Lesson Handout Notes 25231 METER PROVING

A69.1858-LHN-PRO-25231-01
Effective Date: May 26th 2007

Training Program Discipline System Sub-System Training Focus Training Elements

: TECHNICIAN: LEVEL 2 CERTIFICATION : PROCESS : METERING & GAUGING : METER PROVING : BASIC KNOWLEDGE : This lesson targets training on the following training elements: Meter Proving Meter Proving Systems

Training Objectives

: At the end of the Lesson the participants will be able to: State the necessity for meter proving assemblies Describe a typical meter proving system

0 Rev

2007-05-24 Date

Otto Tomasch Prepared by

O.T. Initials

V. Vladut Checked by

V.V. Initials

R.G. Hollamby Approved by

RGH Initials

Initial Document Modifications Page 1 of 12

Form: A62.1858-ADM-FRM-0303

Cegelec 2006

This document is the property of Cegelec (The Company). Distribution and use of this document are strictly governed b y the Companys Document Management Policy and Procedures.

Lesson Handout Notes 25231: Meter Proving

A62.1858-LHN-PRO-25231-01 May 26th 2007
The contents and form of the document are the sole property of The Company and may not be reproduced, distributed or used without the express written permission of The Company.

DOCUMENT INFORMATION

TABLE OF CONTENTS Technician: Level 2 Certification ................................................................................................................................... 1 Process ......................................................................................................................................................................... 1 Metering & Gauging ...................................................................................................................................................... 1 METER PROVING ........................................................................................................................................................ 1 Basic Knowledge .......................................................................................................................................................... 1 1. Product Metering and Export .................................................................................................................................... 3 2. Traceability of Measurement .................................................................................................................................... 3 3. Turbine Meter ........................................................................................................................................................... 3 4. Types of Meter Provers ............................................................................................................................................ 4 4.1 Pipe Meter Prover............................................................................................................................................ 4 4.1.1 Sphere & Twin-Detectors ............................................................................................................................. 5 4.2 In-line Meter Prover............................................................................................................................................. 6 4.3 UNI-IDIRECTIONAL METER PROVER.............................................................................................................. 6 4.4 BI-DIRECTIONAL METER PROVER ................................................................................................................. 8 4.4.1 Standard Equipment and Trim ..................................................................................................................... 8 4.5 Compact Piston Prover ....................................................................................................................................... 9 4.5.1 Operation ...................................................................................................................................................... 9 5. Master Meter ........................................................................................................................................................... 10 6. Inspection Equipment ............................................................................................................................................. 11 7. Prover Loop Maintenance ................................................................................................................................... 11 7.1 Prover Sphere ............................................................................................................................................... 11 7.2 Sphere Detectors .......................................................................................................................................... 11 7.3 Prover Volume Recalibration ............................................................................................................................ 12

Purpose The purpose of this document is to provide the participant study information.

OWNER The owner of this document is the Discipline Team of Ogere Training Facility, Ogere Remo, Ogun State, Nigeria.

CUSTODIAN The custodian of this document is the Data Administrator and Document Controller of the Ogere Training Facility, Nigeria

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1. PRODUCT METERING AND EXPORT Product is measured to determine how much is being consumed or sold. Where hydrocarbon product is being measured to determine payment from a customer, or the payment of taxes or royalties to a government department, the operation is termed fiscal metering. Often the volumes of hydrocarbons involved in fiscal metering can be very high and even small inaccuracies can result in large losses in monetary terms to the supplier or the customer. For this reason great care is taken in fiscal metering and equipment capable of achieving a high degree of accuracy is used. It is common for metering equipment to be controlled by a Computer Supervisory System (CSS). Many different types of meter are available to measure the volumetric flow of hydrocarbons, e.g: Orifice meters Positive displacement meters Venturi meters Turbine meters Flow nozzles Elbow meters

Of these meters, the orifice-type flow meter, is the most commonly used in field service and pipeline systems. Because of their accuracy, however, turbine meters are most widely used in fiscal metering systems.

2. TRACEABILITY OF MEASUREMENT A field of oil or gas is a valuable asset in which the cost of inaccuracies can be high. Therefore, every oil and gas metering station used for commercial or fiscal purposes must be linked to a traceable chain of calibrated standards of liquid volume. Flow meters in locations where accurate readings are required need their readings tested to show they are giving accurate outputs of flow. A meter is tested against a pipe prover, which in turn is calibrated against a volumetric proving tank, which has been tested against standard measuring cylinders. This traceability can give rise to a loss of accuracy. Therefore, every calibration operation must be carried out with the highest possible accuracy. In this way, the oil meter, the final link in the chain, will have the best possible accuracy.

3. TURBINE METER Because of their accuracy turbine meters are most widely used in fiscal metering systems. The turbine meter is essentially a small multi-bladed turbine rotor supported on low friction bearings at the centre of a short pipe spool. The process fluid flows through this pipe spool causing the turbine wheel to rotate at a velocity proportional to the volumetric rate of flow. An electro-magnetic pickup coil is fitted close to the wheel, but external to the pipe. Each time a turbine blade passes the coil a voltage pulse is generated. This pulse is then converted either into rate of flow units or to a quantity computed by a summarizer device. Turbine meters have a very high accuracy, ranging from 0.25% to 0.5% with excellent repeatability. Regulatory authorities approve the use of turbine meters for fiscal metering on condition the meter is regularly checked for accuracy by a meter prover.

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PD Meter Pressure pad and capillary seal

Temperature transmitter

Pressure transmitter

Figure 1: Metering Train

4. TYPES OF METER PROVERS

4.1 PIPE METER PROVER

Calibrated length Detectors Flow from meter Inner wall of pipe

Displacer
Figure 2: Operating Principles of a Pipe Prover

Seal

For a flow rate in a pipe: it will take a calculated time for a displacer to travel a calculated length, whilst driven by the flow of fluid through that pipe of a certain cross-sectional area.

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By placing this displacer in the proving rig and comparing its measurement to that of a flow meter from the line, we can assess the accuracy of the line meter and re-calibrate or replace it, if necessary. 4.1.1 Sphere & Twin-Detectors The accuracy and reliability of pipe provers can be increased considerably by fitting two detectors at each end of the prover instead of one single detector. During normal operation, these are connected to two counters. The associated computer makes a continual comparison of the two counts and if these are different by a defined amount then an alarm will notify that one detector is malfunctioning.

Detection Switch (Figs. 3 & 4)

Figure 3

Figure 4

Spheres (Fig. 5) The Sphere is a one-piece, inflatable, seamless meter proving and pipeline sphere.

Figure 5

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4.2 IN-LINE METER PROVER This type of meter prover is an accurately machined length of pipe with a smooth and uniform bore. A closely fitting sphere can be passed through the length of pipe between two reference points. Detector probes are positioned at the reference points. The sphere is launched into the prover and as it passes the first reference point it generates an electronic signal to start counting the pulses generated from the turbine meter. The counter is stopped when the sphere passes the second detector. The number of pulses recorded is then compared with the known volume displaced by the sphere between the two detectors. After a number of proving runs a meter factor can be determined. Depending on space limitations, a meter prover can be a straight pipe run or a series of pipe loops. The latter requires a four-way valve to provide bi-directional operation enabling the sphere to be run back and forward through the prover. While the prover loop system is used to check and calibrate the product turbine meters, the prover loop itself must be regularly checked and verified as accurate. An independent body of petroleum measurement inspectors / surveyors does this. Recalibration of the meter prover for certification involves passing an accurately metered quantity of water through the prover loop. The volume of water collected is then compared to the meter calculation. This is done a number of times to confirm the accuracy of the prover loop meter factor.

4.3 UNI-IDIRECTIONAL METER PROVER The uni-directional prover incorporates a one-way flow device with mechanical detector switches. A unidirectional prover operates with some type of a sphere hand-kling interchange to transfer the sphere from downstream to upstream. This is a small volume, uni-directional prover. The uni-direct is designed with 10 feet per second ball travel and 35 feet between the switches. Once set on location, these provers are virtually maintenance-free. With their minimal volume, there is a great cost reduction for calibration clean-up, disposal and interfacing different products. All provers, no matter the flow rate or pipe size, are mounted on a skid that is approximately 6 x 25 ft. The seal mechanism is designed to receive very little wear from operation and can last for many years.

Figure 6: Uni-directional Meter Prover

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In-Line Meter Prover

A62.1858-LHN-PRO-25231-01 May 26th 2007

Figure 7: In-line Meter Prover

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Figure 8: Arrangement of a Uni-directional Meter Prover

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Operating steps of a Uni-directional Prover: The fluid is flowing through the line The sphere is introduced into the flow The fluid carries the sphere past both detectors At the first detector, it starts measuring At the second detector, it stops measuring The fluid flow and the pipe area are calculated The meter on test has its own reading of fluid flow The volume of fluid can be measured by assessing the total volume that passes from Detector 1 to Detector 2

This value is then compared to the meter on test to assess its accuracy.

4.4 BI-DIRECTIONAL METER PROVER By far the most readily used prover in the industry for many years. The bi-directional pipe prover has proven itself over and over again as one of the most reliable means available to verify meter readings and establish meter factors. It is still the most recommended and used prover design in the world today. By definition the bi-directional pipe prover is a positive displacement type prover with flow and displacer traveling in both directions by means of a 4-way diverter valve. The bi-directional prover is constructed of pipe, which can be configured in many ways. Probably the most influential advantage of the pipe prover is its ability to allow the full flow of the stream through the meter being proved to pass through the prover. In this regard the bi-directional pipe prover offers a history of long-term reliability with minimum maintenance.

4.4.1 Standard Equipment and Trim Four way diverter valve with viton seals and differential pressure gauge Detector switches, SS construction with viton seals Valve actuator or manual handwheel Sphere - Inflatable polyurethane, nitrile, or neoprene with accessories (pump and sizing ring) Quick opening closure, hinged or davit type Thermometers - mercury in glass with temperature divisions and SS thermowells Pressure gauges with isolation valves Pressure relief valve Vent valves Drain valves Semi-skid beam supports

Figure 9: Bi-directional Meter Prover

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4.5 COMPACT PISTON PROVER The shortage of space on off-shore platforms has provided the incentive to look for ways to drastically reduce the size of pipe-provers. Piston provers are less than one-tenth of the size of conventional provers and may eventually replace conventional provers. The position of the sphere is detected optically and with high precision. Highly improved electronics result in us being able to count the number of pulses seen during a prove.

4.5.1 Operation In the stand-by mode the piston is down stream and stationary. The piston's inner flow-through valve is open (i.e., slightly up-stream of the main piston body), allowing free flow of the fluid through the flow prover's measurement cylinder with insignificant pressure loss.

Figure 10: Compact Piston Prover

Figure 11: Piston with Inner Flow-through Valve open

When the operator starts a proving run sequence (Fig. 11), the computer then signals the explosion-proof motor to pull the piston to the up-stream position. The piston is then completely unlatched from the chain drive return mechanism. The low drag piston traveling down the smooth bore tube is now free to follow the fluid flow with the least possible effect on the flow stream. When the piston is released, the flow-through valve closes by spring tension (Fig. 12). The piston is now synchronized with the fluid velocity.

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Figure 12: Piston with Inner Flow-through Valve closed

After the piston has been released and after a short run-up, the precision optical start of volume switch is actuated, which sends a signal to the proving computer to start the timing sequence. The piston continues downstream with the flow. Upon reaching the end of the volume switch, a signal is sent to the proving computer, which stops the timing sequence. Just after passing the end-of-volume switch, the piston shaft is stopped by a mechanical stop. The flow-through the prover pushes the perimeter of the piston further downstream, opening the flow-through valve, and allowing the flow to continue with little to no pulse or surge in line pressure. To begin the next proving run sequence, a signal is sent from the proving computer, which activates the return mechanism, pulling the piston to the upstream position, where it is released to obtain another data point.

5. MASTER METER In metering applications where the highest standards of accuracy are required, it is common practice to use a portable meter, of high accuracy, known as a Master Meter. This is instead of a Prover. It is connected in series with the meter to be proved and the readings of the two are compared. From time to time, the master meter can be checked against a meter prover to verify its accuracy. Once again, greater accuracy can be generated if two master meters are connected in parallel, so that they can check each other.

Master Meter

Figure 13: Portable Master Meter Skid

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6. INSPECTION EQUIPMENT With one push-type camera (Fig. 14) and one tractor-driven camera (Fig. 15), most sizes and configurations of meter provers can be inspected.

Figure 14

Figure 15

7. PROVER LOOP M AINTENANCE There are two items of equipment associated with the prover that may require maintenance. The need for which will be indicated by the system performance. The first is likely to be the prover sphere and the other the prover sphere detectors. Both may require isolation and draining of the prover loop and the following instructions apply. 7.1 Prover Sphere 1. Ensure that prover sphere is located in the prover loop home chamber, which is fitted with the QOC. 2. See section 8.3.3.1 and 8.3.3.2 for isolating and draining the prover. 3. Open the QOC and bring out the prover sphere by means of the vacuum tool. 4. Check the prover sphere size (diameter of the prover sphere). If the sphere is out of the required dimension, use the pump and tool required for maintenance of the sphere. 5. Check that the filling valve on the sphere is not leaking before inserting the sphere into the prover chamber again. Each valve should be checked for a period of 10 minutes. 7.2 Sphere Detectors Any adjustment of the sphere detectors will involve a recalibration of the loop.

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7.3 PROVER VOLUME RECALIBRATION Calibrating a prover involves determining the base volume displaced between the detector switches. Prover volume calibration can be done using a master meter with a compact prover or by the water-draw method. When calibrating the prover maximum operating pressure will be equal to the operating pressure of the test equipment. The following procedure shall be used for calibrating the prover. 1. Isolate and drain the prover as described in section 8.5.3.1 and 8.5.3.2. 2. Hook-up the test equipment by using nozzle N11 and an external nozzle on the site prepared for this. The N11 nozzle is equipped with a full bore ball valve. 3. Refer to the final section for Calibration Procedures 4. After calibration, disconnect the test equipment and pressurise the prover as described in section 6.1.

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