CMTEM2011 Presentations

Technical Proceedings-

Presentations

6TH

CUSTODY MEASUREMENT

TECHNICAL EXCHANGE MEETING

(CMTEM 2011)

November 21-23, 2011

Dammam Office Building

Saudi Aramco

Maintain Measurement Accuracy from Design to Operation

Authors: Peter Jakubenas – Installed Product Services Manager, FMC Technologies

Bryan Partridge – After Market Manager, FMC Technologies

Jeffery MacKenzie – Global Aftermarket Manager, FMC Technologies

Presented by: Peter Sims – Business Development Manager FMC Technologies

APPLICATIONS

• PIPELINE TERMINALS

• EXPORT TERMINALS

• IMPORT TERMINALS

• FLOATING PRODUCTION STORAGE VESSELS -FPSO AND FSO

CUSTODY TRANSFER AGREEMENTS

• BUYERS

• SELLERS

• CUSTOMS

• GOVERNMENT

• SHIPPERS

FISCALIZATION ACCURACY

• QUANTITATIVE MEASUREMENT

• QUALITATIVE MEASUREMENT

• TRACEABILITY TO RECOGNIZED STANDARDS

• We are seeking the truth!

QUANTITATIVE MEASUREMENT

• METERS

• PROVERS

• FLOW COMPUTERS

• CONTROL SYSTEMS

QUALITATIVE MEASUREMENT

• DENSITY OR GRAVITY

• TEMPERATURE

• PRESSURE

• VISCOSITY

• SAMPLING

• BS & W

DESIGN OBJECTIVES

• ACCURACY- HIGH CERTAINTY- LOW UNCERTAINTY- BOTH INITIAL AND ONGOING

• SAFETY

• RELIABILITY

• OPERATOR EASE

• LOW ONGOING OPERATING COSTS

• LOW CALIBRATION COSTS

• LOW MAINTENANCE COSTS

• VALUE

SYSTEMS APPROACH

• ULTIMATE PERFORMANCE

• PROPERLY SELECTED COMPONENTS TO ACHIEVE LOW UNCERTAINTY

• TURNKEY CONTRACT

• EXPERIENCED

• SUPPLER WITH PRODUCT LINE KNOW HOW AND COMMITMENT

• SUPPLIER WITH ONGOING SUPPORT SERVICES HISTORY

WHAT ACCURACY CAN BE ACHIEVED?

•METERING +/- O.1 % TO +/- 0.25% OVERALL

•TANK GUAGING +/-0.7% UNDER BEST OF CONDITIONS

COST OF UNCERTAINTY

• ASSUME 10,000 BBL PER HOUR @ $100 per BBL (10” Pipeline)

• ASSUME 0.5 % UNCERTAINTY BETTER THAN TANK GUAGING- $0.50 per BBL

• $120,000 AT RISK PER DAY

• $3,600,000 AT RISK PER MONTH

• $43 MILLION AT RISK PER YEAR

UNCERTAINTY- RISK

• Under Registration

– Deprives the seller of entitled revenue

• Over Registration

– Customer complaints and loss of good will

– Possible retroactive rebates

– Potential lawsuits

• We are seeking the truth (CERTAINTY) in measurement

• Uncertainty is RISK associated with the transaction

TYPICAL SYSTEM P&ID

•

DESIGN FOR LOWEST TOTAL OWNERSHIP COST

TOTAL COST FOR ASSET OVER LIFE =

INITIAL COST

+ Y x YEARLY ENERGY COST TO OPERATE

+ Y x YEARLY OPERATOR LABOR COST

+ Y x YEARLY CALIBRATION LABOR COST

+ Y x YEARLY MAINTENANCE LABOR AND MATERIALS COSTS

Where Y represents life of project, typically 20 years.

OPERATING ENERGY COST CONSIDERATIONS

• PUMPING COSTS DUE TO PRESSURE DROP

• PRESSURE DROP DUE TO

– HEADER SIZE AND DESIGN

– STRAINER DESIGN (EXCEPT FOR ULTRASONIC METER SYSTEMS)

– METER TECHNOLOGY SELECTED

o ULTRASONIC

o POSITIVE DISPLACEMENT

o HELICAL TURBINE

o CONVENTIONAL TURBINE

o CORIOLIS

– SAMPLER MIXING METHOD

o JET MIXER- PUMP REQUIRES ENERGY

o STATIC MIXER

– BLOCK VALVE SIZING

– CONTROL VALVE SIZING

METER SELECTION -

• FLOW RATE

• VISCOSITY

• METER RUN QTY. VS SIZE

METER SELECTION RULE OF THUMB BASED ON FLOW RATE

AND VISCOSITY

QUALITY SKID

• LINE EXTRACTION DEVICES

• SLIP STREAM PUMPS

• DENSITOMETER(S)

• VISCOMETER(S)

• FLOW METER AND CONTROL VALVE IN LOOP

• BS & W MONITOR

• SAMPLER

SKID AUTOMATION

• MOTOR OPERATED VALVES

• REMOTE READOUT EQUIPMENT – METER TRANSMITTERS

– TEMPERATURE

– PRESSURE

• CONTROL ROOM OR SKID MOUNTED FLOW COMPUTER I/O

CONTROL ROOM INSTRUMENTS-FOR OPERATOR EASE

• FLOW COMPUTERS

• GRAPHIC PANELS FOR BACKUP

• REDUNDANT CONFIGURATIONS

• PLC FOR VALVE INTERLOCK

CONTROL ROOM INSTRUMENTS

• SUPERVISORY COMPUTERS – CONTROL

– DATA COLLECTION

– AUTOMATED PROVING

– EXTENSIVE REPORTING AND ARCHIVING

– SOPHISTICATED MAN MACHINE INTERFACES

– COMMUNICATION INTERFACES

– METER AND PROVER DIAGNOSTICS

TYPICAL HMI SCREEN

TYPICAL CRT SCREEN

Meter Performance Analysis Software

MAINTENANCE and CALIBRATION ISSUES

• PROPER MATERIALS AND COATINGS TO BATTLE

INTERNAL AND EXTERNAL CORROSION

• EASE OF ACCESS TO EQUIPMENT ROUTINELY CALIBRATED OR SERVICED

• SET UP MAINTENANCE INTERVALS BASED ON EXPERIENCE AND OBSERVED STABILITY OF EQUIPMENT

• INSTALL REDUNDANT EQUIPMENT AND DO CONDITION BASED MAINTENANCE

• TRACK ALL MAINTENANCE

26

Case Study - Metering

Maintenance Contract Overview • Start Date: 1st October 2004 • Duration: 5 years plus 5 x 1

year options • Original Scope

– UK (1 onshore plant, 16 offshore platforms, 68,000 man hours)

– NL (157 onshore sites, 22 offshore platforms, 38,000 man hours)

– NO (1 onshore site, 1 offshore platform, 11,000 man hours)

27

Contract Framework

Program Management

Administration

• Purchasing

• Work registration

• Invoicing

• Payment problems resolution

• Subcontract management

• Monthly commercial reporting

• Monthly forecasting

Planning and Operations

• Compliance Delivery

• Work control systems

• Breakdown response

• Scheduling and planning

• Work Preparation

• 1st technical line support

• SAP Improvements

• Field Execution

• Test equipment management

• Spares management

• Monthly operational reporting

Consultancy and Engineering

• Client reputation protection

• Technical measurement support

• Mismeasurements

• Audit support

• Management of audit actions

• Calibration verifications

• Metering philosophy development

• Procedure writing

• Calibration sheet design

• Engineering design review

• PMA Collaboration

• Project support

• QA

28

Contract Personnel

Program Management (1)

Administration (6) Planning and Operations (44) Consultancy and Engineering (14)

UK

• 1 Contract Manager (50%)1

• 3 Administrators1

NL

• 2 Administrators

• 1 Financial controller (20%)

NO

• 1 Administrator (10%)

UK

• 3 Planning Engineers1

• 22 Metering Technicians1

NL

• 3 Planning Engineers

• 12 Metering Technicians2

NO

• 3 Metering Technicians

• 1 Analyser Specialist3

UK

• 1 Senior Consultant1

• 6 Metering Engineers1

NL

• 1 Senior Consultant

• 4 Metering Engineers

NO

• 1 Senior Consultant

• 1 Metering Engineer

• Total of 65 people:

Equipment Supported

SCOPE OF EQUIPMENT SUPPORTED

• FLOW COMPUTERS:

– S500’S, S600’S, MICRO 5000’S, OMNI, SOLARTRON 7915, 7951, 7925, 7922, 7955, 869M,INTROMET FC500, FC2000, NETOIL, DANIELS S103, PROMAC, CONTREC

• PRIMARY AND SECONDARY DEVICES:

– MAGFLOWS, MULITPHASE METERS, TURBINE METERS, ULTRASONIC METERS, ORIFICE METERS, V-CONE METERS, ANNUBARS, CORIOLIS METERS, POSITIVE DISPLACEMENT METERS, DP AND PT TRANSMITTERS, TEMPERATURE TRANSMITTERS, 3095 MV, GAS AND OIL DENSITY TRANSDUCERS

– MICROMETER, YOKOGAWA, SOLARTRON, FOXBORO, E+H, ABB, KROHNE, ROXAR, FRAMO, FAURE HERMAN, BROOKS, DANIELS, ROSEMEOUNT, PECO, HECO, FMC, MICRO MOTION

– 1”, 2”, 3”, 4”, 5”, 6”, 8”, 10”, 12”.

Equipment Supported

SCOPE OF EQUIPMENT SUPPORTED

• ANALYSERS:

– OIPW ANALYSERS, WIO ANALYSERS, RD ANALYSERS, PYCNOMETERS, CHROMATS, DEW POINT ANALYSERS, H2S ANALYSERS

– ROXAR, DANIELS, SOLARTRON, E+H, SIEMENS, MICHELL, AMETEK, ABB, HOBRE

• PROVERS AND MASTER METERS (10” – 36”):

– 12 SITES

• SAMPLING SYSTEMS:

– WELKER, JISKOOT

31

PERFORMANCE MANAGEMENT: KPI’s

• HSE

• Behavioural

• Performance

• Innovations

• Savings

32

CONTRACT BENEFITS: MANAGEMENT SYSTEMS

33

CONTRACT BENEFITS: MANAGEMENT SYSTEMS

34

CONTRACT BENEFITS

• Complete bespoke management system and infrastructure

developed and implemented:

– Operational infrastructure

– Operating systems and procedures

– Planning and scheduling tools

– Work instructions

– Calibration sheets

– Mismeasurement management

– Audit Management

CONCLUSIONS

• Ongoing costs of operation and maintenance of petroleum custody transfer measurement systems over a 20 year project life can predominate over initial equipment investment.

• It is important to design the equipment for low ongoing costs. Initial cost may be higher to do this.

• Sophisticated diagnostic systems and equipment can reduce ongoing costs; for example condition based maintenance.

CONCLUSIONS

• Operation and maintenance of these systems requires specialists trained on the large variety of components comprising the systems with oversight by engineers.

• Systematic scheduling of preventive maintenance and corrective maintenance can lead to lower maintenance costs.

• A sophisticated reporting system enables greater transparency of total costs and facilitates decisions to optimize costs.

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION

INITIATIVE

KHALID A. AL-FADHL

Chairman, Custody Measurement Standards Committee

Saudi Arabian Oil Company (Saudi Aramco)

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

Outlines:

1. Introduction

2. What is Standards Globalization?

3. Benefits of Globalization

4. Saudi Aramco Engineering Standards Structure

5. Globalization Approach and Strategy

6. Custody Measurement Standards Globalization Initiative

7. Challenges

8. Conclusions

9. Recommendations

Slide # 1

1. Introduction

Saudi Aramco Engineering Standards are at the center of engineering intellectual know-how and serve as the safety net for building safe, reliable and cost effective facilities.

Are the standards aligned with International Standards?

Are they the main reason behind the exponentially increasing capital projects cost?

or, they need optimization?

Slide # 2



Globalization is a process to enhance the alignment Saudi Aramco Engineering Standards with the international or Industry standards.

A result of Benchmarking Exercise conducted in 2007 against regional and International oil companies and standards organizations such as GSO, OGP and ISO.

Slide # 3


2. What is Standards Globalization? (Cont’ed)

Exercise showed that Saudi Aramco is in the leading edge in terms of engineering standards management practices and systems

Chairmen and Subject Matter Experts are required to revisit the requirements that do not add value to the design.

Participate in the activities of the international standards organizations to inject the Saudi Aramco mandatory requirement to these organizations

Slide # 4



Slide # 5



• Eliminate special requirements that may increase project costs

Slide # 5




• Increase the number of potential suppliers of material

Slide # 5





• Reduce manpower required to maintain company standards

Slide # 5






• Help build local industry around international standards to better compete in the global market

Slide # 5






• Help build local industry around international standards to better compete in the global market

• Develop cost estimates more economically.

Slide # 5



Board of Engineers chaired by Engineering Services Chief Engineer bears the responsibility of the Saudi Aramco Engineering Standards and Specifications

Slide # 6



Slide # 7



More than 2300 standards; from which, more than 1200 are considered mandatory.

Slide # 7




37 standards committees with members of more than 500 people from 17 different organizations

Slide # 7




37 standards committees with members of more than 500 people from 17 different organizations

Corporate management systems have been established to manage the review and approval process of the engineering standards

Slide # 7



Corporate management systems have been established to manage the review and approval process of the engineering standards.

Slide # 8


Standard Review Model

Slide # 9



Slide # 10



• Developing a snapshot of the current state of Saudi Aramco standards and conducting Gap Analysis by Saudi Aramco Subject Matter Experts each in his discipline.

Slide # 10




• Performing Value Engineering studies for the engineering standards.

Slide # 10




• Performing Value Engineering studies for the engineering standards.

• Participating in International Standards Development

Slide # 10


Slide # 11


6. Custody Measurement Standards Globalization Initiative:

A. Custody Measurement Engineering Documents:

4 SAEPs (Engineering Procedures)

5 SAESs (Engineering Standards

14 SAMSSs (Material System Specifications)

In addition to Standards Drawings, ISSs, & Inspection Forms

Slide # 12



B. Development and Revision Process of Custody Measurement Engineering documents

Slide # 13



B. Development and Revision Process of Custody Measurement Engineering documents

C. Gap Analysis

• Exception Format is used to develop documents that have a reference international document.

• Normative Format is used to develop documents that do not have a reference international document.

Slide # 13



D. Value Engineering Studies:

Three value engineering studies were performed on most important measurement documents.

Slide # 14


Document

No. Document Title Date

No. of VE

Proposals

No. of VE

Recommend

-ations

Estimated

Cost

Avoidance ($)

SAES-Y-101 Custody Metering of

Hydrocarbon Gases 5/9-13/2009

14 30 7,400,000

SAES-Y-103 Royalty/Custody Metering of

Hydrocarbon Liquids

18 33 30,000,000

34-SAMSS-119 Bi-directional prover

8/2-4/2010

4 19 816,200

34-SAMSS-120 Uni-directional meter prover 4 6 816,200

34-SAMSS-121 Small Volume Prover 2 33 880,000

34-SAMSS-122 Atmospheric Portable Tank

Prover

0 9 0

34-SAMSS-112 Orifice Meter for Gas Custody

Measurement 10/4-5/2011

1 8 TBD

34-SAMSS-114 Ultrasonic Flow Meter for Gas

Custody Measurement

2 11 TBD

Slide # 15



D. Value Engineering Studies:(Cont.’ed)

Two value engineering studies are planned to be performed

Slide # 16


Document No. Document Title Date

SAES-Y-501 Dynamic Sampling of Hydrocarbon Liquids for Royalty/Custody

Transfers

July 2012 34-SAMSS-525 Automatic Sampling Systems for Crude Oil and Refined Products

34-SAMSS-526 Automatic Sampling Systems for Hydrocarbon Gases

34-SAMSS-841 Flow Computer for Custody Transfer Measurement of

Hydrocarbon Liquids

October 2013

34-SAMSS-846 Flow Computers for Custody Transfer Measurement of

Hydrocarbon Gases

34-SAMSS-847 Preset Controller for Truck Loading and Unloading Systems

34-SAMSS-851 Metering Supervisory Computer for Custody Transfer

Measurement of Hydrocarbon Liquids

Slide # 17



E. Participation in the International Standards Organizations:

American Petroleum Institute (API) Petroleum Measurement subcommittees

(COGFM, COMA, COLM & COMQ)

Slide # 18




American Society for Testing and Materials (ASTM)

Committee D02 on Petroleum Products and Lubricants

Slide # 19




• International Organization for Standards (ISO)

Saudi Standard, Metrology and Quality Organization (SASO) delegated Saudi Aramco represented by CMU to review and vote on the international standards submitted by ISO TC-28, Petroleum products and lubricants.

Slide # 20




• American Gas Association (AGA)

CMU participates in AGA activities by reviewing the reports developed in the field of gas measurement.

Slide # 21


7. Challenges:

Slide # 22


7. Challenges:

a) Implementation process of the initiative differs from one discipline to another.

Slide # 22


7. Challenges:


b) Involvement of the Subject Matter Experts in the increasing day-to-day activities.

Slide # 22


7. Challenges:



c) Standards Cross Referencing

Slide # 22


7. Challenges:



c) Standards Cross Referencing

d) Shortages in the local and international subject matter experts

Slide # 22


7. Challenges: (Cont’ed)

e) Geographical diversity do not permit attending International standards organizations working group meetings

Slide # 23




f) Long time for developing and approving the reference standard document

Slide # 23




f) Long time for developing and approving the reference standard document

g) Marketing SA standards requires referring to international standards not SA document

Slide # 23


8. Conclusion

• Saudi Aramco, through Globalization Initiative, made a significant progress in optimizing the alignment of its technical requirements with the international standards.

• Some of the Saudi Aramco standards were adopted by GSO and others were submitted to ISO for adaptation.

Slide # 24


9. Recommendations:

All the necessary resources should be allocated to implement the Globalization Initiative requirements such as:

• Participation of Subject Matter Experts in the International Standard Organizations activities.

• Conducting Value Engineering Studies

Slide # 25


Summary:

1. Introduction





6. Custody Measurement Standards Globalization Initiative

7. Challenges

8. Conclusion

9. Recommendations


Questions?

Real-world proving and maintenance of sampling/quality measurement system accuracy using international standards

JISKOOTTM QUALITY SYSTEMS

CMTEM – Saudi Aramco - Nov 2011

Jon Moreau – Cameron Measurement Systems - Jiskoot

Mark Jiskoot – Cameron Measurement Systems – Jiskoot

Change in the last 20 years?1990s 2011

How much has your quality measurement changed?

Real world sampling accuracy - topics

• International losses

• Quantity – v- quality measurement

• Proving the accuracy of quality measurement systems

• Proving acceptance criteria

• The performance of different system designs• The performance of different system designs

• Effects on density and OWD measurement

• Maintaining system accuracy

EI HMC4 Measurement committee – crude oil losses

$300,000,000

$350,000,000

$400,000,000

$450,000,000

$500,000,000

Potential ‘quality’ measurement loss > $300m pa @ 0.16%

$0

$50,000,000

$100,000,000

$150,000,000

$200,000,000

$250,000,000

0.000% 0.040% 0.080% 0.120% 0.160% 0.200% 0.240%

Losses

Effect of quality measurement on overall accuracy??

• Crude oil cargo - 300,000 m3

1cc sample grabs taken, 10,000 per batch

10 litre sample taken to lab for analysis

1 – 100ml analysed for water - depending on method

• Volume analysed can be 1 in 300 BILLION

Importance of accuracy

1 in 300,000,000,000

• 34SAMSS – 525

• SAES–Y-501

• ISO 3171

• API 8.2 – called by above

• IP 6.2 & ASTM 4177

Sampling standards

• IP 6.2 & ASTM 4177

(same as API)

• Under the Phoenix agreement EI and API are being merged and it will then be balloted to replace ISO 3171

• Will include refined products!

Water injection proving – the process

Proving results – criteria – ISO/IP

Proving to IP or ISO standard

Complies with API, ISO and IP!!

Proving to the API complies on with API

Remember planned unification of ISO and API

Proving results – some systems fail!!

Independently certified systems – ISO pass

Proving certificates!!!!!

Different sampling system types

Fast loop sampling system(External mixing needed if required)

CoJetix sampling system(Combined mixing and sampling)

In-line (probe based) sampling system(External mixing needed if required)

Relative accuracy of crude oil sampling systems

0.80%

1.00%

1.20%

1.40%

Accura

cy

In line sampling system with poor mixing

in-line sampling system with compliant mixing

Fast loop sampling system with compliant mixing

EFFECTOF POOR MIXING

0.00%

0.20%

0.40%

0.60%

0.80%

Accura

cy

Number of water injection tests

MIXING

ON WATER CONTENTMEASUREMENT

Performance of fast loop sampling systems (inc mixing)

Performance of in-line sampling systems (inc mixing)

Density measurement errors

Density measurement – configuration bias

Reducing uncertainty and maintaining accuracy

• Specify, design, install and commission correctly

Step 1• Pipeline mixing – LARGEST EFFECT ON ACCURACY

Step 2• Representative sampling of the batch

Step 2

Step 3• Sample handling and mixing

Step 4• Laboratory analysis process

Step 5• Prove the system in accordance with standards

• Performance Criteria for “Permanent Sampling System Installations”– Grab factor

– Performance factor

– Flow sensor accuracy

– Sampling time factor

Collecting a representative batch sample

– Sampling time factor

– Loop velocity (fast loops)

• Fully automated with the control system monitoring and controlling the sampler – only informing the operator if a failure occurs

• Reduce the number of steps - Portable receivers

reduce uncertainty

Sample handling and mixing

L2)

Fixed receivers with

mixing in the field create a

“second” L2 step in an environment outside lab

control

Maintaining system performance

Prove installed

system by water

injection

Validate and ensure

Confirm mixing

performance

Certified quality

measurement system

ensure system

reliability

Validate system

performance

Validate handling, laboratory process

performance – v – design parameters

Summary

1.

Design and specification

2.

Installation and

commission

8.

Revalidation and proving as required

Certified accuracy

& reduced losses

3.

Proving in accordance

with standards

4.

Batch certification

of performance

5.

Maintenance schedule

6.

Validation of sampling

and analysis process

7.

Confirm operating envelope same as design

So what does your quality measurement look like?

1973 – OR - 2011?

Thank YouQuestions?

November 2011

BTU Gas Measurements

Challenges & Optimization

Abdulaziz A. Al-Faraj

Saudi Aramco

© Copyright 2011, Saudi Aramco. All rights reserved.

Objective

Share with you our experience and challenges

encountered to accurately measure the BTU for

a widely distributed gas network

Outlines

• Background

• Existing Methods

• Challenges

• Optimization Methods

• Conclusion

Background

Jubail Royal Commission

Berri

Dammam/Khobar Area

SGP,UGP,

HGP, HYGP

BGP

KGP

Qatif Junction

Ju’aymah Junction

Berri Junction

Pressure : 300 – 1000 PSIG

Flow : around 4.2 BSCFD in

the Eastern Province

Temperature : 70 – 150 ᵒF

BTU: 900 – 1280

Jubail Royal Commission

Berri Power Plant

Ghazlan Power Plant 1 & 2

Azizyiah Desalination Plant

Wusta

Desalination Plant

Dammam Industrial Plants

Ras Al Khair

Refinery and Fractionation

The Master Gas System consists of:

1- Major gas plant producers

2- Complex pipelines network

3- Major junction sites

4- Low pressure distribution system

5- Metering skids

Importance of Gas Sampling

FT High FT Low PT TT

Orifice

FCV (A)

FCV (B)

Class-I

Valve

SAUDI

ARAMCO CUSTOMER

On-Line

Analyzer

Flow

Computer

Metering Skid Classification

• Secondary

≤ 20 MM SCFD

− Small Gas Metering System

− Composite Sampler

• Primary

200 MM SCFD ≥ Primary ≤ 20 MM SCFD

− Medium Gas Metering System Online GC

− or a representative sample from another GC

• Major

> 200 MM SCFD

− Large Gas Metering System

− Independent Online GC required

SAMPLING METHODS

Automatic (Composite) Sampling

Online Sampling

LIMITATIONS C

om

posi

te

Sam

pli

ng

• Is Not Based ON Real-time Value

• “The Process” Labor/Time Intensive

• Laboratory Dependent

LIMITATIONS O

nli

ne

An

aly

zer

• High Initial Cost

• Need of Highly Skilled Personnel

• Requires Carrier & Calibration Gas

Challenges

Challenges

1- Continuously Improve the Accuracy in Determining the

Value of BTU In Order to Reduce Uncertainty

Challenges 2- Improve Efficiency

3- Gas Composition Variations

Challenges

4- Enhance Coordination Efforts Amongst Involved Parties in

Determining the BTU Value

Challenges

Laboratory

Maintenance Operation

Engineering

5- Match BTU With That of Our Customers to Eliminate

Potential Claims

Challenges

• Using different standards

• Using different measurement methods

• Involvement of different parties

• Periodical PM

• Require Special Crew

• Supply Carrier & Calibration of

Gas

• Secure Resources

5- Special Maintenance Requirements

Challenges

Optimization Methods

1- Automate Gas Sampling Processes In Order to Reduce

Manual Activities

2- Network Enhancement

Gas Composition

& other Data to

F.C

Update MMBTU at

Local Flow Computer

Update MMBTU for selected flow

computers at the costumers sites

Sa

mp

le lin

e

Centralized

Location

Sales Gas Header

AIT

Costumer A

Costumer A

Costumer D

Costumer C

Costumer B

BTU

BT

U


3- Continuously Improve Workforce Skills and

Competencies



4- Improve Existing Policies and Regulations

Conclusion

• Determining the Most Accurate BTU Value is Highly Critical to any

Sales Organizations.

• Gas Sampling Method Selection Shall be Based on Achieving Best

BTU Results

• Online Gas Chromatographs Are in Most Cases More Cost Effective

• Optimization Shall Be Adopted Continuously

Thank You

Custody and Royalty Metering Skids Operation and Maintenance Challenges

Ahmad I. Al-Shaye

Saudi Aramco

NA Pipelines Department

November 21, 2011


Outline

• System Overview

• Our Customers

• Duties and Responsibilities

• Challenges

• Optimization Methods

• Conclusion

Overview

Saudi Aramco Pipelines Mission

Transport hydrocarbons throughout the kingdom safely, reliably and in an environmentally responsible way

Dhahran

Ras Al-Khair

Jubail

Ras Tanura

Our Customers

Sector # Metering Stations Total #

Sales Gas & Ethane (Custody)

RC Primary Industries

42

77 RC Secondary Industries

20

Electricity &Water Desalination

10

Others 5

Crude Oil (Royalty)

Refineries 2

3 Petrochemicals 1

JUPC

HADEED

ALRAZI

KEMYA

PETROKEMYA

SASREF

Zamil EAP

SADAF

Sahra- Tasnee

IBN SINA SHARQ

IBN ZAHR

IBN AL BAYTAR

SAFCO

SAMAD

JUBAIL

SECONDARY

INDUSTRIES 20 Customers

NCP SCP

Sales Gas Ring

APPC

SPC SIPCHEM

WAHA

CHEMANOL

FARABI

SEPC

KAYAN

Sahra- Maaden EDC

SABIC- SIPCHEM

The Sales Gas Ring

MODECOR JANA HASAD SODA GLASS FIBER GULF

GUARD

UGSCL

HAMRANI

LATEX

EPTECO

ASLAK SFCCL

JESCO TAYF

BILAD

Secondary Ring NAJI

INDIPCO

UNI COIL

ACICO

The Secondary Ring

JUPC

PETROKEMYA

Ethane Ring

SEPC KAYAN NCP SHARQ

SADAF KEMYA SABIC (ABS)

SIPCHEM Integrated

The Ethane Ring

FT High FT Low PT TT

Flow Meter

FCV (A)

FCV (B)

Isolation Valve

SAUDI ARAMCO CUSTOMER

Flow Computer Bldg.

Central Dispatch System

Typical Metering Station

Duties and Responsibilities

• General Requirements

• Measurements Operations

• Metering Skids Maintenance

• Customers Issues


• General Requirements

– Operate and Maintain Safely and Reliably

– Conduct Regular Audits

– Revalidate Lateral Lines

– Replace Obsolete Equipment



– Collect Regular Gas/Crude Oil Samples and Send to LAB

– Conduct Periodical Proving on Royalty Crude Oil System



– Enter BTU, API, S&W Values to Generate Delivery Tickets

– Collecting The Daily Delivery Tickets on Weekly Basis

– Generate Monthly Gas Consumption for Billing


• Metering Skids Maintenance

– Instruments Calibrations

– Meter Inspection / Diagnosis

– Checking Flow Calculations

– Perform Software Back up

– Stroking the Main Valve Yearly


• Customers Issues

– Measurement Discrepancies

– Operational Mode changes

– Expansion or Demolition

– New Projects

Challenges

• Continuously Improve Gas Measurement Accuracy In Order to Reduce Uncertainty

Challenges

• Cope with Continuous Growth

– Flexibility

– Adaptability

30

40

50

60

70

80

90

20

03

20

04

20

05

20

06

20

07

20

08

20

09

20

10

20

11

“No. of Metering Stations"

Challenges

• Special Logistics Requirements

– Scattered and Restricted Metering Skids

Challenges

• Meeting Company and Customers’ Demands

– Continuously Improve Efficiency of Processes

– Maintain Optimum Accuracy and Reliability


• Deploy Advanced Technologies

• Automate Manual Activities

• Continue to Perform Regular Audits by Third Party to Raise Confidence Level

Optimization Tools

• Build up Metering Skills and Competencies

• Enhance Planning and Coordination with Customers

Summary

• System Overview

• Our Customers

• Duties and Responsibilities

• Challenges

• Potential Improvement Methods

Thank you

Areas for Improvement in Hydrocarbon Liquid Metering Systems

Dr Mohammed Salim

Saudi Aramco

1


"Any fool can make things bigger, more complex and more violent. It takes a touch of genius - and a lot of

courage - to move in the opposite direction." Albert Einstein, scientist

Partnering for results

2

• Presenting the simplest view of hydrocarbon liquid metering systems

Presentation overview

• Metering system field components

• Metering Control System Architecture

• System components

• Communication

• Intelligence

• Testing

• Training and certification

• Summary

3

Metering system field components

4

Inlet Outlet


5


• Impacts measurement!

• Major field problem component

• Is there no other way?

6


• Valves limit switches

• Automatic integrity test on double block and bleed valves

• Wiring between field and control room

7


• Labor intensive and tedious

• Can we not improve?

8

MSC A MSC B

NETWORK

FC A FC B PLC

Metering control system architecture

9

Metering control system – flow computer

• Is technology simplifying this critical component?

• Are configuration/programming tools making it simple to use?

• Remote I/Os?

• All skid valves for meters it can handle?

10

Metering control system – PLC

• Simple valve control and interlocks

• Failure modes

• How to reduce wiring between field and control room

11

Metering control system – supervisory computer

Operating system

Communication

Application • No major problems • Major concern

• Key areas

– Integration – Redundancy – Reports – Alarms – Documentations – Testing – Training & certification

• Intelligence

12

Metering control system – integration

• Experience in custody transfer measurement process

• Minimum number of software modules to design system

• Standard off-the-shelf SCADA vs in-house packages

• Proprietary vs open source code

13

Metering control system – redundancy

• SCADA off-the-shelf vs programmed

• Data synchronization in redundant systems

• Failure modes and recovery

14

Metering control system – reports

• Reports synchronization in a redundant system

• Archiving for ease of reviewing

• Historical reports archive management

15

Metering control system – alarms

• Improve alarm segregation e.g. system, process and measurement

• Listing all alarms in provided documentation

• system wide acknowledgment

16

Metering control system – documentation

• Documentation should help in removing ‘black box’ concept

• All documentations should be available online on MSC

• One detailed document providing A-Z on re-building system from scratch

17

Metering control system – testing

• Remote I/Os will resolve wiring issues on skid and control panel at FAT

• All FAT tests should be at maximum design

• The FAT documents must demonstrate all design requirements

18

Metering control system – training & certification

• Do we have certification programs?

• Technician training

• Engineer training

19

Metering control system – intelligence

• Reducing data monitoring updates

• Measurement system performance tracking

• Meter history and performance tracking

• Prover history and performance tracking

20

Metering control system – communication

• Failure and recovery modes

• Standard platform for approved SCADA packages

• Intelligent data monitoring

• In-Built redundancy

21

Summary

• Highlighted areas for improvements

- Metering system field components

- Metering control system architecture

- Components

- Communication

- Intelligence

- Testing

- Training and certification

22

Thank you for listening

Any Questions?

23

An Integral Approach To

Custody Transfer Data Management

Han van Dal

Spirit Innovative Technologies

Statement

With respect to Custody Transfer Data the current generation of Metering Control Systems is

• dumb

• inaccurate

• time-consuming

Contents

• What is Custody Transfer Data?

• What can be improved?

• Mismeasurement management

• Relation to system uncertainty

• Case study

• Conclusions

Custody Transfer Data

API MPMS 21.1 (Gas) & 21.2 (Liquid)

• Quantity Transaction Records

• Configuration Logs

• HW & SW Versions

• Event Logs

• Field Test Reports

• Corrections with their reason

Why?

To verify correctness of data

To allow for correction of failures

Old situation

Custody Transfer Data = Set of printouts

Current situation

Custody Transfer Data = Set of electronic files

What can be improved?

Metering Control Systems are made for:

• Daily operation

… and not for:

• Technicians

• Metering specialists

• Auditors

• Accounting staff

Purpose #1: Correctness of data

• Are all settings correct?

• Any changes in settings, SW or HW?

• Calibrations performed in time?

• Any maintenance applied?

• Have measurement failures occurred?

• Have tickets been corrected?

• If so, how and why?

Purpose #2: Correction of failures

• How big is the error (financial value)?

• Is correction worth the trouble?

• What is the best guess for the failed input?

• How to accurately recalculate the ticket?

• How to convince the Buyer?

What else can be improved?

• Is the overall system accuracy within spec?

• Why wasn’t the frozen value detected earlier?

• How is my meter doing?

• Is any transmitter drifting?

• What’s the density of water in all flowcomps?

Integral CT Data Management

• Relational data (meter tickets & audit trail)

• IT (data storage, cyber-security, integrity)

• Configuration management (FC, EFM)

• Mismeasurement management

– Detection

– Overview

– Correction

Mismeasurement detection

• Flow computer alarms

But also:

• Flow meter diagnostics

• Smart transmitter diagnostics

• QMI diagnostics

• On-line data validation

• On-line logical checks

• Control Charts

• CUSUM Charts

-1.5

-1

-0.5

0

0.5

1

1.5

Mismeasurement overview

CT data trend

Historical Meter Ticket Overview .. with

Financial Correction

Measurement Alarms

Measurement Events

Mismeasurement correction

• Best guess for failed input?

• What was the correct setting?

• How to recalculate the ticket?

• How to convince the buyer?

System uncertainty

• Metering equipment

• Proving

• Sampling

• Laboratory analysis

• Flow computers

• Meter ticket recalculation – API MPMS 12.2

– Proving (Meter factor)

– Sampling (density, BS&W)

• Meter ticket correction – Equipment failures

– Faulty data entries

– Failed field calibrations

Meter Ticket Recalculation

1. BATCH NUMBER 050511

2. TYPE OF LIQUID NG

3. METER CLOSING READING (DATE/TIME) 05/06/11 00:00

4. METER OPENING READING (DATE/TIME) 05/05/11 00:00

5. NET DELIVERY TIME 24.001 hours

6. METER CLOSING READING 23208593 bbl

7. METER OPENING READING 23167330 bbl

8. INDICATED VOLUME 41263 bbl

9. AVERAGE FLOW RATE 1705.4 bbl/h

10. GROSS VOLUME 41258.87 bbl

11. AVERAGE METER FACTOR 1.0001

12. OBSERVED RELATIVE DENSITY 0.0000 M

13. OBSERVED TEMPERATURE 0.0 °F M

14. RELATIVE DENSITY AT 60°F 0.6646

15. WEIGHTED AVERAGE TEMPERATURE 94.4 °F

16. TEMPERATURE CORRECTION FACTOR (CTLm) 0.9732

17. WEIGHTED AVERAGE PRESSURE 317.6 psig

18. PRESSURE CORRECTION FACTOR (CPLm) 1.0044

19. COMBINED CORRECTION FACTOR (CCFm) 0.9775

20. NET STD VOL AT 60°F & 14.696 psia (0 psig) 40355.30 bbls

21. NET STD VOL AT 15°C & 101.325 kPa (0 kPa (ga)) 6410.843 m3

22. NET WEIGHT 4185.52 long tons

22. NET WEIGHT 4252.70 metric tons


Up to 0.01% difference at stable conditions

100000 bbl

65 API60

75 ᵒF

195 psi

GSV 99180 bbl

100000 bbl

65 API60

76 ᵒF

205 psi

GSV 99120 bbl

API MPMS 12.2

200000 bbl

65 API60

75.5 ᵒF

200 psi

GSV 198320 bbl


Significant difference at highly fluctuating conditions

For example

Flow computer

GSV = 37942 bbl

API MPMS 12.2

GSV = 37978 bbl

Up to 0.10%


1. METER CLOSING READING (DATE/TIME) 05/06/11 00:00

2. METER OPENING READING (DATE/TIME) 05/05/11 00:00

3. NET DELIVERY TIME 24.001 hours

6. METER CLOSING READING 23388.593 MMSCF

7. METER OPENING READING 23167.330 MMSCF

8. TOTAL VOLUME 221.263 MMSCF

11. AVERAGE FLOW RATE 221.012 MMSCFD

12. AVERAGE DIFF PRESSURE 23.12 inch WC

13. AVERAGE TEMPERATURE 113.3 °F

17. AVERAGE STATIC PRESSURE 1317.6 psig

18. AVERAGE DENSITY 6.45 lb/SCF

Inaccurate for

• Gas

• dP flow meters

• q ≈ √(dP x P) FWA dP is useless

Meter Ticket Correction

• Case : Temperature fails for 35 minutes

• What is the additional uncertainty of the different correction methods for liquid and gas ?


• Basic conventional correction method

• Optimal conventional correction method


• New API MPMS Ch21 based correction method

* Patent pending *


Relative to corrected quantity that would have been calculated at 1 sec resolution

Correction Liquid

Turbine

Steady

Liquid

Turbine

Fluctuating

Gas

Orifice

FWA dP

Gas

Orifice

TWA √dPxP

Basic correction 0.06% 0.83% 3.22% 0.30%

Optimal correction 0.02% 0.14% 3.22% 0.22%

API 21 based cor. 0.00% 0.00% 0.00% 0.00%

Conclusions

• Accurate correction is currently NOT possible for many applications

• New API 21 method is accurate for all meter types, liquid and gas

• Automation of Mismeasurement Management

– makes systems smart

– saves time and resources

– avoids disputes with buyer

dumb smart

inaccurate accurate

time-consuming time-saving

Smart, accurate and highly automated Metering Control Systems

to achieve comprehensive and integral

Custody Transfer Data Management

THANK YOU FOR YOUR ATTENTION

CMTEM2011 Presentations

Documents

Transcript of CMTEM2011 Presentations