CMTEM2011 Presentations

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
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
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
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
3. Benefits of Globalization
Slide # 5
3. Benefits of Globalization Eliminate special requirements that may increase project costs
Slide # 5
3. Benefits of Globalization Eliminate special requirements that may increase project costs Increase the number of potential suppliers of material
Slide # 5
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
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
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
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
Slide # 7
More than 2300 standards; from which, more than 1200 are considered mandatory.
Slide # 7
37 standards committees with members of more than 500 people from 17 different organizations
Slide # 7
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
Corporate management systems have been established to manage the review and approval process of the engineering standards.
Slide # 8
Standard Review Model
Slide # 9
5. Globalization Approach and Strategy
Slide # 10
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
Performing Value Engineering studies for the engineering standards.
Slide # 10
Performing Value Engineering studies for the engineering standards. Participating in International Standards Development
Slide # 10
Slide # 11
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
6. Custody Measurement Standards Globalization Initiative: B. Development and Revision Process of Custody Measurement Engineering documents
Slide # 13
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
6. Custody Measurement Standards Globalization Initiative: D. Value Engineering Studies: Three value engineering studies were performed on most important measurement documents.
Slide # 14
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
6. Custody Measurement Standards Globalization Initiative: D. Value Engineering Studies:(Cont.ed) Two value engineering studies are planned to be performed
Slide # 16
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
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
American Society for Testing and Materials (ASTM) Committee D02 on Petroleum Products and Lubricants
Slide # 19
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
American Gas Association (AGA) CMU participates in AGA activities by reviewing the reports developed in the field of gas measurement.
Slide # 21
7. Challenges:
Slide # 22
7. Challenges:
a) Implementation process of the initiative differs from one discipline to another.
Slide # 22
7. Challenges:

b) Involvement of the Subject Matter Experts in the increasing day-to-day activities.
Slide # 22
7. Challenges:

b) Involvement of the Subject Matter Experts in the increasing day-to-day activities. c) Standards Cross Referencing
Slide # 22
7. Challenges:

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
7. Challenges: (Conted)
e) Geographical diversity do not permit attending International standards organizations working group meetings
Slide # 23
f) Long time for developing and approving the reference standard document
Slide # 23
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
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
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
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
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
3- Continuously Improve Workforce Skills and Competencies
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

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

General Requirements
Operate and Maintain Safely and Reliably Conduct Regular Audits Revalidate Lateral Lines Replace Obsolete Equipment

Measurements Operations
Collect Regular Gas/Crude Oil Samples and Send to LAB Conduct Periodical Proving on Royalty Crude Oil System

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

Metering Skids Maintenance
Instruments Calibrations Meter Inspection / Diagnosis Checking Flow Calculations Perform Software Back up Stroking the Main Valve Yearly

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
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
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
Major field problem component Impacts measurement! Is there no other way?
Automatic integrity test on double block and bleed valves Valves limit switches Wiring between field and control room
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

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

Significant difference at highly fluctuating conditions
For example
Flow computer GSV = 37942 bbl API MPMS 12.2 GSV = 37978 bbl
Up to 0.10%

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 ?

Basic conventional correction method
Optimal conventional correction method

New API MPMS Ch21 based correction method
* Patent pending *

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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Technical Proceedings-

November 21-23, 2011 Dammam Office Building Saudi Aramco

Maintain Measurement Accuracy from Design to Operation

CUSTODY TRANSFER AGREEMENTS

We are seeking the truth!

WHAT ACCURACY CAN BE ACHIEVED?

TYPICAL SYSTEM P&ID

DESIGN FOR LOWEST TOTAL OWNERSHIP COST

Where Y represents life of project, typically 20 years.

OPERATING ENERGY COST CONSIDERATIONS

METER SELECTION FLOW RATE VISCOSITY METER RUN QTY. VS SIZE

METER SELECTION RULE OF THUMB BASED ON FLOW RATE AND VISCOSITY

CONTROL ROOM OR SKID MOUNTED FLOW COMPUTER I/O

CONTROL ROOM INSTRUMENTSFOR OPERATOR EASE

CONTROL ROOM INSTRUMENTS

TYPICAL HMI SCREEN

TYPICAL CRT SCREEN

Meter Performance Analysis Software

MAINTENANCE and CALIBRATION ISSUES

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

Planning and Operations

Consultancy and Engineering

PERFORMANCE MANAGEMENT: KPIs

CONTRACT BENEFITS: MANAGEMENT SYSTEMS

CONTRACT BENEFITS: MANAGEMENT SYSTEMS

Complete bespoke management system and infrastructure developed and implemented:

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

2. What is Standards Globalization?

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

2. What is Standards Globalization? (Conted)

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

4. Saudi Aramco Engineering Standards Structure

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

4. Saudi Aramco Engineering Standards Structure

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

4. Saudi Aramco Engineering Standards Structure

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

4. Saudi Aramco Engineering Standards Structure

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

4. Saudi Aramco Engineering Standards Structure

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

4. Saudi Aramco Engineering Standards Structure

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

Standard Review Model

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

5. Globalization Approach and Strategy

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

5. Globalization Approach and Strategy

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

5. Globalization Approach and Strategy

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

5. Globalization Approach and Strategy

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________

CUSTODY MEASUREMENT STANDARDS GLOBALIZATION INITIATIVE _______________________________________________________________