Meter Provers

Training package PTP 20

Meter Provers in
Mina Al Fahal Oil Terminal

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 Table of contents
Page No
1. Introduction 03

2. Overall Block Diagram 03

3. Meter Prover Overview 04

4. Turbine Meter 04

5. PD Meter 06

6. Meter Prover 06

7. Uni-Directional Meter Prover 07

8. Bi-Directional Meter Prover 09

9. Pre-proving checks 10

Meter Provers
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1. Introduction

To maintain high level of oil production, a quantity of approximately 120,000 tons per day, on
average, needs to be exported from the tank farm. Errors in measuring these quantities of oil can
be very costly. For example, a 0.5% error in loading, say, a 200,000 tons tanker represents 1000
tons of crude oil.

An accurate metering system has there fore been installed which measures the quantity of oil that
is exported from the tank farm, whether it be from a single tank or from several.

The volume of crude oil exported is measured by individual meters whose accuracy is frequently
checked by sending a precise volume of oil through the meter prover.

Since the size of meter system is controlled by the decided accuracy of the measurements (the
larger the meter, the larger the potential errors), the number of meters is selected on the basis of
the maximum loading rate required. Thus there are two banks of crude export meters, each bank
consists of four sixteen inch turbine meters. Each meter has a capacity of 25000 bbls/h but, since
the prover capacity is only 15000 bbls/h, each meter is operated at approximately 50% of its
capacity.

Meters are checked with the meter prover while loading each oil tankers. Meter provers are
checked by Master Meter Prover, once in a year.

2. Overall Block diagram

OIL TERMINAL
Filter
OVERALL BLOCKMODIAGRAM
V
FCV
Metering
METERING&
Long Residue
from ORC FLong
X FT FQ
MOV
METERPROVER
Residue Metering
Tanks
FIRC
MOV
Filter Metering FCV

MOV
FX FT FQ

FIRC Upper Tank Farm

MOV Metering
CRUDE
Filter Metering FCV
OIL Pressure Crude oil to SBM 1 / 2
MOV
F
Reduction
X F T FQ Lower Tank Farm
Station
FIRC
MOV
Filter Metering FCV
Crude oil to ORC
MOV Metering
M eter FX FT FQ CrudetoSBM-2
Bank-2 FIRC
EETP
MOV
Clean water to sea
3. Meter ProverFXOverview
MOV
CrudetoSBM-1
M eter TI
Start PI
Prover

STOP PI TI 3

MeterBank-1 CrudetoT-0804
Meter bank - 1 and 2 has got one common Meter Prover (Uni- Directional) and Long Residue
Meter Bank has got another Meter Prover which is Bi-Directional.
Turbine Meters and PD Meters are used to measure the oil flow in the Meter Banks at Mina Al
Fahal Oil Terminal (PD Meters in the Long Residue Metering Bank).

4. TURBINE METER
The turbine meter is classified as an inferential type of flow meter because the
measured variable is velocity that is proportional to the rate of fluid flow. The older
types of meters used a mechanical gear system to measure the rotor speed but later
versions all use an electromagnetic coupling system that reduces the errors due to
friction.

The turbine meter is essentially a small, multi-bladed, turbine rotor supported on low-
friction bearings at the center of a short pipe spool. The process liquid causes the
wheel to rotate at a speed proportional to the rate of flow. An electromagnetic
detecting coil is mounted outside the pipe and close to the wheel. Each time a turbine
blade passes the coil a voltage pulse is generated and this can be converted either into
rate of flow units or to a quantity computed by a summator device. The turbine meter
provides a frequency output signal that varies linearly with the volumetric flow rate.
The entire fluid to be measured enters the flow meter through the inlet rotor support.
This rotor support serves two functions.
a) Providing support to the rotor.
b) Conditions (straightens the flow direction) the fluid prior to the measurement
made by the rotor.
The fluid passing through the meter causes the rotor to turn with an angular velocity
which is proportional to the linear velocity of the fluid and therefore to the volumetric
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flow rate. The pick-up assembly transduces the rotor speed (velocity) to an equaling
frequency signal. In this system the meter housing must be non-magnetic. Usually 300
series stainless steel (316 s.s) is used. The rotor blades must be magnetically permeable
material. 17-4 PH or 400 series stainless steel is commonly used.
The pick-up assembly consists of a small powerful permanent magnet and a coil
winding. The blades on the rotor influence the magnetic field set up by the permanent
magnet as they move. When the rotor blades passes through the field of the permanent
magnet it provides an easier path for the field to distort. The relative motion between
the magnetic field and the coil winding generates an AC voltage, the frequency of
which is proportional to the flow rate.
I.E. Rotor speed a to the velocity

Rotor speed = k * V

But we know Q = A * V

1
= A rotor speed
k

Q = K * rotor speed

Where K = meter factor or the K - factor. The K-factor is given by the manufacturer
in pulses per volume.

FIGURE No. 3 TURBINE METER

Note: Individual meters in the banks have 3 pick ups, one for local display, one for panel display
and the third one for the computer display in the control room.

5. PD Meters
This class of flow meters employs a positive displacement (PD) metering device. The operating
principle is equivalent to the cyclic filling and emptying of a container and then counting the
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cycles completed over a period of time. This means that the flowing stream to be measured is
divided into small segments of known volume, and the total flow is determined by adding
together the total number of each segment.

All positive displacement meters consists of an external housing, an internal measuring unit and a
mechanism, which drives a counter.

As the fluid enters the meter, it is separated from the main part of the stream in a measuring
chamber. As the fluid flows on, out of the meter, a drive mechanism is activated which causes an
indicator to add another volume unit to it's total. The flow of the fluid through the meter causes
the mechanism to turn, continuously capturing volumes of fluid to be measured.

6. Meter Provers
Generally two different types of calibrators are used to calibrate the flow measuring
devices. They are
1. DP transmitter.
2. Meter prover loop.

DP transmitter
It is used in conjunction with inferential head type of primary elements like orifice
plate ,flow nozzle, venturi tube and dall tube to measure the flow and then it converts
the flow signal into 4 to 20 mA current signal for further processing in the control
room.

Meter prover loop

It is used to prove the accuracy of Turbine Meters and PD Meters in the oil terminal.
Two types of Meter Provers are in use.
1. Unidirectional Provers
2. Bi-Directional Provers
Working principles of both units are same.
This type of meter employs sphere detector probes to initiate and to stop the counting
of an electronic counter. The electronic counter starts counting when the sphere passes
through the first detector. The counter is stopped when the sphere passes the second
detector. So, the number of pulses recorded are compared with the known volume
displaced by the sphere between the two detectors.

Meter prover loop

This is an important and accurate calibration device used in MAF Terminal Metering
facility and in Nimr workshop area to prove the accuracy of PD meters and Turbine
Meters.

Meters approved for custody transfer of hydrocarbon liquid products through pipelines
require to be calibrated for accuracy at regular intervals and under actual operating
conditions of pressure, temperature and flow rate. The device used for this purpose is
called a meter prover. Permanently installed meter provers usually calibrate turbine
meters and positive displacement meters, which generate pulses.

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A meter prover is a calibrated length of pipe of smooth and uniform bore through
which a closely fitting sphere can be passed between two reference points. Sphere
detector probes are accurately positioned at the reference points.

The sphere is launched into the line and as it passes the first detector it initiates an
electronic counter to start counting the pulses transmitted from the meter. The counter
is stopped when the sphere passes the second detector and the number of pulses
recorded are compared with the known volume displaced by the sphere between the
two detectors. After several runs a meter factor can be established (Normally 5 or 10
runs).

7. Uni-Directional Provers

Basic principles.
Although the design criteria for pipe provers have evolved considerably in the years
since the principle of operation was established, the basic design features are still
essentially the same. All conventional pipe provers consists of a length of industrial
pipe, usually fabricated from mild steel. To prevent the internal surface from
corroding, the pipe is lined, normally with a backed-on phenolic coating or epoxy
resin.

A synthetic rubber sphere (similar to those used as line-clearing pigs at many

terminals) is inserted into the pipe. The sphere is tight fit and in fact distorts slightly.

Uni-Directional Meter Prover

Stop

Sphere

Start
Sphere
Counter detector
Pulses

Turbine Meter

The prover must be 100% full of oil before meter proving begins. Oil is flown through
the prover, so that the sphere is swept through the pipe with no oil passing the
mechanical seal between the sphere and the pipe wall.

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 The passage of the sphere through the prover is monitored by two electro-mechanical
sphere detectors. These open and close an electronic "gate" which allows the pulse
generated by the meter under test to enter an electronic batch counter.

The meter's K-factor can subsequently be calculated by comparing the volume of the
pipe between the detectors with the pulse counted during the proving run. The volume
between the detectors is known as the base volume and is usually (but not always)
expressed at standard conditions of temperature and pressure.

Working principles

The above picture of the uni-directional pipe prover, which is shown as a U-shaped
section of pipe laid on its side. (The pipe loop can be one U or several Us). Flow is
diverted from the meter trunk line to the prover down stream of the meter under test.
It passes into the lower leg of the prover, around the 180 degree bend and out again
via the upper leg. The upper and lower legs are connected by a valve, which can
contain the sphere and through which it can pass.

When a meter proof is required, the sphere handling valve is rotated, which causes the
sphere to drop into the over-size section of pipe directly below the valve (the sphere
launcher trap).

It is then picked up by the flowing liquid and carried into the section of pipe in which
it is tight fit. Once in this section, the sphere immediately assume the liquid velocity
(since no product can pass between the sphere and the pipe wall) and is swept towards
to the first sphere detector. When the sphere trips the first detector, a micro switch
opens an electronic gate which divert the pulses generated by the meter under test into
an electronic counter. Pulses are totalised in the counter as the sphere continues it's
progress around the calibrated section of the prover. When the second detector is
tripped, the gate is closed, and no more pulses are counted. The sphere then emerges
into another over-size section of pipe (the sphere receiving trap or separating tee),
where it decelerates.

Prison bars in the line prevent the sphere from passing into the pipe work downstream
of the prover, and it comes to rest on top of the sphere-handling valve. The sphere can
subsequently be passed through the valve to start another proving run.

8. Bi-Directional Meter Prover

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The meter prover may be either a straight length of pipe or a series of loops with a
four-way valve to provide a bi-directional operation enabling the sphere to be passed
back and forth through the meter prover. A bi-directional system is illustrated where
the PD meters can be checked through the meter prover without taking it from service
by opening the valves to the prover line and closing the bypass valve. Bi-directional
provers are used to prove the meters on the Long Residue lines in the MAF oil
terminal.

The fundamental difference between bi-directional meter provers and the uni-
directional type is that the flow can now be reversed through the prover, so the traps at
either end of the pipe can act as both launching and receiving traps, and the sphere-
transfer valve is dispensed with.

The majority of bi-directional provers in operation today employ a four-way diverter

valve.Valves of these type divert flow from the inlet port to either the left or the right
hand leg of the prover, and receive flow from the opposite leg and divert it to the outlet
port. Flow diverter valves never stop the flow-they only divert it. It is a motor
operated valve.

9. Pre-proving Checks

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Many of the checks which must be made when a meter prover is calibrated must also
be carried out when it is used operationally. For example, the accuracy of temperature
and pressure transducers must be checked at regular intervals against certified
standards.

It must also be possible to demonstrate that the sphere handling valve or flow diverter
valve has completed its operation cycle and sealed tight before the sphere trips the first
detector, and that it doesn't leak during proving runs.

The seal integrity of several other valves must also be regularly checked. This include
drain valves if they are not open ended, vent valves if they feed into a closed system,
the valves on recalibration stubs and , most important, the block valves on the meter
trunk line.

There must be no leakage past the sphere displacer. It should therefore be removed
from the prover at regular intervals and subjected to a careful visual examination.
Particular attention must be paid to any cuts or scuffs on the surface which could act as
a leak path.

If the meters to be proved are upstream of the prover and arranged in a bank connected
to the prover via a manifold, all the block valves on the prover inlet and outlet headers
must be checked for leakage. It must also be established that the temperature and the
pressure transducers on the meter runs are accurate. Monitoring the security and fidelity
of the pulse transmission system is another very important aspect of meter proving.

Unless temperature equilibrium is established through out the metering and meter
proving system before meter proofs are attempted, it is likely that repeatable results
will not be attainable. Operators must therefore ensure that temperature is uniform
throughout the system before commencing meter proofs. Temperature equilibrium in
the pipe prover is best achieved by running the sphere displacer around the prover (and
back again, if it is a bi-directional prover) ten times or so without recording the pulse
counts. This allows the seal integrity of the sphere- transfer or flow diverter valve and
the drain valves to be checked. The high points on the prover should also be vented at
this times. Vapour in the prover is one of the most common causes of poor meter
proofs repeatability.

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