FloBoss S600 Pro Training Manual

Rev May/06 Batching B-1

APPENDIX B – BATCHING

B.1 Station Volume loading This method of batching is designed for a station/stream(s) combination within the same Floboss S600 flow computer. It is intended to monitor and control a load using the required batch volume together with the flow rate setpoints for start up, nominal and top off.

Two modes of a volume load batch are supported:

a) Stand alone (self contained)

b) Supervised eg. By a remote host computer.

B.2 Stand alone station volume loading This mode is intended for the Floboss S600 station computer to drive a batch from start to completion allowing for operator interaction along the way.

The batch is stepped through a set of stages where the current stage is executed every second. The stage remains the same until an event causes a change eg. Operator command or required volume now loaded.

Commands to drive the batch are :-

1. Define - accept the volume load parameters and reset batch totals

2. Start - open valves and commence start up flow

3. Nominal - ramp up to nominal flow

4. Top off - ramp down to the top off flow rate.

5. Hold - pause the batch

6. Terminate - end the batch

Interaction with the station flow switching module via station flow rate setpoints and the commands to start/shutdown the flow switching algorithm enables streams to be opened and closed and their flow rate setpoints to be controlled.

B.2.1 Stand alone Volume loading –– idle stage If the command “define” is issued and batch permit flag is set then:

Zero the batch totals

Increment the batch number

Instruct the sampler to reset

FloBoss S600 Pro Training Manual

Rev May/06 Batching B-2

Issue the “define” command to the streams.

Next stage = wait sampler.

B.2.2 Stand alone Volume loading –– wait sampler stage If the command “terminate” is issued then next stage = idle.

If the sampler has successfully reset then next stage = batch defined.

B.2.3 Stand alone Volume loading –– batch defined If the command “terminate” is issued then next stage = idle.

If the command “start” is issued then:

Snapshot the station cumulative totals.

Set the sampler running.

Issue the “start” command to the streams.

B.2.4 Stand alone Volume loading – wait for streams to start If the command “terminate” is issued then:

command streams to terminate their batch

set next stage = batch complete.

If the available streams have all assumes the status of “monitoring” then:

set the station flow switching command to start

set next stage to begin startup flow.

B.2.5 Stand alone Volume loading –– begin startup flow Set station flowate flow setpoint to station batch start flow setpoint.

If the command “terminate” is issued then:

command streams to terminate their batch

set the station flow switching command to start

set next stage to batch complete.

If the stage is still in start up and station flowrate >= batch startup flow rate setpoint then set next stage to be in start up.

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B.2.6 Stand alone Volume loading –– in start up flow Copy the specified nominal flow rate setpoint to stream flow setpoint.

If the command “terminate” is issued then:

command streams to terminate their batch

set the station flow switching command to start

set next stage to batch complete.

If the command “hold” is issued then:

command streams to hold their batch

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to begin hold.

If the command “top off” is issued then:

set next stage to begin top off.

If the stage is still in start up and Volume loaded > specified volume then:

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to batch complete.

If the stage is still in start up and volume loaded > (specified – top off volumes) then set next stage to begin top off.

B.2.7 Stand alone Volume loading –– begin nominal flow Set station flowate setpoint to station batch nominal flow setpoint.

If the command “top off” is issued then:

set next stage to begin top off.

If the command “terminate” is issued then:

command streams to terminate their batch

set the station flow switching command to shutdown

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set next stage to batch complete.

If the command “hold” is issued then:

command streams to hold their batch

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to begin hold.

If the stage is still in begin nominal flow and Volume loaded > specified volume then:

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to batch complete.

If the stage is still in begin nominal flow and volume loaded > (specified – top off volumes) then set next stage to begin top off.

If the stage is still in start up and station flowrate >= batch nominal flow rate setpoint then set next stage to be in nominal flow.

B.2.8 Stand alone Volume loading –– in nominal flow Set station flowate setpoint to station batch nominal flow setpoint.

If the command “top off” is issued then:

set next stage to begin top off.

If the command “terminate” is issued then:

command streams to terminate their batch

set the station flow switching command to shutdown

set next stage to batch complete.

If the command “hold” is issued then:

command streams to hold their batch

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to begin hold.

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Rev May/06 Batching B-5

If the stage is still in nominal flow and Volume loaded > specified volume then:

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to batch complete.

If the stage is still in nominal flow and volume loaded > (specified – top off volumes) then set next stage to begin top off.

B.2.9 Stand alone Volume loading –– begin top off flow Set station flowate setpoint to station batch top off flow setpoint.

If the command “terminate” is issued then:

command streams to terminate their batch

set the station flow switching command to shutdown

set next stage to batch complete.

If the command “hold” is issued then:

command streams to hold their batch

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to begin hold.

If the stage is still in begin top off and Volume loaded > specified volume then:

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to batch complete.

If the stage is still in begin top off and station flowrate >= batch nominal flow rate setpoint then set next stage to be in top off flow.

B.2.10 Stand alone Volume loading –– in top off flow Set station flowate setpoint to station batch top off flow setpoint.

If the command “terminate” is issued then:

command streams to terminate their batch

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Rev May/06 Batching B-6

set the station flow switching command to shutdown

set next stage to batch complete.

If the command “hold” is issued then:

command streams to hold their batch

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to begin hold.

If the stage is still in begin top off and Volume loaded > specified volume then:

set station flowate setpoint = 0.0.

set the station flow switching command to shutdown

set next stage to batch complete.

If the stage is still in begin top off and station flowrate >= batch nominal flow rate setpoint then set next stage to be in nominal flow.

B.2.11 Stand alone Volume loading –– begin hold Set station flowate setpoint to zero.

If the command “terminate” is issued then:

command streams to terminate their batch

set the station flow switching command to shutdown

set next stage to batch complete.

If the command “start” is issued then:

set the station flow switching command to startup

set next stage to begin start up.

If the stage is still in begin hold and station flowrate is zero then set next stage to be in hold.

B.2.12 Stand alone Volume loading –– in hold Set station flowate setpoint to zero.

If the command “terminate” is issued then:

command streams to terminate their batch

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set the station flow switching command to shutdown

set next stage to batch complete.

If the command “start” is issued then:

set the station flow switching command to startup

set next stage to begin start up.

B.2.13 Stand alone Volume loading –– wait for streams to close Set station flowate setpoint to zero.

If the command “terminate” is issued then:

command streams to terminate their batch

set the station flow switching command to shutdown

set next stage to batch complete.

If the stage is still in wait for streams to close and station flowrate is zero then set next stage to be wait for streams to complete.

B.2.14 Stand alone Volume loading –– wait for streams to complete If the command “terminate” is issued then:

command streams to terminate their batch

set the station flow switching command to shutdown

set next stage to batch complete.

If all the streams have reached their batch complete stage then set next stage to batch complete.

B.2.15 Stand alone Volume loading – batch complete Trap the station totals and print the batch report.

Set next stage to idle.

B.3 Supervised Station Volume loading This method of volume loading is intended to be controlled from a remote supervisory system but the individual batch commands to the streams are still issued by this module.

The batch is stepped through a set of stages where the current stage is executed every second. The stage remains the same until an event causes a change eg. Operator command or required volume now loaded

FloBoss S600 Pro Training Manual

Rev May/06 Batching B-8

Any commands for flow switching are expected to be issued from the supervisory system

B.3.1 Supervised Volume loading –– idle stage If the command “define” is issued and batch permit flag is set then:

Zero the batch totals

Increment the batch number

Instruct the sampler to reset

Issue the “define” command to the streams.

Next stage = wait sampler.

B.3.2 Supervised Volume loading –– wait sampler stage If the command “terminate” is issued then next stage = idle.

If the sampler has successfully reset then next stage = batch defined.

B.3.3 Supervised Volume loading –– batch defined If the command “terminate” is issued then next stage = idle.

If the command “start” is issued then:

Snapshot the station cumulative totals.

Set the sampler running.

Issue the “start” command to the streams.

B.3.4 Supervised Volume loading – wait for streams to start If the command “terminate” is issued then:

command streams to terminate their batch

set next stage = batch complete.

If the available streams have all assumes the status of “monitoring” then:

set the station flow switching command to start

set next stage to monitor flow.

B.3.5 Supervised Volume loading –– monitor flow If the command “terminate” is issued then:

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Rev May/06 Batching B-9

command streams to terminate their batch

set next stage to batch complete.

B.3.6 Supervised Volume loading –– wait for streams to complete If the command “terminate” is issued then:

command streams to terminate their batch

set the station flow switching command to shutdown

set next stage to batch complete.

If all the streams have reached their batch complete stage then set next stage to batch complete.

B.3.7 Supervised Volume loading – batch complete Trap the station totals and print the batch report.

Set next stage to idle.

B.4 Alarms Pre warning of batch approaching completion

Batch complete.

B.5 Stream Volume loading This can run as a stand alone (self contained) batch or as part of a station (supervised) batch. Either method supports retrospective K factor or Meter Factor corrections whereby at any stage during the batch, if the K factor or Meter Factor is modified, say after a prove, then each batch total is adjusted as follows:

Adjusted total = batch total * ratio

Where

ratio = old K Factor / new K Factor

Or

ratio = new Meter Factor / old Meter Factor

Or

ratio = GVC1 / GV1

GVC1 = corrected gross volume for period 1

GV1 = gross volume for period 1

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Rev May/06 Batching B-10

This method is should be used with Aramco applications

Further K factor / Meter Factor changes do not invoke this correction but the Floboss S600 will commence to use the latest value in subsequent totalisation.

Note:

• This correction method is invalid for applications using K factor/ Meter Factor linearisation as an accurate historic K factor / Meter Factor is difficult to arrive at

• The retrospective Adjustment is not applied to Indicated Volume

B.6 Stand alone Stream volume loading This method is intended for a single stream to control a volume load, with no interaction with any other streams or supervisory sequences

The batch is stepped through a set of stages where the current stage is executed every second. The stage remains the same until an event causes a change eg. Operator command or required volume now loaded.

Commands to drive the batch are :-

1. Define - accept the volume load parameters and reset batch totals

2. Start - open valves and commence start up flow

3. Nominal - ramp up to nominal flow

4. Top off - ramp down to the top off flow rate.

5. Hold - pause the batch

6. Terminate - end the batch

B.6.1 Stand alone volume loading –– idle stage If the command “define” is issued and batch permit flag is set then:

Zero the batch totals

Increment the batch number

Instruct the sampler to reset

Next stage = wait sampler.

B.6.2 Stand alone volume loading –– wait sampler stage If the command “terminate” is issued then next stage = idle.

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If the sampler has successfully reset then next stage = batch defined.

B.6.3 Stand alone volume loading –– batch defined If the command “terminate” is issued then next stage = idle.

If the command “start” is issued then:

a) Snapshot the cumulative totals and the current K factor.

b) Set the sampler running.

c) Open the stream valves with flow setpoint = 0.0.

d) Next stage = begin startup flowrate.

B.6.4 Stand alone volume loading –– begin startup flow If the stream valves are now open then flow setpoint = start up flow setpoint.

If the volume loaded >= specified volume then:

a) Flow setpoint = 0.0

b) Close the stream valves

c) Next stage = batch complete.

If the volume loaded >= (specified volume – top off volume) then next stage = begin top off..

If the command “terminate” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = wait for stream to close.

If the command “hold” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = begin hold

If observed flow >= start up flow setpoint then next stage = in start up flow.

B.6.5 Stand alone volume loading –– in start up flow Copy the specified nominal flow rate setpoint to stream flow setpoint..

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If the volume loaded >= specified volume then:

a) Flow setpoint = 0.0

b) Close the stream valves

c) Next stage = batch complete.

If the volume loaded >= (specified volume – top off volume) then next stage = begin top off..

If the command “nominal” is issued then next stage = begin nominal flow.

If the command “terminate” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = wait for stream to close.

If the command “hold” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = begin hold.

B.6.6 Stand alone volume loading –– begin nominal flow Copy the specified nominal flow rate setpoint to stream flow setpoint.

If the volume loaded >= specified volume then:

a) Flow setpoint = 0.0

b) Close the stream valves

c) Next stage = batch complete.

If the volume loaded >= (specified volume – top off volume) then next stage = begin top off..

If the command “nominal” is issued then next stage = begin nominal flow.

If the command “top off” is issued then next stage = begin nominal flow.

If the command “terminate” is issued then:

a) Flow setpoint = 0.0

b) Close the stream va lves (via the line close command)

c) Next stage = wait for stream to close.

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Rev May/06 Batching B-13

If the command “hold” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = begin hold.

If the observed flowrate >= nominal flow rate setpoint then next stage = in nominal flow.

B.6.7 Stand alone volume loading –– in nominal flow Copy the specified nominal flow rate setpoint to stream flow setpoint.

If the volume loaded >= specified volume then:

a) Flow setpoint = 0.0

b) Close the stream valves

c) Next stage = batch complete.

If the volume loaded >= (specified volume – top off volume) then next stage = begin top off..

If the command “nominal” is issued then next stage = begin nominal flow.

If the command “top off” is issued then next stage = begin nominal flow.

If the command “terminate” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = wait for stream to close.

If the command “hold” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = begin hold.

If the observed flowrate >= nominal flow rate setpoint then next stage = in nominal flow.

B.6.8 Stand alone volume loading –– begin top off flow Copy the specified top off flow rate setpoint to stream flow setpoint.

If the volume loaded >= specified volume then:

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a) Flow setpoint = 0.0

b) Close the stream valves

c) Next stage = batch complete.

If the volume loaded >= (specified volume – top off volume) then next stage = begin top off..

If the command “terminate” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = wait for stream to close.

If the command “hold” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = begin hold.

If the observed flowrate >= nominal flow rate setpoint then next stage = in nominal flow.

B.6.9 Stand alone volume loading –– in top off flow Copy the specified top off flow rate setpoint to stream flow setpoint.

If the volume loaded >= specified volume then:

a) Flow setpoint = 0.0

b) Close the stream valves

c) Next stage = batch complete.

If the volume loaded >= (specified volume – top off volume) then next stage = begin top off..

If the command “terminate” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

c) Next stage = wait for stream to close.

If the command “hold” is issued then:

a) Flow setpoint = 0.0

b) Close the stream valves (via the line close command)

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c) Next stage = begin hold.

B.6.10 Stand alone volume loading –– begin hold Zero stream flow rate setpoint.

If the command “terminate” is issued then next stage = wait streams close.

If the command “start” is issued then next stage = begin start up flow.

If the observed flowrate = 0.0 then next stage = in hold.

B.6.11 Stand alone volume loading –– in hold Zero stream flow rate setpoint.

If the command “terminate” is issued then next stage = wait streams close.

If the command “start” is issued then next stage = begin start up flow.

B.6.12 Stand alone volume loading –– wait for stream to close Zero stream flow rate setpoint.

If the command “terminate” is issued then next stage = wait streams close.

If the observed flowrate = 0.0 then

a) next stage = batch complete b) instruct the sampler to stop

B.6.13 Stand alone volume loading –– batch complete Snapshot the final totals.

Trigger the batch report.

Next stage = idle.

B.7 Supervised Stream volume loading The batch is stepped through a set of stages where the current stage is executed every second. The stage remains the same until an event causes a change eg. Operator command or required volume now loaded.

This method of volume loading is intended to be controlled either in conjunction with the S600 station batching application or from a remote supervisory system.

B.7.1 Supervised volume loading –– idle stage If the command “define” is issued and batch permit flag is set then:

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Zero the batch totals

Increment the batch number

Instruct the sampler to reset

Next stage = wait sampler.

B.7.2 Supervised volume loading –– wait sampler stage If the command “terminate” is issued then next stage = idle.

If the sampler has successfully reset then next stage = batch defined.

B.7.3 Supervised volume loading –– batch defined If the command “terminate” is issued then next stage = idle.

If the command “start” is issued then:

a) Snapshot the cumulative totals and the current K factor.

b) Set the sampler running.

c) Open the stream valves with flow setpoint = 0.0.

d) Next stage = monitor batch

B.7.4 Supervised volume loading –– batch monitoring If the command “terminate” is issued then next stage = batch complete.

B.7.5 Supervised volume loading –– batch complete Snapshot the totals. Trigger the batch report. Next stage = idle.

B.8 Reports Produced at the start of the batch, hourly thereafter and at the end of the batch:

Example layout :

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BATCHREPORT =========================================================

Daniel Europe Ltd

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Swinton Grange

Malton

North Yorkshire

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STATION NAME: LIQ TURBINE

LOCATION: LINES 1,2,3

CUMULATIVE BATCH FLOW RATE

UVOL 88888.1 5234.3 m3 123.8 m3/h

CVOL 86564.8 5077.8 Sm3 110.6 Sm3/h

MASS 75789.2 4756.2 tonne 93.3 t/h

FWA PRESS : 23.5 barg

FWA TEMP : 18.4 Deg.C

FWA DENS : 835.1 kg/m3

FWA FLOW : 56.4 m3/h

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