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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
2. What is Standards Globalization?
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
3. Benefits of Globalization
Slide # 5
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
3. Benefits of Globalization
• Eliminate special requirements that may increase project costs
Slide # 5
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
3. Benefits of Globalization
• Eliminate special requirements that may increase project costs
• Increase the number of potential suppliers of material
Slide # 5
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
3. Benefits of Globalization
• Eliminate special requirements that may increase project costs
• Increase the number of potential suppliers of material
• Reduce manpower required to maintain company standards
Slide # 5
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
3. Benefits of Globalization
• Eliminate special requirements that may increase project costs
• Increase the number of potential suppliers of material
• Reduce manpower required to maintain company standards
• Help build local industry around international standards to better compete in the global market
Slide # 5
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
3. Benefits of Globalization
• Eliminate special requirements that may increase project costs
• Increase the number of potential suppliers of material
• Reduce manpower required to maintain company standards
• Help build local industry around international standards to better compete in the global market
• Develop cost estimates more economically.
Slide # 5
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
4. Saudi Aramco Engineering Standards Structure
Board of Engineers chaired by Engineering Services Chief Engineer bears the responsibility of the Saudi Aramco Engineering Standards and Specifications
Slide # 6
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
4. Saudi Aramco Engineering Standards Structure
Slide # 7
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
4. Saudi Aramco Engineering Standards Structure
More than 2300 standards; from which, more than 1200 are considered mandatory.
Slide # 7
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
4. Saudi Aramco Engineering Standards Structure
More than 2300 standards; from which, more than 1200 are considered mandatory.
37 standards committees with members of more than 500 people from 17 different organizations
Slide # 7
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
4. Saudi Aramco Engineering Standards Structure
More than 2300 standards; from which, more than 1200 are considered mandatory.
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
4. Saudi Aramco Engineering Standards Structure
Corporate management systems have been established to manage the review and approval process of the engineering standards.
Slide # 8
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
Standard Review Model
Slide # 9
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
5. Globalization Approach and Strategy
Slide # 10
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
5. Globalization Approach and Strategy
• 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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
5. Globalization Approach and Strategy
• 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.
• Performing Value Engineering studies for the engineering standards.
Slide # 10
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
5. Globalization Approach and Strategy
• 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.
• Performing Value Engineering studies for the engineering standards.
• Participating in International Standards Development
Slide # 10
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
Slide # 11
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
6. Custody Measurement Standards Globalization Initiative:
B. Development and Revision Process of Custody Measurement Engineering documents
Slide # 13
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
6. Custody Measurement Standards Globalization Initiative:
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
6. Custody Measurement Standards Globalization Initiative:
D. Value Engineering Studies:
Three value engineering studies were performed on most important measurement documents.
Slide # 14
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
6. Custody Measurement Standards Globalization Initiative:
D. Value Engineering Studies:(Cont.’ed)
Two value engineering studies are planned to be performed
Slide # 16
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
6. Custody Measurement Standards Globalization Initiative:
E. Participation in the International Standards Organizations:
American Petroleum Institute (API) Petroleum Measurement subcommittees
(COGFM, COMA, COLM & COMQ)
Slide # 18
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
6. Custody Measurement Standards Globalization Initiative:
E. Participation in the International Standards Organizations:
American Society for Testing and Materials (ASTM)
Committee D02 on Petroleum Products and Lubricants
Slide # 19
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
6. Custody Measurement Standards Globalization Initiative:
E. Participation in the International Standards Organizations:
• 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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
6. Custody Measurement Standards Globalization Initiative:
E. Participation in the International Standards Organizations:
• American Gas Association (AGA)
CMU participates in AGA activities by reviewing the reports developed in the field of gas measurement.
Slide # 21
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
7. Challenges:
Slide # 22
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
7. Challenges:
a) Implementation process of the initiative differs from one discipline to another.
Slide # 22
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
7. Challenges:
a) Implementation process of the initiative differs from one discipline to another.
b) Involvement of the Subject Matter Experts in the increasing day-to-day activities.
Slide # 22
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
7. Challenges:
a) Implementation process of the initiative differs from one discipline to another.
b) Involvement of the Subject Matter Experts in the increasing day-to-day activities.
c) Standards Cross Referencing
Slide # 22
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
7. Challenges:
a) Implementation process of the initiative differs from one discipline to another.
b) Involvement of the Subject Matter Experts in the increasing day-to-day activities.
c) Standards Cross Referencing
d) Shortages in the local and international subject matter experts
Slide # 22
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
7. Challenges: (Cont’ed)
e) Geographical diversity do not permit attending International standards organizations working group meetings
Slide # 23
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
7. Challenges: (Cont’ed)
e) Geographical diversity do not permit attending International standards organizations working group meetings
f) Long time for developing and approving the reference standard document
Slide # 23
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
7. Challenges: (Cont’ed)
e) Geographical diversity do not permit attending International standards organizations working group meetings
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
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
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
Summary:
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. Conclusion
9. Recommendations
CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________
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
Optimization Methods
3- Continuously Improve Workforce Skills and
Competencies
Optimization Methods
Optimization Methods
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
© Copyright 2011, Saudi Aramco. All rights reserved.
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
Duties and Responsibilities
• General Requirements
– Operate and Maintain Safely and Reliably
– Conduct Regular Audits
– Revalidate Lateral Lines
– Replace Obsolete Equipment
Duties and Responsibilities
• Measurements Operations
– Collect Regular Gas/Crude Oil Samples and Send to LAB
– Conduct Periodical Proving on Royalty Crude Oil System
Duties and Responsibilities
• Measurements Operations
– Enter BTU, API, S&W Values to Generate Delivery Tickets
– Collecting The Daily Delivery Tickets on Weekly Basis
– Generate Monthly Gas Consumption for Billing
Duties and Responsibilities
• Metering Skids Maintenance
– Instruments Calibrations
– Meter Inspection / Diagnosis
– Checking Flow Calculations
– Perform Software Back up
– Stroking the Main Valve Yearly
Duties and Responsibilities
• 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
Optimization Methods
• 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
© Copyright 2011, Saudi Aramco. All rights reserved.
"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
Metering system field components
5
Metering system field components
• Impacts measurement!
• Major field problem component
• Is there no other way?
6
Metering system field components
• Valves limit switches
• Automatic integrity test on double block and bleed valves
• Wiring between field and control room
7
Metering system field components
• 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
Meter Ticket Recalculation
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
Meter Ticket Recalculation
Significant difference at highly fluctuating conditions
For example
Flow computer
GSV = 37942 bbl
API MPMS 12.2
GSV = 37978 bbl
Up to 0.10%
Meter Ticket Recalculation
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 ?
Meter Ticket Correction
• Basic conventional correction method
• Optimal conventional correction method
Meter Ticket Correction
• New API MPMS Ch21 based correction method
* Patent pending *
Meter Ticket Correction
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
Top Related