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The document discusses maintaining measurement accuracy from design through operation of custody transfer systems.

Some applications discussed include pipeline terminals, export terminals, import terminals, and floating production storage vessels.

Design objectives discussed include accuracy, safety, reliability, low ongoing costs, and value.

Technical Proceedings-

Presentations
6 CUSTODY MEASUREMENT TECHNICAL EXCHANGE MEETING (CMTEM 2011)
TH

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 INSTRUMENTSFOR 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

st Duration: 5 years plus 5 x 1 year options Original Scope

Case Study - Metering Maintenance Contract Overview Start Date: 1 October 2004
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)

26

Contract Framework
Program Management

Administration

Planning and Operations

Consultancy and Engineering

Purchasing Work registration Invoicing Payment problems resolution Subcontract management Monthly commercial reporting Monthly forecasting

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

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

27

Contract Personnel
Total of 65 people:
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

28

Equipment Supported
SCOPE OF EQUIPMENT SUPPORTED FLOW COMPUTERS: S500S, S600S, MICRO 5000S, 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

PERFORMANCE MANAGEMENT: KPIs

HSE
Behavioural Performance

Innovations
Savings

31

CONTRACT BENEFITS: MANAGEMENT SYSTEMS

32

CONTRACT BENEFITS: MANAGEMENT SYSTEMS

33

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

34

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

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

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? (Conted)

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. SAES-Y-101

Document Title

Date

No. of VE
Proposals 14

No. of VE Recommend -ations 30

Estimated Cost Avoidance ($) 7,400,000

Custody Metering of Hydrocarbon Gases 5/9-13/2009

SAES-Y-103

Royalty/Custody Metering of Hydrocarbon Liquids

18

33

30,000,000

34-SAMSS-119 34-SAMSS-120 34-SAMSS-121 34-SAMSS-122

Bi-directional prover Uni-directional meter prover Small Volume Prover Atmospheric Portable Tank Prover 8/2-4/2010

4 4 2 0

19 6 33 9

816,200 816,200 880,000 0

34-SAMSS-112

Orifice Meter for Gas Custody Measurement 10/4-5/2011

TBD

34-SAMSS-114

Ultrasonic Flow Meter for Gas Custody Measurement

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. SAES-Y-501

Document Title Dynamic Sampling of Hydrocarbon Liquids for Royalty/Custody Transfers

Date

34-SAMSS-525 34-SAMSS-526

Automatic Sampling Systems for Crude Oil and Refined Products Automatic Sampling Systems for Hydrocarbon Gases

July 2012

34-SAMSS-841

Flow Computer for Custody Transfer Measurement of


Hydrocarbon Liquids

34-SAMSS-846

Flow Computers for Custody Transfer Measurement of Hydrocarbon Gases October 2013

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: (Conted)

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

Slide # 23

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

7. Challenges: (Conted)

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: (Conted)

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

Questions?

JISKOOTTM QUALITY SYSTEMS

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

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 Effects on density and OWD measurement

Maintaining system accuracy

EI HMC4 Measurement committee crude oil losses

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


$500,000,000 $450,000,000

$400,000,000

$350,000,000

$300,000,000

$250,000,000

Losses

$200,000,000

$150,000,000

$100,000,000

$50,000,000

$0 0.000% 0.040% 0.080% 0.120% 0.160% 0.200% 0.240%

Effect of quality measurement on overall accuracy??

Importance of 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
1 in 300,000,000,000

Sampling standards
34SAMSS 525 SAESY-501 ISO 3171 API 8.2 called by above 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


1.40%

In line sampling system with poor mixing


1.20%

in-line sampling system with compliant mixing Fast loop sampling system with compliant mixing

1.00%

Accuracy

0.80%

EFFECT OF POOR MIXING ON WATER CONTENT MEASUREMENT

0.60%

0.40%

0.20%

0.00% Number of water injection tests

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
Pipeline mixing LARGEST EFFECT ON ACCURACY Representative sampling of the batch Sample handling and mixing Laboratory analysis process Prove the system in accordance with standards

Step 1

Step 2

Step 3

Step 4

Step 5

Collecting a representative batch sample


Performance Criteria for Permanent Sampling System Installations
Grab factor Performance factor Flow sensor accuracy 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

Sample handling and mixing


Reduce the number of steps - Portable receivers reduce uncertainty
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

Confirm mixing performance v design parameters

Certified quality measurement system

Validate and ensure system reliability

Validate handling, laboratory process

Validate system performance

Summary
1. Design and specification 8. Revalidation and proving as required 2. Installation and commission

7. Confirm operating envelope same as design

Certified accuracy & reduced losses

3. Proving in accordance with standards

6. Validation of sampling and analysis process

5. Maintenance schedule

4. Batch certification of performance

So what does your quality measurement look like?

1973 OR - 2011?

Thank You Questions?


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
Ras Al KhairJubail Royal Commission Berri Power Plant consists of: The Master Gas System Jubail Royal Commission 1-KGP Major gas plant producers
Pressure : 300 1000 PSIG Flow : around 4.2 BSCFD in the Eastern Province

2- Complex pipelines Berri

Berri Junction

Temperature : 70 150 F BTU: 900 1280 network Wusta Desalination Plant

3Major junction sites BGP

Ghazlan Power Plant 1 & 2

Refinery and Fractionation Juaymah Junction 4- Low pressure distribution system

5- Metering skids Dammam/Khobar Area


Qatif Junction
SGP,UGP, HGP, HYGP

Azizyiah Desalination Plant

Dammam Industrial Plants

Importance of Gas Sampling


Flow Computer On-Line Analyzer

FT High

FT Low

PT

TT

FCV (A)

SAUDI ARAMCO

CUSTOMER

Class-I Valve

Orifice

FCV (B)

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

Composite Sampling

Is Not Based ON Real-time Value The Process Labor/Time Intensive Laboratory Dependent

LIMITATIONS

Online Analyzer

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

Challenges
3- Gas Composition Variations

Challenges
4- Enhance Coordination Efforts Amongst Involved Parties in Determining the BTU Value
Engineering Maintenance Operation

Laboratory

Challenges
5- Match BTU With That of Our Customers to Eliminate Potential Claims
Using different standards Using different measurement methods Involvement of different parties

Challenges
5- Special Maintenance Requirements
Periodical PM
Require Special Crew Supply Carrier & Calibration of Gas Secure Resources

Optimization Methods
1- Automate Gas Sampling Processes In Order to Reduce Manual Activities

Optimization Methods
2- Network Enhancement
Centralized Location

AIT

Gas Composition & other Data to F.C

BTU

BTU

Costumer A
Update MMBTU at Local Flow Computer

Costumer A

Sample line

Costumer C
Costumer B Costumer D

Sales Gas Header

Update MMBTU for selected flow computers at the costumers sites

Optimization Methods
3- Continuously Improve Workforce Skills and Competencies

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


November 21, 2011

Ahmad I. Al-Shaye Saudi Aramco NA Pipelines Department


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

Ras Al-Khair

Jubail

Ras Tanura

Dhahran

Our Customers
Sector
RC Primary Industries

# Metering Stations
42
20

Total #

Sales Gas & Ethane (Custody)

RC Secondary Industries Electricity &Water Desalination Others Refineries

77
10 5 2

Crude Oil (Royalty)

Petrochemicals

The Sales Gas Ring


KAYAN JUBAIL SECONDARY CHEMANOL ALRAZI NCP SCP SPC SIPCHEM SEPC INDUSTRIES 20 Customers HADEED

JUPC

APPC

Sales Gas Ring


WAHA

Zamil EAP KEMYA SHARQ

SahraTasnee SahraMaaden EDC SABICSIPCHEM

FARABI IBN SINA

SAMAD IBN AL BAYTAR SAFCO

PETROKEMYA

SASREF

SADAF

IBN ZAHR

The Secondary Ring


SODA GLASS FIBER GULF GUARD
MODECOR

JANA

HASAD

BILAD

NAJI

Secondary Ring

INDIPCO

HAMRANI

UNI COIL

SFCCL

ASLAK

LATEX

ACICO

UGSCL

TAYF

JESCO

EPTECO

The Ethane Ring


NCP SEPC JUPC KAYAN SHARQ

Ethane Ring

PETROKEMYA

SABIC (ABS)

SIPCHEM Integrated

KEMYA

SADAF

Typical Metering Station


Flow Computer Bldg.

Central Dispatch System

Isolation Valve SAUDI ARAMCO

FT High FT Low

PT

TT

FCV (A)

CUSTOMER

Flow Meter

FCV (B)

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
No. of Metering Stations"

Cope with Continuous Growth


Flexibility Adaptability

90

80
70 60 50 40

30 2005
2003 2004 2006 2007 2008 2009 2010 2011

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

Copyright 2011, Saudi Aramco. All rights reserved.

Partnering for results

"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

Presentation overview
Presenting the simplest view of hydrocarbon liquid metering systems Metering system field components

Metering Control System Architecture


System components Communication

Intelligence
Testing Training and certification Summary

Metering system field components

Inlet

Outlet

Metering system field components

Metering system field components

Major field problem component Impacts measurement! Is there no other way?

Metering system field components

Automatic integrity test on double block and bleed valves Valves limit switches Wiring between field and control room

Metering system field components

Labor intensive and tedious

Can we not improve?

Metering control system architecture


MSC B

MSC A

NETWORK

FC A

FC B

PLC

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

Intelligence

Key areas Integration Redundancy Reports Alarms Documentations Testing Training & certification No major problems

Major concern

Application Communication Operating system

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 The FAT documents must demonstrate all design requirements All FAT tests should be at maximum design

18

Metering control system training & certification

Technician training

Engineer training
Do we have certification programs?

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

Custody Transfer Data Management


Han van Dal Spirit Innovative Technologies

An Integral Approach To

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 wasnt the frozen value detected earlier? How is my meter doing? Is any transmitter drifting? Whats 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

0.5

-0.5

-1

-1.5

Mismeasurement overview
CT data trend

Measurement Alarms Historical Meter Ticket Overview .. with Financial Correction 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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 22. BATCH NUMBER TYPE OF LIQUID METER CLOSING READING (DATE/TIME) METER OPENING READING (DATE/TIME) NET DELIVERY TIME METER CLOSING READING METER OPENING READING INDICATED VOLUME AVERAGE FLOW RATE GROSS VOLUME AVERAGE METER FACTOR OBSERVED RELATIVE DENSITY OBSERVED TEMPERATURE RELATIVE DENSITY AT 60F WEIGHTED AVERAGE TEMPERATURE TEMPERATURE CORRECTION FACTOR (CTLm) WEIGHTED AVERAGE PRESSURE PRESSURE CORRECTION FACTOR (CPLm) COMBINED CORRECTION FACTOR (CCFm) NET STD VOL AT 60F & 14.696 psia (0 psig) NET STD VOL AT 15C & 101.325 kPa (0 kPa (ga)) NET WEIGHT NET WEIGHT 050511 NG 05/06/11 00:00 05/05/11 00:00 24.001 23208593 23167330 41263 1705.4 41258.87 1.0001 0.0000 0.0 0.6646 94.4 0.9732 317.6 1.0044 0.9775 40355.30 6410.843 4185.52 4252.70

hours bbl bbl bbl bbl/h bbl M M

F F psig

bbls m3 long tons metric tons

Meter Ticket Recalculation


100000 bbl 65 API60 76 F 205 psi GSV 99120 bbl

100000 bbl 65 API60 75 F 195 psi GSV 99180 bbl

Up to 0.01% difference at stable conditions


API MPMS 12.2 200000 bbl 65 API60 75.5 F 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. 2. 3. 6. 7. 8. 11. 12. 13. 17. 18. METER CLOSING READING (DATE/TIME) METER OPENING READING (DATE/TIME) NET DELIVERY TIME METER CLOSING READING METER OPENING READING TOTAL VOLUME AVERAGE FLOW RATE AVERAGE DIFF PRESSURE AVERAGE TEMPERATURE AVERAGE STATIC PRESSURE AVERAGE DENSITY 05/06/11 00:00 05/05/11 00:00 24.001 23388.593 23167.330 221.263 221.012 23.12 113.3 1317.6 6.45 hours MMSCF MMSCF MMSCF MMSCFD inch WC F psig 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


Correction
Liquid Turbine Steady
0.06%

Liquid Turbine Fluctuating


0.83%

Gas Orifice FWA dP


3.22%

Gas Orifice TWA dPxP


0.30%

Basic correction

Optimal correction
API 21 based cor.

0.02%
0.00%

0.14%
0.00%

3.22%
0.00%

0.22%
0.00%

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

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 inaccurate time-consuming smart accurate time-saving

Smart, accurate and highly automated


Metering Control Systems to achieve comprehensive and integral

Custody Transfer Data Management THANK YOU FOR YOUR ATTENTION

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