Realizing a Class 1 Ultrasonic Gas Meeter without HP Calibration - an innovative approaches contributing to an economic upstream metering solution Thomas Horst - Sick
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Realizing a Class 1 Ultrasonic Gas Meeter
without HP Calibration - an innovative
approaches contributing to an economic
upstream metering solution
Thomas Horst - Sick
REALIZING A CLASS 1 ULTRASONIC GAS FLOW METER WITHOUT HP CALIBRATION
Author: Thomas Horst - SICK AG
Co-Author: S. Stoof, A. Prade – SICK AG
European Flow Measurement Workshop 2015
2SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
GAS PRODUCTION APPLICATIONS
Challenging conditions in gas production:▸ Varying flow rates
▸ Varying gas quality
▸ Saturated gas streams with entrained liquids
Demand for meters that are:▸ Robust for use in production environments
▸ Economic in a long-term perspective
In fact: Meters for gas production applications are mainly covered by dP meters.
UPSTREAM MEETS ULTRASONICS
USM provide several advantages over dP meters:
( + ) Higher turn-down ratio( + ) Reduced pressure drop( + ) Virtually no maintenance( + ) Valuable diagnostics data
What about Ultrasonic meters in gas production?
USM are equally applicable:
• Highly robust, even for high LVF – no wear• Self-draining, self-recovering
3SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
COMPLETING THE VALUE CHAINUPSTREAM METERING WITH USM’S
Upstream Midstream Downstream
Production Gathering Transmission Storage Distribution Residential
4SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
Gathering SystemIf same owners, just 1 meter If different may be 1 owned by gatherer and sometimes a check meter on the pad
Multi Well Gas w / production and test separators• 2 to many wells• Each wells are cycled through a test separator, either
automatically or manually• On site facilities can be small to very large
Tanks or pipeline
Test Separator
ProductionSeparator
PRODUCTION CONFIGURATIONS
5SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
LARGE TURN-DOWN
FLOWSIC600 DRU covers typical range of 2..6 inch orifice plate meters.
6SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
� Dual path meter design
� Precise meter body manufacturing with tight tolerance limits
� Tailor-made US sensors and path layout
� Integrated 10D upstream piping
� Individual LP calibration
LOW UNCERTAINTY (CLASS 1 METER) WITHOUT INDIVIDUAL HIGH PRESSURE CALIBRATION
Meter body manufacturing precision
Superior transducer technology
Zero flow test and verification
In-house ambient air flow calibration
Quality assurance for HP natural gas
Steps to uncertainty: ±1%
� No individual HP calibration
� Significantly reducedsystem price.
7SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
EVALUATION ON A PRODUCTION LOT OF 25 METERSMANUFACTURING PRECISION
59,95
59,96
59,97
59,98
59,99
60
60,01
60,02
60,03
60,04
60,05
14
39
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40
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42
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44
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46
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48
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52
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54
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56
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58
14
40
00
47
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40
00
49
14
40
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51
14
42
00
61
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63
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65
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67
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69
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71
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73
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75
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79
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81
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Pat
h an
gle
[deg
]
Path angle
Path 1 Path 2
Tolerance limit ±0.02 deg
134,8
134,85
134,9
134,95
135
135,05
135,1
135,15
14
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40
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42
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44
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46
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50
14
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52
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54
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56
14
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58
14
40
00
47
14
40
00
49
14
40
00
51
14
42
00
61
14
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00
63
14
42
00
65
14
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00
67
14
42
00
69
14
42
00
71
14
42
00
73
14
42
00
75
14
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00
77
14
42
00
79
14
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00
81
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83
Pat
h le
ngth
[mm
]
Path length
Path 1 Path 2
Tolerance limit ±0.1 mm
0
0,05
0,1
0,15
0,2
0,25
0,3
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40
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50
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52
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14
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56
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00
58
14
40
00
47
14
40
00
49
14
40
00
51
14
42
00
61
14
42
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63
14
42
00
65
14
42
00
67
14
42
00
69
14
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00
71
14
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00
73
14
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75
14
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00
77
14
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00
79
14
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00
81
14
42
00
83Par
alle
ilism
[mm
]
Path Paralleilism
Tolerance limit <0.3 mm
21,9
22
22,1
22,2
22,3
22,4
14
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00
40
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00
42
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44
14
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00
46
14
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48
14
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00
50
14
39
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52
14
39
00
54
14
39
00
56
14
39
00
58
14
40
00
47
14
40
00
49
14
40
00
51
14
42
00
61
14
42
00
63
14
42
00
65
14
42
00
67
14
42
00
69
14
42
00
71
14
42
00
73
14
42
00
75
14
42
00
77
14
42
00
79
14
42
00
81
14
42
00
83
Pat
h po
sitio
n [m
m]
Path position
Path 1 Path 2
Tolerance limit ±0.15 mm
8SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
AMBIENT AIR CALIBRATION RESULTS
-2,5
-2,0
-1,5
-1,0
-0,5
0,0
0,5
1,0
1,5
2,0
2,5
0 100 200 300 400 500 600 700
Err
or [%
]
Flow rate [m³/h]
Ambient air calibration – as left
RESULTS ON A PRODUCTION LOT OF 25 METERS
9SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
VERIFICATION OF OUT-OF-THE-BOX PERFORMANCE RESULTS ON HIGH PRESSURE TEST FACILITY
-2,5
-2,0
-1,5
-1,0
-0,5
0,0
0,5
1,0
1,5
2,0
2,5
0 100 200 300 400 500 600 700
Err
or [%
]
Flow rate [m³/h]
High pressure flow test – as found
4bar 50 bar Ambient Air 2bar
10SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
FLOW DISTURBANCE TEST RESULTS
-1,00
-0,75
-0,50
-0,25
0,00
0,25
0,50
0,75
1,00
6904802756934,5
Dev
iatio
n to
Bas
elin
e [%
]
Flow rate [m³/h]
Flow disturbance test of FLOWSIC600 DRUFC: CPA 55E, Distance: 10D, OIML R137 (mild) / ISO 17089
7094_S16 zurueck_CPA55E_10D_SEL 7099_S16 zurueck_CPA55E_10D_SER7100_S16 zurueck_CPA55E_10D_DER 7103_S16 zurueck_CPA55E_10D_DEL7104_S16 zurueck_MUT90Gr_CPA55E_10D_DEI 7108_S16 zurueck_CPA55E_10D_GV7110_S16 zurueck_CPA55E_10D_STP 7111_S16 zurueck_CPA55E_10D_CO7112_S16 zurueck_CPA55E_10D_DI
11SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
� Test at CEESI Nunn
� 13 barg and 55 barg
� 95..100% GVF
WET GAS TESTING
12SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
Comparison: dual chamber orifice with one beta (0,517) – Natural gas / WaterWET GAS TEST RESULTS
: Continuous operation for alltested LVF
: Acceptable allocation accuracy up to 0.5 % LVF
� USM is robust even in wet gas conditions
FLOWSIC600 DRUOrifice Meter Error Difference Relative to Dry GasPressure = 800 psia - With CPA
-5,0
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
45,0
0 10 20 30 40 50
Ref Gas Velocity (ft/s)
Error
GVF = 99.88
GVF = 99.76
GVF = 99.52
GVF = 98.83
GVF = 97.70
GVF = 95.44
2 Path Meter Error Difference Relative to Dry GasPressure = 800 psia - With CPA
-5,0
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
45,0
0 10 20 30 40 50
Ref Gas Velocity (ft/s)
Error
GVF = 99.88
GVF = 99.76
GVF = 99.52
GVF = 98.83
GVF = 97.70
GVF = 95.44
13SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
INNOVATIVE LIQUID DETECTION DIAGNOSTICS
� Fully automated monitoring of all diagnostic parameters
� Algorithm using diagnostics to generate a warning when liquids are present that may have an impact on process quality or measurement accuracy
� Operation expenditures stay low due to intelligent diagnostics telling you when maintenance and inspections are really necessary
14SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
� High rangeability
� Virtually maintenance-free
� Identification of time periods with potential measurement issues by inbuilt liquid detection
� Indication of measurement data quality
� Potential for production optimization to avoid liquid production
FLOWSIC600 DRU – CUSTOMER BENEFITS
15SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
� Measurement effects of wet gas on ultrasonic meters are significant and not trivial to overcome
� FLOWSIC600 DRU is not a wet gas meter , but is robust for wet gas production applications and provides substantial added value by
▸ Large turn-down
▸ Low OpEx
▸ Long-term stability
▸ Liquid detection diagnostic
� Further research must be done on liquid correction of USM
� Tests and projects are ongoing – results will be published subsequently
SUMMARY
16SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
What are main concerns for US metering in gas produ ction?
� Economic in CapEx and long-term perspective?
� Robust for production applications?
� Low measurement uncertainty?
� Diagnostic values with added value in upstream applications?
UPSTREAM MEETS ULTRASONICS
17SICK Flow Solutions | European Flow Measurement Workshop 2015March 2015
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