Refrigeration Unit (IAR ). 5.2 Engine Console The COMOC-V engine console consists of an operator interface for local control of each CFR engine. The console contains a display with knock intensity and fuel air position readouts. In addition, illuminated buttons permit control of the compression ratio, fuel air ratio, fuel switching, automatic / manual control, and continuous fuel switches. 5.3 Carburetor The COMOC-V carburetor has been re-designed to include additional features over the traditional COMOC-III carburetor design. Included in the stepper motor fuel switching mechanism are position proximity sensors to detect position feedback. This feedback verifies that a fuel switch has taken place. The new sensor detects this condition and allows the COMOC system to alarm and discard engine readings during this period. 5.4 Heat Exchanger The COMOC-V heat exchanger is supplied to cool COMOC-V Carburetor the prototype and product fuel before it enters the intake venturi of the engine. It is mounted to the CFR crankcase and requires a coolant mixture which is supplied Core Lab s IAR. The ASTM method requires that fuel be cooled to approximately 55 Fahrenheit. The heat exchanger includes rotometers that provide independent proto / product fuel flow regulation. 5.5 Fuel Junction Assembly The fuel junction assembly is usually mounted to the engine s foundation block. This assembly provides switching solenoids and fuel pumps to supply the appropriate fuel to the CFR engine. Manual block valves are available to supply canned fuel to the engine for engine analyzer calibration and the system qualification checkout exercise. Core Lab Refinery Systems 11

12 6.0 COMOC-V Upgrade - Migration from COMOC-III Systems 6.1 Description The COMOC-V Upgrade is a low cost alternative to upgrading existing COMOC-III Systems. Included in the upgrade is new state of the art computer hardware and software. This enable s COMOC-III users to replace their aging proprietary DEC-VAX hardware with COMOC-V s latest computer technology. The engine peripherals; COMOC-III carburetors, heat exchanger s, engine consoles, fuel junction assemblies, and I/O interface cabinets remain unchanged. 6.2 COMOC-V Upgrade Overview Core Lab Refinery Systems 12

13 7.0 COMOC-V Specifications Accuracy Octane RON MON Number Year 2000 Compliancy ASTM Compliancy COMOC-V complies with Core Labs Y2K compliancy program. See document T-TECW.001 for further information. COMOC-V meets all the instrument requirements for ASTM Standard D-2885 and provides the ability to certify gasoline product. 8.0 Site Requirements HVAC Ambient room temperature should not exceed 80 degrees Fahrenheit. The room should receive between 5 and 12 air changes per hour. The room pressure should be maintained at 0.1 inches of water (positive pressure). Intake air should be taken from a non-hazardous area, typically 20 to 30 feet above ground, away from exhaust output through an explosion proof air conditioner. Thermal loads (heat dissipation) are as follows: Motor Method Engine Research Method Engine Intake Air Refrigeration Unit 13,100 BTU/Hr. 10,100 BTU/Hr. 4,100 BTU/Hr. Engine Foundation Engine Cooling Water Crankcase Ventilation The engine should be mounted on an isolation block per ASTM D2699 and D2700 Section A The block anchors the engine to the floor and provides vibration isolation. Cooling water should be cooler than 95 degrees Fahrenheit and be potable and free of sediment. Flow rate 1.5 Gal/min. (Per engine) minimum pressure of 20 psi. There will be a temperature rise of 30 degrees as it flows through the engine condenser coil and water cooled exhaust system. Water supply should be piped as close to the engine as possible with a manual shutoff valve. Crankcase ventilation is furnished by a breather valve located on the left crankcase door. The outlet is fitted for 3/4" pipe to conduct crankcase vapors out of the room. A condensation trap should be provided to prevent moisture from running back into the crankcase. Core Lab Refinery Systems 13

14 Exhaust Ventilation Engine Air Consumption Sound Levels Electrical Requirements Exhaust Back Pressure - The exhaust back pressure at the water cooled exhaust pipe should be as low as possible, but in no case should it be outside the limits of 0 to 10 inches (254mm) of water pressure. Discharge Pipe - It is desirable to use a discharge pipe of 3 in. (76.2 mm) minimum diameter with 60 ft. (18.28m) maximum length and containing no more than three (3) elbows or other restrictions. It is recommended to have a separate exhaust system for each engine. If a common discharge pipe is used for a multiple exhaust system, the limits of 0 to 10 inches (254mm) of water pressure. A trap must be provided in the water drain line and the drain line must discharge to atmospheric pressure, one for each engine. The CFR engines consume intake air at the following rates: Research Engine 6.48 cfm (11 mˆ3/hour) Motor Engine 9.73 cfm (16 mˆ3/hour) The specific humidity of the intake air should be between 25 to 50 grains/lb of dry air. The peak noise level for the Motor or Research engine at maximum knock intensity is approximately 80 db(a) including the 10 db(a) background reading. The analyzer console uses about 1.5A from the 115v circuit of the CFR engine s main fuse. The CFR engine requires both single phase current (for the engine control and instruments) and three phase current (for the synchronous motor). Engine voltages and line frequencies are selected from the site facilities. A transformer is available to produce the 115 VAC circuit if it is not available. The analyzer can operate from 48 to 62 hertz line frequency. However, correct engine rpm is only achieved by using 50 or 60 hertz power. The spark plug ignition wire must be replaced on the CFR engine with an EMI/RFI noise suppression cable Core Laboratories COMOC-V and IAR are trademarks of Core Laboratories Microsoft and Windows are registered trademarks of Microsoft Corporation SQL Server is a trademark of Microsoft Corporation DEC and VAX are trademarks of Digital Equipment Corporation OPTOMUX is a registered trademark of Opto 22 CFR is a trademark of Dresser, Inc. Core Lab Refinery Systems 14