SUBSEA MULTIPATH ULTRASONIC LIQUID FLOW METER · PDF filePer Lunde, CMR, Dept. of Industrial...

Per Lunde, CMR, Dept. of Industrial Instrumentating / Gas Metering - 01.04.03

SUBSEA MULTIPATH ULTRASONICLIQUID FLOW METER

Status per March 2003

(NFR project no. 137730 / 211)

Per LundeChristian Michelsen Research AS (CMR)

Bergen

Programseminar for Norges forskningsråds Olje- og gass - program,Statoil Forus, Stavanger, April 3-4, 2003


Contents

• Basis & Background

• Project description

• Selected examples from the project development work

• Preliminary flow testing results (Phase 2A)

• Related CMR projects and developments

• Economic & social benefits, synergy effects


CMR work approach within instrumentation

• “Transfer of basic research to industrial applications”:� Development of advanced measurement methods and

instrumentation for industry and society� Contribute to get R&D results into the market, for use e.g. in

the oil & gas industry• Characterised by extensive international competition and

cooperation

• Close cooperation with the University of Bergen (UoB):� Education (external supervising of Dr. Scient / Cand. Scient)� Project cooperation� Ultrasonic instrumentation (18 years of cooperation)

• Close cooperation with industry & national institutions


CMR ultrasonic flow metering developmentsInstrument (examples) Manufacturer

•••• UCM-2 ocean current flow meter Simrad•••• FGM 130 flare gas flow meter Roxar Flow Measurement

•••• MPU 1200 fiscal gas flow meter FMC Kongsberg Metering• Ultrasonic fiscal oil flow meter FMC Smith Meter / (prototype) FMC Kongsberg Metering

•••• SAM 400 sand detector Roxar Flow Measurement


• More than 25 years of continuous and systematic R&D forindustry in this area, in particular oil & gas industry

CMR background within ultrasonic flow metering

• Competitive at an international level:� Signifiant projects have been won in Norway and abroad, ininternational competition

• The group posesses competence and technological skillof importance for:

� Development of new measurement methods, products andtechnology for Norwegian industry

• Example: “Subsea multipath ultrasonic liquid flow meter”


Project background

• North Sea: Focus change, from topside to subseaproduction:

�Platformless field developments�Satelite fields�Subsea processing / separation

• Calls for new measurement technologies:�Process monitoring

– Separators�Flow metering (at separator outlet)

– Oil– Wet gas

Addressed here


Technological Breakthrough -Developments of Tomorrow

Illustrasjon: ABB

PLATFORMLESSFIELDDEVELOPMENT

PLATFORMLESSFIELDDEVELOPMENT

Power Supply

Wellstream transfer > 200 km

Separation of Water in Oil

Wet Gas Compression


• Competitive alternative to conventional flow meteringtechnology (Orifice, Turbine, PD-meters)

Ultrasonic fiscal flow meters (USM,oil & gas)

• Operational advantages�Non-intrusive (no flow obstruction)�No pressure loss�No moving parts�Large measurement range (turn-down ratio)�Potentials of non-wetted measurement, pigging, etc.�Potentials of remote operation

• New measurement possibilities / additional information

• Capabilities to meet national regulation requirements (NPD,AGA, API)

• Standardization started (ISO, API)


Project description


Subsea multipath ultrasonic liquid flow meter• Objective: Develop prototype ultrasonic multipath transit

time flow meter, for precision measurement of oil andpetroleum products:

�Topside�Subsea

• Duration: 2000-2003

• Budget: 12.5 MNOK, NFR: 3.1 MNOK

• Partners:�CMR�FMC Kongsberg Metering (Kongsberg, Norway)�FMC Smith Meter (Erie, USA)�Research Council of Norway


Applications• Topside oil metering:

�Custody transfer, sales metering:• Pipeline transport• Ship and truck loading

�Leak detection�Technology: Turbine, PD (traditional), Ultrasonic (new)

• Subsea oil metering:�Allocation metering�Separator monitoring�New and improved cost-efficient technology maycontribute to improved recovery:

• Development of small fields• Tail production of old fields


Challenges• Topside oil metering:

�Very high accuracy requirements (custody transfer):• Repeatability: ±±±± 0.05 % (API)• Linearity: ±±±± (0.15 – 0.25) % of m.v.

�Crude oil ↔↔↔↔ Refined products

• Subsea oil metering:�No possibility of regular flow calibration (proving)�Drift, Lifetime, Robustness, Reliability�Minimum of maintenance possible�Crude oil (containing gas, water, particles)


Planned project outcomes• Phase 2A:

�8” industrial prototype Liquid USM�Topside, Custody transfer, Light oil (Re > 20000)�Accuracy:

• Repeatability: ±±±± 0.05 % (API)• Linearity: ±±±± (0.15 – 0.25) % of m.v.

• Phase 2B and 3:�Same as above, for Crude & Light oil (Re > 3000)� Influence of Gas bubbles, Water-in-oil, Solid particles, Wax

• Phase 4:�Prototype subsea Liquid USM


Signalgenerator

Receivingcables &electronics

Transmittingcables &electronics

Pulsedetection

Transmittingtransducer

TOP VIEW FRONT VIEW

Receivingtransducer

2Ryi

z

xL pi

φi

Liquid USM principles



Signalgenerator



Pulsedetection


TOP VIEW FRONT VIEW

Receivingtransducer

2Ryi

z

xL pi

φi

A single path in a USM:(ex.: downstream propagation)



Signalgenerator



Pulsedetection


TOP VIEW FRONT VIEW

Receivingtransducer

2Ryi

z

xL pi

φi

�=

−−≈

N

i iii

iiii tt

ttyRwRQ

1 21

2122

2

|2sin|)(

7200φ

π

A single path in a USM:(ex.: downstream propagation)

Volumetric flow ratemeasurement:

[m3/h]


A few selected examples from the

project development


Key tasks• Sensitivity analysis / Component work specifications

• Transducer technology

• Flow profiles / Acoustic path configuration /Integration method

• Electronics and precision time detection

• Meter body

• Signal processing

• Sound attenuation

• System integration & functional testing

• Flow testing

Addressed here

Addressed here


Metal encapsulated transducers


Receivingtransducer

L pi

φi

High pressuresWide temperature rangeBroadbandRobustness

• Finite-element modelling (FEMP):- Piezoelectric transducers

- Developed in a cooperation between

the University of Bergen and CMR




Receivingtransducer

L pi

φi

•••• Characterization measurements

High pressuresWide temperature rangeBroadbandRobustness




Receivingtransducer

L pi

φi

•••• Characterization measurements

•••• Finite-element modelling (FEMP)

High pressuresWide temperature rangeBroadbandRobustness Frequency

-100

-90

-80

-70

-60

-50

-40

Hvv

[d

B re

1V/

V - 1

m]

FEMPMeasurement, 273738t02, Corrections: El.Term. & DiffractionMeasurement, 273738t07, Corrections: El.Term. & DiffractionMeasurement, 273738t09, Corrections: El.Term. & DiffractionMeasurement, 273738t11, Corrections: El.Term. & Diffraction

FEMP modelling

Measurements

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

Con

duct

ance

[mS]

FEMP, 2715 (no Peek)Measurement, 27374a01Measurement, 27384a01Measurement, 27424a01Measurement, 27434a01Measurement, 27444a01

Measurements

FEMPmodelling

Electrical

Acoustical


Flow profiles & USM integration method

Ref.: GERG Technical Monograph 11 (2000)

•••• Axial flow profiles

•••• Transversal flow profiles(swirl, cross-flow, etc.)


USM integration method – Straight pipeReynolds number dependency

(Flow profile measurements & CFD + GARUSO calculations)Example: 4-path USM, “asymmetric criss-cross”, Gauss-Jacobi integration

Oil meteringGas metering

-1

-0.75

-0.5

-0.25

0

0.25

0.5

0.75

1

1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08Reynolds number

Dev

iatio

n fr

om re

fere

nce

(%)

LAMINAR FLOW TURBULENT FLOW

CFD - calculated profile

Power law profile

Parabolic profile

Measured profiles


USM integration method – Bend effectsMeter orientation effects (CFD + GARUSO calculations)

Examples: 12” USM, 4 paths / 4 chords, “Asymmetric criss-cross”, Gauss-Jacobi integration 12” USM, 8 paths / 4 chords, “Criss-cross configuration”

Bend in-flow profiles:•••• Axial: Power-law•••• Transversal: None

Axial flow(asymmetric)

Transversalswirl

-2

-1.5

-1

-0.5

0

0.5

1

1.5

2

0 45 90 135 180 225 270 315 360Orientation of meter (degrees)

Dev

iatio

n fr

om re

fere

nce

(%)

4-path meter

8-path meter

USM 10D downstream

Double 90o bendout-of-plane


In-house facilities (examples)

•••• Mechanical workshop (Prototech AS, subsidiary)

•••• Advanced computer modelling tools

Flow rig facilities

Shock & vibration testing

Pressure chambers (200 bar) HPHT testing (1000 bar, 200 oC)


Preliminary flow testing results,

Phase 2A


8” prototype Liquid USM under test CMR (Bergen) & FMC (USA), January-March 2003

•••• Repeatability

•••• Linearity

•••• Reproducibility

•••• Influence of flow profiles

•••• ------ ” ------ flow conditioners

•••• ------ ” ------ fluid viscosity


Flow testing results

Confidential, excluded

from handouts


Open (non-classified) publications

• Papers at national / international conferences: 10

• Papers in refereed journals (international): 2

• Other publications (books): 2

Period: 2000 – April 2003Technology related to ultrasonic flow metering of oil and gasProject reporting excluded


Examples of related CMR projects

Benefits & Synergy effects


Current CMR ultrasonic flow metering projectsProjects (examples)•••• Clamp-on separator level monitoring (UID):

- Topside & Subsea

•••• Wet gas liquid film profiler (2001-03):- Topside & Subsea

•••• Zero flare gas metering (2003-05)

•••• SIP - Ultrasonic technology for improved exploitation of petroleum resources (2003-06):

- Mass measurement of gas and oil- Energy measurement of gas- Flow & concentration metering H2 and CO2- HPHT Transducer technology- Non-wetted flow metering technology- Subsea flow metering- 2 Dr. scient fellowships

PartnersCMR, Hydro, Statoil,NFR

CMR, NFR, Statoil,ConocoPhillips

Roxar FM, CMR, Statoil,ABB Gas Tech., NFR

CMR, Oil companies,NFR


Economic and social benefits• Measurement technology: increasingly important role for cost-effective

exploitation of petroleum resources

• Consequences for Norway and operators; Far beyond themeasurement technology itself:

� Determines economic value of oil and gas production� Contributes to optimize processing and production� Influences on degree of oil recovery (small fields, tail production)

• Ultrasonics: increasingly important (topside, subsea, downhole)� Substantial and rapid development internationally� Strengthening of Norwegian competence on modern metering technology

• Norwegian manufacturing industry:� Strengthening of competiveness and innovating effort� Position Norway as a deliverer in this considerable market� Synergy effects to existing and new products:

- FMC Kongsberg Metering MPU 1200, MPU 600, MPU 200- Roxar Flow Measurement FGM 130, etc.

• Education of candidates for Norwegian industry


• Natural gas: - Custody transfer - Allocation - Check metering - Flare gas - Wet gas

• Liquids: - Oil - Water

• Hydrogen

• CO2

• Steam

• Emissionmonitoring

Ultrasonic flowmetering

Generic synergy effects (examples)Process acousticinstrumentation

Downhole acousticinstrumentation

Marine acoustics

• Separatormonitoring:

- Topside - Subsea

• Wax / scaledetection

• Liquid filmmeasurement:

- Topside - Subsea

• Sandmonitoring:

- Topside - Subsea

• MWD

• Sonic logging

• Formationevaluation

• Borehole &pipelineinspection

• Productionlogging / flowmetering

• Cement bondlog

• Current profiling

• Sonar

• Echo sounders /fishery acoustics

• Environmentalmonitoring (ice)

• Acousticpositioning

• Acousticcommunication

• Sea bedmapping


Acknowledgements

• CMR project team: Per Lunde, Reidar Bø, Kjell-Eivind Frøysa,Remi Kippersund, Stig Heggstad, Rune Fardal, Morten I.Andersen, Øyvind Nesse

• University of Bergen, Dept. of Physics (Hydroacousticsgroup): Magne Vestrheim, Jan M. Kocbach

• FMC Kongsberg Metering: Skule Smørgrav, Morten Marstein,Atle Abrahamsen

• FMC Smith Meter Inc. (USA): Ray Kalivoda, Jim Breter, DaveResch, Bob Smith

• Research Council of Norway (NFR)


Open (non-classified) publications on Ultrasonic flow metering technology, 2000-2003 (1)

• Lunde, P., Frøysa, K.-E. and Vestrheim, M.: “Challenges for improved accuracy and traceability in ultrasonic fiscal flow metering of natural gas”.In: Proc. of 23rd Scandinavian Symposium on Physical Acoustics, Ustaoset, Norway, 30 January – 2 February, 2000.. Ed.: U. R. Kristiansen,Scientific/Technical Report No. 420003, Norwegian University of Science and Technology, Dept. of Telecommunications, Acoustics, Trondheim (May2000), pp. 19-21 (ISSN 1501-6773).

• Kocbach, J. M., Lunde, P. and Vestrheim, M.: “Finite element modeling of piezoceramic disks including radiation into a fluid medium”. In: Proc. of23rd Scandinavian Symposium on Physical Acoustics, Ustaoset, Norway, 30 January – 2 February, 2000.. Ed.: U. R. Kristiansen, Scientific/TechnicalReport No. 420003, Norwegian University of Science and Technology, Dept. of Telecommunications, Acoustics, Trondheim (May 2000), pp. 43-46(ISSN 1501-6773).

• Lunde, P., Frøysa, K.-E. and Vestrheim, M.: “Challenges for improved accuracy and traceability in ultrasonic fiscal flow metering”, Proc. of the 18th

North Sea Flow Measurement Workshop, Perthshire, Scotland, 24-27 October 2000.

• Lunde, P., Frøysa, K.-E. and Vestrheim, M. (eds.): “GERG project on ultrasonic gas flow meters, Phase II”, GERG Technical Monograph TM112000, Groupe Européen de Recherches Gazières (VDI Verlag, Düsseldorf, 2000). (ISBN 3-18-385408-2)

• Kocbach, J. M., Lunde, P. and Vestrheim, M.: "Tables of resonance frequencies for disks of PZT-5A, PZT-5H, Pb(ZrTi)O3 and PbTiO3",Scientific/Technical Report No. 2000-07, University of Bergen, Department of Physics (December 2000).

• Frøysa, K.-E. and Lunde, P.: “A ray theory approach to investigate the influence of flow velocity profiles on transit times in ultrasonic flow meters forgas and liquid”. In: Proc. of 24th Scandinavian Symposium on Physical Acoustics, Ustaoset, Norway, 28-31 January 2001. Ed.: U. R. Kristiansen,Scientific/Technical Report No. 420103, Norwegian University of Science and Technology, Dept. of Telecommunications, Acoustics, Trondheim (June2001), pp. 82-97.

• Baker, A.C., Frøysa, K.-E., Furset, H. and Lunde, P.: “Ultrasonic scattering from liquid droplets in wet gas”. In: Proc. of 24th ScandinavianSymposium on Physical Acoustics, Ustaoset, Norway, 28-31 January 2001. Ed.: U. R. Kristiansen, Scientific/Technical Report No. 420103, NorwegianUniversity of Science and Technology, Dept. of Telecommunications, Acoustics, Trondheim (June 2001), pp. 48-49.

• Kocbach, J. M., Lunde, P. and Vestrheim, M.: “Resonance frequency spectra with convergence tests for piezoceramic disks using the finite elementmethod”, Acustica, 87(2), 271-285 (March/April 2001).


Open (non-classified) publications on Ultrasonic flow metering technology, 2000-2003 (2)

• Hallanger, A., Frøysa, K.-E. and Lunde, P.: “CFD simulation and installation effects for ultrasonic flow meters in pipes with bends”, In: Proc. ofMekIT’01, First National Conference on Computational Mechanics, Trondheim 3-4 May 2001. Eds.: Skallerud, B. and Andersson, A.I. (TapirAkademisk Forlag, Trondheim, Norway, 2001), pp. 147-167.

• Frøysa, K.-E., Lunde, P. and Vestrheim, M.: "A ray theory approach to investigate the influence of flow velocity profiles on transit times inultrasonic flow meters for gas and liquid", Proc. of the 19th North Sea Flow Measurement Workshop, Kristiansand, Norway, 22-25 October 2001.

• Lunde, P. and Frøysa, K.-E.: "Handbook of uncertainty calculations. Ultrasonic fiscal gas metering stations". Handbook prepared on behalf of theNorwegian Society for Oil and Gas Measurement (NFOGM) and the Norwegian Petroleum Directorate (NPD). ISBN 82-566-1009-3 (December 2001).

• Lunde, P. and Frøysa, K.-E.: “Mass and energy measurement of gas using ultrasonic flow meters”. In: Proc. of the 25th Scandinavian Symposium onPhysical Acoustics, Ustaoset, Norway, 27-30 January 2002. Ed.: U. R. Kristiansen, Scientific/Technical Report No. 420103, Norwegian University ofScience and Technology, Dept. of Telecommunications, Acoustics, Trondheim (June 2002). (CD issue, ISSN 1501-6773).

• Hallanger, A., Frøysa, K.-E. and Lunde, P.: “CFD simulation and installation effects for ultrasonic flow meters in pipes with bends”, InternationalJournal of Applied Mechanics and Engineering, 7(1), 33-64 (2002).

• Lunde, P. and Frøysa, K.-E.: "Handbook of uncertainty calculations. Ultrasonic fiscal gas metering stations". Presented at NFOGMs Temadag,Scandic Hotel Bergen Airport, March 21, 2002, Norwegian Society for Oil and Gas Measurement (NFOGM).

• Lunde, P., Frøysa, K.-E., Neumann, S. and Halvorsen, E.: "Handbook of uncertainty calculations. Ultrasonic fiscal gas metering stations". Proc. ofthe 20th North Sea Flow Measurement Workshop, St. Andrews Bay, Scotland, 22-25 October 2002.

• Vestrheim, M., Lunde, P. and Fardal, R.: "Endelig element modellering av piezoelektriske transduser vibrasjoner". Presented at Norsk AkustiskSelskaps Høstmøte 2002, Bergen, Norway, 25-26 October 2002.

• Lunde, P., Frøysa, K.-E. and Vestrheim, M.: “Transient diffraction effects in ultrasonic flow meters for gas and liquid”. In: Proc. of 26th

Scandinavian Symposium on Physical Acoustics, Ustaoset, Norway, 26-29 January 2003. Ed.: U. R. Kristiansen, Scientific/Technical Report,Norwegian University of Science and Technology, Dept. of Telecommunications, Acoustics, Trondheim (2003). (Proceedings in preparation.)

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