Operational and Technical Overview - corelab.com · capable of handling simultaneously up to 10 engines and 3 in-line ... Mainte nan ce Conso le, ... Since COMOC-V data is accessible

COMOC-V™Operational

andTechnical Overview

REFINERY SYSTEMS DIVISION, USA19 Roszel Road

Princeton, NJ 08540-6299Phone (609) 452-8600

Fax (609) [email protected] http://www.refinerysystems.com

February 23, 2005

COMOC-V Operational and Technical Overview

Core Lab Refinery Systems 2

CONTENTS

1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.0 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.0 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.0 COMOC-V™ Computer System . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.0 COMOC-V CFR™ Engine Hardware . . . . . . . . . . . . . . . . . . . . . . . 116.0 COMOC-V Upgrade - Migration from COMOC-III Systems . . . . . . 127.0 COMOC-V Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138.0 Site Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13



1.0 IntroductionThis 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, thedifferent computer technologies leveraged, the operator interface, and security issues. Foradditional 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 FeaturesThe COMOC-V System is the successor to the industry standard COMOC-III

System. COMOC-V when used in conjunction with CFR™ Research and Motor Methodengines automatically determines the quality of in-line blended gasoline’s. COMOC-V iscapable of handling simultaneously up to 10 engines and 3 in-line blenders. Octaneanalysis is performed by the knock intensity approach as defined by ASTM D 2885.

/ Compliant with the latest ASTM D 2885 Method - Since Core LaboratoriesRefinery Systems Division is an active member in ASTM, the COMOC-V Systemis continually updated as the ASTM D 2885 method evolves.

/ Provides an Open PC Architecture - Since COMOC-V utilizes personalcomputers and Microsoft® Windows® operating systems, COMOC-V is able toleverage the power of technologies such as Open Database Connectivity(ODBC) and Dynamic Data Exchange (DDE). In addition, new technologies willbe added to COMOC-V as the software industry develops and adopts them.

/ Simple User Friendly Computer Operations - Utilizes the Microsoft WindowsGraphical User Interface. This interface is known throughout the computerindustry and eliminates the need for specialized training.

/ Provides Necessary Engine/Analyzer Functions - COMOC-V includes ASTMcompliant D 2885 Blending, Prototype Tank Calibration, System QualificationCheckout, and Analyzer Calibration procedures.

/ Includes Rugged Engine Hardware - Provides a modern analyzer enclosure,digital KI recorder, fuel position verification and easy access to calibration points.Also included are a re-designed spill type carburetor, heat exchanger and fueljunction assembly.



/ Supports Unattended Automation - Utilizing ODBC or DDE technology, theblender control system can propagate blend recipe parameters to the COMOC-VSystem to provide unattended automation. In addition, COMOC-V providesoctane deviation parameters through the same interface to provide a closed-loopcontrol.

/ Expandable Analyzer Network - Add additional COMOC-V engine analyzers atany time by connecting to the 4 wire RS-422 network.

/ Expandable User Network - Add additional COMOC-V control and viewerconsoles by connecting a desktop computer to the in-house or vendor providedTCP/IP network hub. The COMOC-V client software is designed to be compatiblewith the latest internet browsers.

/ Secure Analyzer Network - The COMOC-V Data Server software runs on theWindows Server operating system and utilizes the extensive security featuresbuilt into the operating system.

/ Remote Access - With an optional router and Internet connection the COMOC-Vnetwork can be connected to the Internet for secure remote access.



3.0 System Overview



COMOC-V Data Server Model

4.0 COMOC-V Computer System

4.1 DescriptionThe COMOC-V system components consist of the COMOC-V Data Server, Blender

Console, Maintenance Console, and network interconnection hardware. These devices aretied together via Ethernet cables and a network hub to form the COMOC-V network.

4.2 COMOC-V Data ServerThe COMOC-V Data Server (C5DataServer) is the heart of the COMOC-V System.

C5DataServer is a 32 bit multi-threaded Windows service application.

4.2.1 Data Acquisition and ControlC5DataServer 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 255devices on the RS-422 network. The I/O scan rate is configured via the COMOC-Vdatabase. 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 theCFR engines are physically running.

4.2.2 Historical and Real-Time Data StorageThe 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 calibrationdata, blender control system interfacing, and user configuration. The real-time data tablesare updated periodically as configured by the system configuration. Historical data is storedby engine number and by blend identifiers. The following engine functions are historizedby date and engine number; fuel air search, engine calibration, proto calibration, andsystem checkout. All blending data is stored in the database history with a blend identifier(10 alpha-numeric characters). Limits to the number of historical entries are defined by thesystem administrator.



4.2.3 Web Server InterfaceThe 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 clientdata via the HTTP (world-wide web) protocol. Data is acquired through the ADO interfaceincluded with MDAC. IIS has built-in security which require each client to log in to the webserver before allowing access to the site. The C5DataServer Service uses Object Linkingand Embedding for Database (OLE DB) for database access.

4.2.4 Blender Control System InterfaceJust as the traditional COMOC-III System, COMOC-V supports hard-wired analog

and digital I/O communication to blender control systems. Signals supported are; deltaoctane 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 apurely digital interface to blender control systems. This digital communication takes placeover the Ethernet network hardware installed in the C5DataServer computer. This interfaceeliminates calibration errors that can occur in digital to analog and analog to digitalconversions. Since COMOC-V data is accessible with Transact SQL commands, othertasks running on the C5DataServer computer or other computers on the network can readand write to the database. This open architecture permits a blender control system to storeblend recipe data needed by the COMOC system in to the COMOC database. Some of thedifferent technologies available for accessing the database include; DDE, NetDDE,OLEDB, DCOM. Once the data is stored in the correct database table, COMOC simplyreads the data and launches the blend monitoring feature of the COMOC system. To closethe loop, when new octane number data becomes available the COMOC system updatesthe database and the blender control system reads the data to perform recipe control.

4.3 COMOC-V Client Consoles

4.3.1 DescriptionTwo 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 roomand 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 anda web browser. The user logs in to the COMOC-V Data Server with a user name andpassword. At this point the browser is configured to invoke a web page or URL (uniformresource locator) which displays the COMOC-V system.



COMOC-V Logon Page (displayed in Intenet Explorer)

4.3.2 Site Map

Once the user has pointed their browser to theCOMOC-V URL, the COMOC-V home page will bedisplayed in their browser. At this point the COMOC-Vlogo page is displayed which contains versioninformation, a user name field, and a password field.An operator is required to login to the COMOC Systembefore proceeding. Once logged in, the System Statuspage is displayed with real-time engine and blend data.In addition, a menu bar enables navigation throughoutthe COMOC system. The menu bar contains 8 top levelselections; COMOC-V Login, Blend Details, Commands,Configuration, Engine Status, Reports, System Status,and Help. Some users may not have access to all areasof the site. For instance, a laboratory technician may nothave a need to access the blend definition page.Therefore this page will not be accessible by this user.

4.3.3 COMOC-V Home Page



System Status Page (displayed in Internet Explorer)

Blend Detail Page (displayed in Internet Explorer)

4.3.4 System Status

4.3.5 Blend Details



4.3.6 SecurityAccess 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 userdatabase. Upon verification of the login information a cookie is generated and sent to thebrowser. From this point forward any access to the COMOC system is granted through useof this browser cookie. Access is granted until the user logs off the system or until thecookie expires. The default expiration of the cookie is 30 minutes. This expiration is aconfigurable parameter. If a more secure environment is desired, the Secure SocketsLayer (SSL) interface can be set up to enable data encryption between the client and theserver.



COMOC-V Carburetor

5.0 COMOC-V CFR™ Engine Hardware

5.1 DescriptionThe COMOC-V System comes with complete engine hardware and accessories.

The system requires valid working CFR Research and Motor method engines withcompression ratio motor control. The system also requires engine coolant from a Core LabIntake Air Refrigeration Unit (IAR).

5.2 Engine ConsoleThe 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 positionreadouts. In addition, illuminated buttons permit control of the compression ratio, fuel airratio, fuel switching, automatic / manual control, and continuous fuel switches.

5.3 CarburetorThe COMOC-V carburetor has been re-designed to

include additional features over the traditional COMOC-IIIcarburetor design. Included in the stepper motor fuelswitching mechanism is a position proximity sensor todetect position feedback. This feedback verifies that a fuelswitch has taken place. The new sensor detects thiscondition and allows the COMOC system to alarm anddiscard engine readings during this period.

5.4 Heat ExchangerThe COMOC-V heat exchanger is supplied to cool

the prototype and product fuel before it enters the intakeventuri of the engine. It is mounted to the CFR crankcaseand requires a coolant mixture which is supplied Core Lab’s IAR. The ASTM methodrequires that fuel be cooled to 50° Fahrenheit (10°C). The heat exchanger includesrotometers that provide independent proto / product fuel flow regulation.

5.5 Fuel Junction AssemblyThe 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 theCFR engine. Manual block valves are available to supply canned fuel to the engine forengine analyzer calibration and the system qualification checkout exercise.



6.0 COMOC-V Upgrade - Migration from COMOC-III Systems

6.1 DescriptionThe 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™ hardwarewith COMOC-V’s latest computer technology. The engine peripherals; COMOC-IIIcarburetors, heat exchanger’s, engine consoles, fuel junction assemblies, and I/O interfacecabinets remain unchanged.

6.2 COMOC-V Upgrade Overview



7.0 COMOC-V Specifications

Accuracy Octane RON MON

Number

80 0.21 0.21

85 0.16 0.16

90 0.12 0.19

95 0.11 0.20

100 0.12 0.26

Year 2000 Compliancy COMOC-V complies with Core Labs Y2K compliancy program. See

document T-TECW .001 for further information.

ASTM Compliancy 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 13,100 BTU/Hr.

Research Method Engine 10,100 BTU/Hr.

Intake Air Refrigeration Unit 4,100 BTU/Hr.

Engine

Foundation

The engine should be mounted on an isolation block per ASTM D2699 and

D2700 Section A5.2.3. The block anchors the engine to the floor and provides

vibration isolation.

Engine Cooling

Water

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. W ater supply should be piped

as close to the engine as possible with a manual shutoff valve.

Crankcase

Ventilation

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.



Exhaust

Ventilation

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.

Engine Air

Consumption

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.

Sound Levels 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.

Electrical

Requirements

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.

©2003,2005 Core Laboratories

COMOC-V is a trademark of Core LaboratoriesMicrosoft and Windows are registered trademarks of Microsoft Corporation

SQL Server is a trademark of Microsoft CorporationDEC and VAX are trademarks of Digital Equipment Corporation

OPTOMUX is a registered trademark of Opto 22CFR is a trademark of Dresser, Inc.

Documents

Operational and Technical Overview - corelab.com · capable of handling simultaneously up to 10 engines and 3 in-line ... Mainte nan ce Conso le, ... Since COMOC-V data is accessible