1.0 INTRODUCTION Flow measurement is an important aspects in Oil And Gas Industry since measurement requires accurate determination of hydrocarbon produced starts from producing fields, accounting for export and further down when the products being processed and finally for consumer use. : There are basically 3 types of measurement that is commonly practiced in the oil and gas industry. Those are a) Custody Transfer Type This type of measurement is also called fiscal measurement and it involves direct selling of hydrocarbon product to another party (known as buyer). In Malaysia this type of measurement can be found on all crude oil and gas terminal. For export of crude oil, the terminals involved are Miri Crude Oil Terminal, Labuan, Bintulu, Terengganu in Kerteh and the newest Dulang Marine Terminal offshore Terengganu. b) Allocation Type/Entitlement This type of measurement is to account, how much share a partner is entitled for its oil in a common sharing facilities/system. It is also to allocate back the production to their respective platforms/well. An example is the Tembungo Metering System (PCSB) which is sharing a common pipeline and export facilities of SSPC ie. Labuan Crude Oil Terminal. c) .Reservoir And Field Management This type of measurement is basically for operational purposes ie. for reservoir studies and field management. It is to account and estimate how much the oil reserve left in the reservoir. An example of this is the well test measurement. Measurement of liquid can be carried out in two ways!~ a) Static Measurement - ie. measurement being carried out when the liquid is in static condition eg. is the storage tank. b) Dynamic Measurement - ie. measurement being carried out when the liquid is dynamic or moving example is the liquid metering system.This lecture will only focussed on the dynamic measurement of liquid widely known as liquid metering system. 1.1 What is a (liguid) metering systen. A metering system is a combination of various kinds of instrument put together as a system used to determine the total throughput of ligquid/gas. The choice of these instrument as well as the design and configuration will determine the performance of the metering system. The choice of the instrument will also based on the purpose of the metering system ie. whether it is used for crude allocation or custody transfer. 1.2 Whey metering system (dynamic measurement) is preferred than static measurement The static measurement is not preferred because of the following reason:- a) Operationally not convenience. b) Less accurate compared to metering storage tank measurement error = +0.25% metering error = 0.17% Error on tank measurenent - misreading of tapes - misreading of thermometer - calibration of tanks etc. 1.3 What is the reason to have a metering system. A metering system is required because of the following purposes:- a) For custody transfer purposes between a buyer and a seller which will account for the total sales/export. The export duty to be paid to the government will be based on the amount recorded on the metering system. Example:~- PETRONAS export/sell its crude oil to Japan through Dulang Metering system at the Dulang Marine terminal. Total metered figures = 400,000 barrel (agreed tariff US$20/barrel) 400,000 bbl = Us$s,000,000 (M$21, 600,000)b) For allocation purposes ie. split of entitlement between 2 or more parties involved back in sharing the same facilities or the amount of crude to various platforms/wells. Basically it was implemented on relinquished platforms/field. Example is between SSPC and PCSB in Sabah Waters, sharing Labuan Crude Oil Terminal facilities. ¢) To determine and estimate the remaining oil reserves in the field as well as the amount that have been produced from the field. This is basically used for reservoir management purposes only. For different application of the liquid metering system the accuracy designed for each system differs. Custody transfer metering system is designed to have an accuracy better than 0.25% and comes under the secruiting of SIRIM. For allocation metering system on relinquished fields the accuracy should be better than 2%.UNIT OF MEASUREMENT, VARIABLES AND CONVERSION FACTORS In Malaysian oil industry, liquid is usually being measured or quantitied in volume. In other parts of the world, volume is also widely used but due recent development of technology in some parts of the world, il is being measured is term of mass. 2.1 Volume Liquid volume are normally measured in units of kilolitres (kl). However international trading of liguid hydrocarbon in Barrels (Bb1) is still used. Actual Volume is the amount of space occupied by a given amount of liquid under operating or line conditions of pressure and temperature. Standard Volume is the volume that a given amount Of liquid would occupy at standard conditions of temperature and pressure. This standard conditions is defined by the statute or contract. In usual case, temperature at standard 15°C, and pressure at 101.325 k PaAbs. 2.2 Mass, force and weight Mass is amount of matter contained in a body. In SI System of units the mass unit is the kilogram (kg) « In the SI System of Units, the force unit is the newton (N). It is the force, that when applied to a 1-kg mass will cause an acceleration of 1 m/s2. The relationship between force, mass and acceleration is:- F = Mta ge where F = force in newton m = mass of body in kg gc = a constant Substituting local gravity (gl) for acceleration and give the relationship between mass and weight force as w gly Be wnere= = ‘9.81 n/s2 ge ikon Nes2Pressure is defined as a force exerted over an area and can be expressed:- PSE aA where P = pressure F = force A area In English units, pressure is expressed as pounds per square in (PSI). In the SI System, pressure is defined as Newtons (unit of force) per square metre (unit area) and is expressed as N/m2 or pascal (Pa). Other pressure units are inches of water, bar and standard atmospheres. As pascal is a small unit of pressure, the more common unit is kilo pascal (kPa). i) Absolute pressure is pressure measured with respect to a perfect vacuum. If there is absolutely no force exerted on a given area, then that area is exposed to zero absolute pressure, ii) Atmospheric pressure is the pressure exerted by the column of air that comprises the atmosphere. Although this pressure varies with location, it is convenient to define a standard atmosphere of pressure at sea level as 14.696 psi (abs) (101.325 kPa (abs). Actual atmospheric pressure is measured with a barometer and varies with altitude. at 5000 ft (1524m), it is approximately 12.3 psi (84.8 kPa): at 10,000 ft (3048m), it is 10 psi (69 kPa). iii) Gauge Pressure Pressure gauges measure the difference between the pressure inside a pressure element and the surrounding atmospheric pressure. To obtain absolute pressure, atmospheric pressure must be added to the gauge reading. iv) Vacuum is the amount of pressure reduction below atmospheric pressure. As the absolute pressure is reduced, the amount of vacuum is increased. Vacuum measurement is important because it indicates how far a pressure is below the actual atmospheric pressure. Atmospheric pressure minus vacuum equals absolute pressure.v) Head Pressure is that pressure exerted by a column of fluid (liquids or gases). In flow measurement, differential pressure is measured in’units of inches of water column, the pressure exerted by a column of water of a certain height or inches of Mercury (in Hg). vi) Differential Pressure (d.p) is the difference in pressure between two points. Common applications of d.p measurement are pressure drop across an orifice plate for flow measurement, pressure drop across a filter or strainer to’ determine when cleaning is required. vii) Base Pressure is the defined pressure at which a standard volume of liquid exist. Base pressures normally are close to atmospheric pressure but may be higher or lower. Atmospheric pressure results from nature. Base pressure is defined by statute (law) and by contract and becomes the agreed pressure at which volumes will be calculated for any given meter location. Temperature Temperature is sensed as the degree of hotness of coldness of an object or an environment. In physics, temperature is explained as the relative activity of molecules. Head energy will flow from a hotter region to a cold region due the difference in temperature. On the Fahrenheit Thermometer Scale (used in English system of units) used in the measurement of temperature, the lowest point is 32° corresponding to the freezing and boiling points of water respectively measured at atmospheric pressure at sea level. On the Celsius Thermometer Scale (SI System), 0° and 100° are chosen to represent freezing and boiling points of water under the same conditions. A relationship can be developed to relate degree F and degree Celsius as follows:- Tr. 32 = TC 9 212-32 100 - 0 or TF 9/5 * TO + 32 or TC = 5/9 (IF - 32) where TF, TC are temperatures of substance or material at any point of measurement.For measurement purpose, it is necessary to reference the temperature to absolute zero, the point where all molecular activity of any material is believed to cease. In SI units, unit of Kelvin (k) is used for absolute temperature while English unit Rankine (*R) is used to represent absolute temperature. To convert degree Celsius (°C) and degree Fahrenheit (*F) to their absolute units, relationships are given below:- TR TR TR = 273.15 459.67 Some of the examples of temperature measuring devices include mercury-in-glass thermometer, thermocouples, resistance thermometers, thermistor, etc. Unit of Measurement SI units were used in Liquid Metering system: 1, Volume - Kilolitres (kL) 2. Mass - Kilogram (kg) 3. Temperature - Celsius (°C) 4. Pressure - Kilopascal (kPa) 5. Energy - Megajoules (MJ) 6. Length - Metre’ (m) Standard reference and condition:- - Pressure of 101.325 kPt (Abs) - Temperature of 15°C Conversion Factors 1. M3/hr - Litres/min 4.68 m3/hr (4.68 kL/hr) = 4.68 X 1000 litre/60 min = 78 Litre/min 2. 1 klitre = 1000 litre3.0 UID METERING am Flowmeters There are several meters available in the market that can be used for liquid measurement. Orifice Meters b) Vortex Meters ¢) Magnetic Meters a) Turbine Meters e) Positive Displacement Meters The PD Meters and Turbine Meter are common flowmeters used in liquid metering system for liquid measurement. Turbine Meters are widely used in liquid custody transfer metering system due to:- a) Good accuracy b) Excellent repeatability ¢) Low pressure drop a) Easy to install and maintain e) Good pressure and temperature rating There are difference types of PD Meters used in liquid measurement :- a) Rotary sliding vive b) Geared impeller c) Piston a) Oval gear meter Principle operation The operation of the three types of metering system differs from each other there are similarity in some areas. The method of operation for the custody transfer (which is always in batching operation) fig 1 differ from allocation metering system operation (which is a continuous operation), fig 2.TYPICAL CRUDE OIL. METERING SYSTEM. Fié iD : + = f} veaisas ONIUaLIW WO Jane TWOWAL 40 SUVAGHOSFaw ConPuTee | tar te0a et (8) oy GusREEAOT Ld walkers a Co a t 2 gn esata pe 7 FIG 2 Sample of an allocation metering system Tembungo Metering System.soe Crude 011 Export. The metering system for measuring the crude oi1 drawn from the storage comprises the following Three or more identical and parallel metering streams.The pipe size and meter capacity is designed so that any two meter lines can normally measure the total flow.The third meter acts as a stanby or spare to cover the eventually of any fault development in the other two meters.Also each meter’s electronic totalising- system can be individually check “offline” (for functioning teste). The meters are protected by ‘in line’ filters or strainers,with quick release fitting for ease of basket cleaning. The meters are usually of turbine type with tungsten carbide bearings in order to achieve the fluid cushioning of the the rotor so as to minimize wear and reduce the effect of variations in flowrate and viscosity (temperature).In order to increase the resolution of the meter the rotor is fitted “studs” or “slots” whice generate more pulses per unit volume. In order to minimize any supply or airborn electrical interference whice might effect the tranducer signal in the transmission line between the tranducer and the totaliser,the following equipment is provided 1) Pre-amplifier to boost the low level signal from the pick up coil to a high level signal so as to maintain a high signal/noise ratio on the transmission lines.2) Dual Transmission lines in parallel take the signal two pick up coils situated 180 deg out of phase Somparator. 3) The Comparator compares the respective signals from each transmission line and sets off an alarm when a pre-set number of transients or spurious pulses is detected The meter pulse signals are totalised in a “gross sounter".The meter factor obtained during proving is set into the Scaling Device so that the “pulse output 8 converted into volume at atmosphere pressure. The volume at line temperature and atmospheric pressure is continuosly adjusted and accumulated in the “nett counter. This 1s achieved by a device known as the temperature normaliser or compensator,which continually monitors the “line” temperatire and applies the appropriate volume correction factor to reduced the volume at observed temperature to equivalent volume at 15 deg c Frequency (flowrate),temperature and pressureare continually recorded on a three pen recorder for each meter stream. A pipe prover situated down stream of the meters is available as required to prove each meter individually in turn,without interfering or reducing the total crude 011 production flow. In line sampling of the crude oi] is usually achieved by installing an automatic sampler in each meter stream (vertical pipe) or in common header.Depending on the percentage of water in the crude oil/or the associated (dissolved) gas various types of sampler may be considered.JaNT — i Asn wanona aniva laveninod saaTvA x08 a 1NT SUINIVALS F _— We RANA LALO waAOUd suazan NTU santvAa |OWINOD MOTE SANTVA ¥OOTS usluno NV govwous Fanwo OL“d-p pur sunssoud 2985 F40 -4ndqno ‘aun ton snonurqucs UIIm suayeu aurquny suaysks Yutuoyam wioyre tg + (aoqeaedas 4801) soueWiojaed JoTAuasad 403 ;UOH (2 “quawd nbs Teuosqeudde uorzuOW (P *paqsefur-aa sep (9 suorydunsuos se 43T1 (a poue tJ) sans jou amq uoM se 7110 suywserap OL | quamaanseay, [euorqesadg (so dues uo verewortsuap £q Ay 1suap) uoreaZaquy ‘aun toa snonuyquos UIT danoud adrd pue suoqau eurquny, woqsky SupaaiaN wuosIe La uoraanpoad 12307 40/pue (Artekoy) ysurese vor e201 [8 JO sasodund voy vandyBnouua, wuojaetd TenprATpuT auImu2zap of, loulounseay auyad p Jo Tu09 uoryeaBaquy ssew yaunjon snonuy4u09 squnbry {cumini ~ pereuas raya} Saeed Je (| 9ueqig - (eoss yeas) ‘1Y0 apne - Joy (Gurpeot drys yr wooed JQ NTO. ISOdHNd UIIm annoug adrg uo) suaishs Suiaay r0a 4 (aa 3a Sutaaqew 21 ‘fang quowoanseay buy sumrow suai, uous Jo syuRy au0ug “Ky Tekoy surmsarap of AeKOW [——__thiay ainort LN SLNSHINNSWAH NOT nud)4.0 STEPS OF PI! ER CALIBRATION The steps below outline the pipe prover calibration using master meter method/master pipe prover, and crude as the test (Refer diag. for equipment configuration). CALIBRATION 1, Calibrate Prover the master meter using Master Pipe Prover and obtain its meter factor. Meter Factor must be repeatable +0.01% of the average meter factor for the consecutive runs. (The master pipe prover must first be certified by SIRIM and has its certified base volume). 2. Using Master Meter, calibrate bidirectional pipe prover and obtain its prover volume. Calculate pulse repeatability - Using Master Meter, Meter Factor, calculate round trip prover volume. Round trip prover volume must be repeatable by +0.01% of the average volume for five consecutive round trips passes. 3. Recalibrate/reprove the master meter using the Master Pipe Prover and obtain its meter factor. Meter Factor must be repeatable +0.01% of the average Meter Factor for five consecutive runs. Check that the old meter factor (ie. obtain before pipe prover proving) is in agreement with recent meter factor within +0.02% of average meter factor. If it is more than +0.02% repeat the whole process again. 4, Using the Master Meter average meter factor (MF1_+ MP3) calculate the true prover volume. Check 2 again the repeatability ie +0.01% of the average volume for five consecutive round trip passes. LEAK CHECK The purpose of this leak check is to ensure that the prover volume is valid in all other flowrate, as no continuous leak has occured on the prover. (AS continuous leak could not be detected in same flowrate for difference runs). After calibration of the pipe prover, a leak check has to be conducted by proving again the prover of a higher or lower flowrate by 25% of previous proving rate. 1) Calibrate the master meter using master prover as per calibration step 1.,2) 3) 4) 5) Calibrate the bidirectional prover using master meter as per calibration Step 2 but only 3 consecutive runs with repeatable volume +0.01% of average volume is required. Recalibrate/reprove the master meter as per calibration step 3. Calculate the true prover volume as per calibration Step 4. Check that the calibration prover volume and leak check prover volume is within +0.02%. If it agrees, the calibration prover volume is the true prover volume. If it does not agree within the limit, SIRIM will decide whether the calibration prover volume can be used as a true prover volume or recalibration of the prover is required. For crude oil prover system, calibration is done using master meter/master pipe prover with water as a testing medium. For condensate or product prover system, calibration is done using master meter/master prover tank and water as a testing medium.5.0 METER PROVING OPERATION Meter Proving operation is an exercise to determine the meter factor for the meter and also to check that the meter operates within its tolerance limit. It is actually a procedure required to compare the volume indicated by the meter register with the actual volume which has passes through the meter, expressed as a ratio. This ratio can be expressed as:- Meter Factor = ual Vol ssed_throu: Indicated volume by meter register Why a meter factor is required? It is required to correct the meter indicated volume in such a way that what ever volume of crude oil enters the meter should go out ie. should be registered or counted. Register 1000 kL 1000 kL 1000 kL Meter In out This is achieved by applying the meter factor to the metered throughput quantity. 998 kL 1000 kL 998 X 1.002004 = 1000 kL Meter (M.F = 1.002004) There are a number of temperature and pressure corrections to be taken into account. (K Factor = Nui ulses colle: i i n Volume at run temp. and press. of meter (Total Indicated Volume) How Meter Proving Is Carried out Meter proving can either be carried manually or automatically, but PETRONAS requirement is that meter proving should be done automatically. In automatic meter proving operation, all value sequencing and calculations are performed by computer. Results of meter proving will be printed out at the end of proving exercise. In manual proving operation, values selection and calculation is carried out manually. Steps in Meter Proving Operation:-5.1 Perform Line set-up a) ») °) a) Choose meter required for proving. Select prover vol A or B to be used. Specify flowrate for meter proving (automatic proving). Usually the operating flowrate is the proving flowrate. Initiate proving operation by pressing appropriate key on the prover computer. Prover computer will perform all relevant value lining:- - All other prover diverter values closed . - Meter run outlet values during operation that required to open must open, except meter run that meter being proved which must be closed. - Prover return/outlet value open. (It proving is done manually, all values closing and opening has to be done manually). Before resume proving the computer will check the conditions to ensure it is stable and within the stabilisation period specified. (This step is not done during manual proving). The conditions are:- i) Temperature - Temperature of Meter and Prover will be checked. The difference must be within the allowable specified ‘c ‘Spa ii) Flow - Flow stability will be checked against the setpoint. If the Temperature and/or Flow is unstable the computer will automatically abort the proving operation. Values operation During operation:~ Al A3 A3 Bl B2 B3 is open, D is closed. (B4 C4 is closed - as spare meter run). C1 c2 c3 is closed.- Proving Operation on M1 a) Al A2 A3 remains open. 82 and B3 remain open. But B1 closed. b) 2 C3 remains closed. ¢) Cl open, B1 closed, D open. PROVING OPERATION a) Each proving trial will consist of a round trip of the sphere through the pipe prover. (Prior to each pass through the prover, the pulse counter in the computer will be resert). b) After counter been reset, 4 Way Value will be commanded to rotate. (If 4 Way Value fail to rotate, proof will automatically be aborted). ©) After 4 Way Value rotated, proving program monitor for the 1st detector switch. If counter not start within the calculated time limit, proof will be aborted. a) The second detector is monitored the same way. It should stop within the limit calculated. e) Prover program will also monitor the 4 Way Value. If the D.P switch indicates failure/leak, the proof will be automatically aborted. f) After each round trip a trial meter factor is calculated and after 5 round trips a check based on the meter factor is made for a successful proof Sequence. The calculation are as follows: Each TMF - AVG OF 5 < or AVG OF 5 +#0.000245 (40.0245%) - If 5 consequtive trials do not satisfy the best, another trial run will be made after which another test be done using the above formula on most recent 5 consequtive trials. (Refer table 1). - The best is repeated until 10 trials been made and if no successful sequence is obtained, the proof will be aborted. (If operator intend to reprove the meter, he has to initiate new proving operation). (Refer table 2). - Once successful proof is obtained, (the result will be printed out) giving a valid meter factor. The operator will transmit the most recent meter factor to flow computer by pressing confirmation key. (Sample of proving trial report as per table 2 and final proving report as per table 3). - 15 -TABLE I 1. 5 consequtive trials within repeatability +0.0245% (Meter A) during 1 to 5 runs. ‘rial No Trial Factor 1.006333 1.006580 1.006224 1.006419 1.006363 oeene Average Meter Factor = 1.0063838 Checking Method : Each TMF - AV MF X 100 < +0,0245% AV MF or Highest Deviation of MF from Average M.F < +0.0245% Average M.F ie. 1.006580 - 1.0063838 X 100 = +0.019% 1,0063838 Highest deviation of M.F from average meter factor is +0.019% which is less than +0.0245% 2. 5 consequtive trials within repeatability +0.0245% during 5 to 10 runs. Trial No Trial Factor 1.006333 ) 1.006580 ) 1.00680 )A 1.006419 ) 1.006363 ) 1.006351 1.006731 1.006432 1.000531 ° 1.000321 ) ) )B ) de ) RPeevaueenr o a % Average M.F A = 1.006499 Highest deviation M.F from Average M.F = 0.0299% Average M.F B = 1.006503Meter Factor Calculations Basic Calculations: Meter Factor = Actual Volume Thro ter Where: - S.F = By = ctsp = cpsp = cHlp = 54a = Indicated Volume By Meter Register = Volume of Prover with Pressure & Temp. Corrections Expressed in no of pulses Indicated vol. of prover registered by meter expressed in no of pulses. = S.F X BV X Ctsp X Cpsp X C+lp X Cplp Pulses X Ctlm X Cplm Meter Set Factor (Pulses/M3) Base Volume of the prover round trip (at standard conditions) . Correction for the effect of temperature on steel of prover 1+ (1-15) X ¥ for temper where T = Temperature in Deg c. Y¥ = Coefficient of cubical expansion per Deg c. (0.00003348 per Deg C for mild or low carbon steel). Correction for the effect of pressure on steel of prover. 1 + (PD/ET) where P Internal pressure in Kilopascal D = Internal diameter in (mm) E Modules of elasticity (207 X 10-1 for mild steel) T = Wall thickness in (mm) Correction for the effect of temperature on liquid in the pipe prover. (Can either be obtained from table 54 or 54H). This table can be fale cans as formula but applicable for a. certain ranges of density. E (-XDT (1 + 0.8 X DT) where X = (Ko/P2) + (K1/e) KO = 613.9723 Ki = 0 DI = Deg c- 15 'c540 = Pulses crn cpln 1 + Ql DIC - Q2 pT2 where Deg c - 15 -P1/RD 15 + P2 ~P3/RD15 + P4 Density in kb/m3/999.098 P1, P2 value obtained table stored in computer, Total pulses registered by a meter for a round trip movement of sphere in the prover. Correction for temp. of the liquid in the meter (C+1 using meter temperature) Correction for pressure of the liquid in the meter (Cpl using meter pressure)