LIQUID MEASUREMENT STATION DESIGN

Class # 2230.1

Todd Meador
Application Engineer
Emerson
5650 Brittmoore Rd
Houston, Tx USA

Introduction
Liquid measurement stations are installed where petroleum products are transferred from seller to buyer under
terms outlined by a contract and/or government authorities. These terms dictate how the liquid will be measured,
and because money is changing hands and authorities are involved, the design of the station is crucial to ensure
the accuracy and quality of the measurement. This paper outlines design considerations and other factors that
should be considered when designing and constructing a measurement station for hydrocarbon liquids.
Applications
Liquid measurement stations are used in a variety of applications including crude oil, refined products, NGL, LNG,
and chemicals. Meter stations may be single meter runs or multiple meter runs. Meter stations may also include
a spare meter run that can be put into operation when another meter run is under maintenance. Liquid meter
stations can be built in the field where they will be installed, or built in a facility that specializes in measurement
stations. If the measurement station is built at a facility, it can be tested prior to shipment to ensure integration at
site is as seamless as possible.
Measurement stations can be found along a pipeline network, on offshore production platforms, Marine tanker
loading/offloading stations, and floating production storage and offloading (FPSO) vessels. Each of these
locations presents unique challenges when designing the measurement station, however, the main equipment
used for each remains essentially the same.
Measurement of petroleum products is typically done at or near ambient temperature and moderate pressures
less than 700 psi. Products such as LNG are done at very low, cryogenic temperatures, and other products such
as heavy, viscous crudes are heated to make transportation easier. Additionally, measurement stations located
closer to the well are likely to be at much higher pressures due to the condition encountered at the product at the
well head. These factors should all be considered when designing measurement stations.
Arrangement
A typical four (4) parallel meter run station is illustrated in Figure 1. The meters and other secondary devices are
selected based on careful consideration of various parameters including, but not limited to, flow rate, density,
viscosity, pressure, and temperature. When selected and installed correctly, these devices can achieve
measurement uncertainties of ±0.25% or better. The following equipment is typically considered when designing
a liquid measurement station.
Inlet Block Valves
Inlet Block valves are typically gate or ball valves installed at the inlet of each meter run. The purpose of these
valves is to isolate the individual meter runs for maintenance purposes. Inlet block valves typically do not need to
be double block and bleed type valves, and may or may not be automated.
Strainers
The purpose of the strainer is to protect the meter from foreign objects that could damage the meter internals.
Basket strainers are the most common type of strainer installed for metering applications. Basket strainers are
designed with over-sized vertical bodies with perforated removeable baskets installed to collect medium to large
contaminants in the flowing stream. Strainers are commonly supplied with differential pressure indicators,
switches or transmitters to alert an operator when the basket needs cleaning. Because strainers are typically
both the high and low point upstream of the meter, they are a suitable location to install high point vents and low
point drains. Additionally, the oversized body slows the fluid velocity down allowing air to break out of the fluid
and release through an air eliminator.

385
Meters
The flow meter is the primary measurement device and the most critical component of the liquid measurement
station. The proper meter must be carefully selected for each given application. Some of the variables that
influence meter selection include flow rate, turndown (ratio of max flow to min flow), viscosity and pressure drop.
Meters for custody transfer applications typically have a linearity (meter’s deviation from minimum flow rate
specification to maximum flow rate specification) of ±0.25% or better, and repeatability (meter’s ability to give the
same reading under the same conditions) of ±0.027% Uncertainty or better. In meter stations where the
operating flow rates exceed the meter’s turndown, multiple meters should be installed in parallel. There are four
common flow meters used in liquid measurement stations;
Turbine Meter – The turbine meter is an inference type meter that uses the flow to turn an internal turbine.
The speed of the rotation is directly proportional to the rate of flow through the meter. Turbine meters use
an electronic pick-up coil and preamplifier to output pulses that can be totalized. There are two types of
turbine meters used in liquid measurement systems; conventional rotor and helical rotor. Conventional
rotor turbine meters offer good linearity and repeatability on low viscosity fluids, and helical rotor turbine
meters offer good linearity and repeatability with much higher viscosity fluids. Turbine meters are offered
in very small sizes to very large sizes. Turbine meters are influenced by flow profile, so upstream flow
conditioning is required.
Positive Displacement Meter – The positive displacement meter utilizes an internal rotating chamber that
divides the flow into pre-determined volumetric sections. A gear train is used to convert the flow in the
meter to an external device. Transmitter are commonly mounted on the gear train to provide a pulse
output that can be totalized. Positive displacement meters offer good linearity and repeatability, and can
be used for low and high viscosities. Special clearances or trims may be required when using positive
displacement meters at very high and very low viscosities and temperatures. Positive Displacement
meters are not influenced by flow profile, and therefore do not require upstream flow conditioning.
Positive displacement meters also offer relatively low pressure drop at high flow rates.
Coriolis Meter – Coriolis meters utilize vibrating curved tubes with upstream and downstream magnetic
sensors. Under zero-flow conditions, both the upstream and downstream sensors vibrate in phase with
each other. When the liquid flow through the tubes, a Coriolis effect is created on the tubes causing a
phase shift. This phase shift is directly proportional to the mass flow rate. Coriolis meters offer good
linearity and repeatability with very large turndown and a wide range of viscosities. Coriolis meters can
be equipped with diagnostics to verify the meter’s operation between proving. Coriolis meters are not
influenced by flow profile, and therefore do not require upstream flow conditioning. Coriolis meter’s utilize
pulse sampling techniques, so special consideration must be taken when sizing your prover.
Ultrasonic Meter – Ultrasonic meters utilize multiple piezo-electric transducers to send ultrasonic signals
at an angle through the liquid. The difference in the transit time of the signal moving with the flow and
against the flow is directly proportional to the fluid velocity. Ultrasonic meters offer good linearity and
repeatability with low to moderate viscosities. Special considerations may be required at high viscosities.
Ultrasonic meters can be made in very large sizes for high flow applications. Coriolis meters are
influenced by flow profile, so upstream flow conditioning is required. Ultrasonic meters can be equipped
with diagnostics to verify the meters operation. Ultrasonic meters utilize pulse sampling techniques, so
special consideration must be taken when sizing your prover.
Pressure and Temperature Transmitters
Pressure and temperature transmitters are installed downstream of each meter as well as on the inlet and outlet
of the prover. The purpose of the pressure and temperature transmitter is to apply correction factors to correct for
the thermal expansion or contraction and the compressibility of the fluid being metered to a reference condition.
The pressure and temperature transmitters are highly accurate and should be re-calibrated periodically.
Flow Control Valves
Flow control valves are installed on multi-run meter stations to equalize the flow in all meter runs and prevent one
meter run from “hogging” the flow. Flow control valves are also used during proving operation to maintain
constant flow during proving and to vary the flow to generate meter factors at multiple flow rates. Flow control
valves are typical installed downstream of each meter to maintain back pressure on the meter runs. Flow control
valves are commonly installed upstream of the outlet block valve and downstream of the prover takeoff. This
removes the flow control valve from the flow during proving allowing the flow control valve downstream of the

386
prover to control flow for the meter run being proved. Flow control valves may be butterfly, globe, or ball valves
and may have pneumatic or electric operators.
Downstream Block Valves & Prover Takeoff Valves
A downstream block valve is installed at the outlet of each meter run used to isolate flow for that meter.
Additionally, a prover takeoff valve is supplied to isolate each meter run from the prover manifold. During normal
operation of a meter run, the downstream block valve is open, and the prover takeoff valve is closed. When a
proving sequence is initiated for a particular meter, the prover takeoff valve is opened and the downstream block
valve is subsequently closed. This diverts all liquid that is metered to the prover. All other meter runs in a multi
run system remain in the normal downstream valve open, upstream valve closed sequence until the previous
proving sequence is completed and a proving sequence is initiated on another meter run. These valves are
typically automated and can be used to open and close meter runs to optimize the flow rate for each meter,
particularly ramp up and ramp down.

The downstream and prover takeoff valves must be highly reliable, double block and bleed design. Due to the
high frequency of operation of these valves, the ability of the valves to maintain bubble tight shut-off is imperative
to the proving operation. Even a small amount of fluid leaking past these valves can cause significant
measurement error. These valves should be supplied with a means to verify seal integrity.
Prover
Although other types of provers exist, this paper will focus only on mechanical displacement provers. Mechanical
displacement provers calibrate meters by displacing a known volume of liquid between two switches with a
mechanical displacer. The mechanical displacer is typically either an inflatable sphere or a piston. The volume
between the switches is calibrated by the waterdraw technique using calibrated cans traceable to NIST. The
most common prover types are bidirectional provers, compact provers, and unidirectional provers. Provers may
be permanently installed or portable, however the advantage of an on-site prover is that calibration is done at
actual operating conditions which eliminates errors from installation.
Four-Way Valve
The Four-way valve is used on bidirectional provers to change the direction of the flow through the prover so the
displacer can make multiple passes. The four-way valve must be high integrity with a means to verify positive
seal. Typically a differential pressure switch or transmitter is installed on the valve to monitor pressure differential
between the body cavity and the upstream or downstream connection. The four-way valve is typically automated
so that the prover sequence can be controlled by an external device.
Detector Switches
The sphere inside the ball prover pipe, or piston inside a piston prover actuates detector switches mounted on the
prover. The switches start and stop a digital counter for the meter being proved. The meter pulse count,
temperature and pressure correction factors, and prover base volume are used to determine the meter factor.
Quality System
A quality system is supplied to monitor the quality of the liquid being metered. Quality systems typically include a
sampler, a density meter, and a BS&W monitor. The sampler takes small samples from the pipe and stores them
in transportable containers. These containers are taken to a lab for analysis.
Flow Computer
A flow computer is supplied with a meter station to perform all custody transfer calculations. The flow meter
pulses, pressure, and temperature signals are wired directly to the flow computer and the flow computer corrects
the volume to standard pressure and temperature. The flow computer controls the proving operation and applies
the meter factor to each meter after proving. The flow computer may also store and print metering tickets. Flow
computers should be secure and should maintain an audit trail to prevent tampering with the flow computer.
It is common for a flow commuter to be paired with a PLC to control valve sequencing, bring meter runs on and
offline, aligns valves for proving, and control sample extractor. Use of a PLC allows separation of the
measurement and general operational functions. The PLC should not perform any tasks directly related to the
measurement ticket.

387
A supervisory system may be used in conjunction with the flow computer and PLC. This is typically a computer
based operator interface for the devices on the measurement system. The supervisory system will supply a
graphical representation of the metering system to an operator and allow the operator to perform certain tasks
such as initiate proving operation, set sample rate, and print and archine measurement tickets.
Mechanical Design
Arrangement of all the equipment on the measurement station should allow access to all of the devices located on
the system for operation and maintenance. Piping manifold and header design is important to the liquid flow
pattern in the measurement station. Proper sizing and arrangement will provide balanced flow between the meter
runs without sacrificing pressure drop. A good rule of thumb is to keep header velocities below 15 feet per
second for best flow distribution and minimizing pressure drop. Depending on pressure drop requirements, all
valves and piping outside of the meter runs (inlet/outlet valves, strainer inlet/outlet, prover header, etc.) are
typically one or two sizes larger than the meter for turbine, ultrasonic, and coriolis meters. All piping is typically the
same size as the meter for positive displacement meters.
Other features may be included to improve operation of the measurement station. These include quick opening
closures on the prover launch chamber and strainers to make removal of the prover sphere and the strainer
basket easier, jackscrews and spacer plates to facilitate removal of the meter runs, and jib cranes or overhead
cranes to aid in lifting larger items in the meter station.
A pressure relief valve should be installed on each meter run or any section of piping that could be isolated while
filled with liquid to protect the piping from over pressure due to thermal expansion. High point vents and low point
drains should be installed on each meter run to allow air to be bled during startup and liquid to be drained for
maintenance. While these items are crucial to the safety and reliability of the meter station, they should be kept to
a minimum.
If densitometers, samplers, BS&W monitors are included, care should be taken to install these so that they are
measuring a representative sample of the fluid. Additional mixing may be necessary to ensure the liquid is
sufficiently mixed.
Meter stations can be made in a modular design. This provides economic advantages over field constructed
systems by allowing the station to be completely assembled and tested before installation at site. Structural
frames may be used to support the pre-fabricated piping. Electrical wiring of all electronic devices to terminal
strips in junction boxes minimizes site installation time. System functionality, complete with remote
instrumentation and software may be verified in a controlled setting with the engineers that designed the system
present rather than in the field where all stakeholders may not be present.
Modular units can easily be transported to site where tie-in of piping and wiring between the remote panel and the
local junction boxes is completed. Installation of a factory tested unit ensures that all components are compatible
and that the system is in optimum working condition prior to site testing and final commissioning at site.
Conclusion
In closing, liquid measurement station design is critical to ensure accurate measurement. All components must
be carefully evaluated and selected for the given conditions to achieve the lowest uncertainty.

388
389