Crude And Hydrocarbon Measurement Technologies

Youssef Farid Basrawi

Specialist
Flow Measurements
Saudi Arabian Oil Company (Saudi Aramco)
Dhahran, Saudi Arabia 31311

KEYWORDS

Applications of Crude and Hydrocarbon Flow Measurement Technologies, Better Accuracy and Finer
Precision Yield Proper Accountability and Tremendous Savings.

ABSTRACT

The paper talks about the principles and applications of current and emerging crude and hydrocarbon
flow measurement technologies. It highlights the applications of flow metering technologies, in the
world and in the Kingdom of Saudi Arabia. Emphasis is put on better precision and higher accuracy in
volumetric and mass custody and royalty transfer through put measurement, of crude and hydrocarbon
fluids. Through finer precision and higher accuracy, when applied to exports and domestic consumption,
proper accountability can be achieved and tremendous cost savings realized. “ We cannot be held
accountable for what we can not measure ”. Topics of presentation consist of the science of
measurement, application of current and emerging technologies in the world of hydrocarbon
measurements and the proactive role Saudi Aramco is playing in this research and application. The
technologies that will be briefly discussed are, the use of the master meter in certifying crude and
product meter provers as an applied technology and its comparison in accuracy to conventional methods
of meter prover certification. Other devices consist of the principles and sciences of gas flow
measurement, the various water- in- crude detection instruments, currently under research in Saudi
Aramco and the application and viability to custody measurement, where accuracy is far more stringent
than that of process condition, of the new mass and hellicoidal flow meters.

A brief outline of the presentation is as follows:

• Measurement - The philosophy & science.
• The role of Saudi Aramco in the national and international arena of measurements in the crude and
hydrocarbon industry.
• Need for better accuracy and finer precision for proper accountability.
• The principles and application of the various types of flow measuring devices and instrumentation.
• Recommendations.

INTRODUCTION

For custody and royalty transfers of exports and domestic consumption, accuracy and fine precision play
the key role in influencing the current applications of crude and hydrocarbon products flow measurement
technologies. Saudi Aramco is playing a proactive role in such applications, domestically and
internationally. Such technologies are; the application of the master meter technology in certifying crude
and product meter provers, its cost effectiveness, operational benefits and accuracy. Other devices
consist of the principles and sciences of gas flow measurement, the various water- in- crude detection
instruments, currently under research in Saudi Aramco and the application and viability to custody
measurement, where accuracy is far more stringent than that of process condition, of the new mass
and
hellicoidal flow meters.

MEASUREMENTS

• The Science and Philosophy. A reference standard used for the quantitative comparison of
properties. The quantitative and numerical assessment of the dynamic and static properties of
naturally occurring phenomena and substances. In the hydrocarbon industry this is translated to the
measurement of fluid flow and static tank gauging. Examples of fluid properties:
- Cold (absence of heat) Temperature (T) ° (F-C).
- Mass Volume (V) Cubic Length (cu. ft.- cu. m.).
- Energy Velocity (S) Length/Time (ft./s. – m./s.).
- Rate Flow (Q=V/t) Cubic Length/Time (cu. ft./s.-cu m./s.).
Other parameters are pressure, viscosity, density and so on.

TYPES OF MEASUREMENTS

• Royalty Transfer. A specialized form of measurements. The basis for paying a fee or percentage of
the revenues generated by the sales (royalty) to owners of private or state owned enterprises.
• Custody Transfer. A measurement of transfer of a deliverable at the point of change of
responsibility, providing quantity and quality information used for the physical and fiscal
documentation of a change in ownership and/or responsibility of commodities between two parties
possessing a contractual agreement and bound by the terms and conditions of such a contract.

APPLICATIONS TO CUSTODY TRANSFER OF CRUDE & HYDROCARBON

LIQUIDS

• Global Overview. Necessity dictates inventions. If we are to account quantitatively for what we
perceive as naturally occurring phenomena, we need to devise accurate and precise measurement
methods to obtain meaningful information and use it to ensure credibility and integrity of our
systems. Measurement is an institution:
- International Standard Organization (I.S.O.), France.
- National Institute for Standards and Testing (N.I.S.T.), U.S.A.
- American Petroleum Institute (A.P.I.), U.S.A.
- Institute of Petroleum (I.P.), Europe.
- Instrument Society of America (I.S.A.), U.S.A.
- Saudi Arabian Standards Organization (S.A.S.O.), K.S.A.
• Hydrocarbon Industry. Measurement of hydrocarbon fluids was conceived by economical
demands, so the need for economical resources of fuel and energy becomes imperative. Hydrocarbon
fluids, to date, are the most economical source of fuel and energy.
• Loss Control And Risk Management. In recent years, the prices of fuel and crude dictated that
accuracy and precision be enforced, especially when large volume throughputs of crude and
hydrocarbon products exchange custody between supplier and consumer.
• Laboratory Analysis. Laboratory analysis in the hydrocarbon industry comprises of Sediment
analysis and API Gravity & Composition determination.
• Saudi Aramco. As part of the Saudi Aramco’s ongoing objectives to continuously maintain world
class operational standards, measurement of crude and gas output volumes must be conducted with
the utmost accuracy. This is accomplished by effective monitoring, enforcement and compliance
with government as well as international measurement standards and requirements, ensuring proper
design, installation, and operation of royalty and custody metering facilities. These objectives are
applied in refineries, terminals, gas plants, pipelines and tank farm operations. They are also applied
to crude and hydrocarbon royalty/custody transfer measurements, loss control and surveys of
measurement facilities. Figure1 shows the sales and distribution facilities of the hydrocarbon
industry.
 North

Scale: 1cm: 3000km Legend: Sea Land

FIG. 1 - WORLD SALES AND DISTRIBUTION FACILITIES

ACCURACY, PRECISION AND PROPER ACCOUNTABILITY

• Measurement Accuracy. Achieving consistent high accuracy measurements is the primary purpose.
Custody Transfer Measurement Facilities can achieve an accuracy of better than + 0.25%. Figure 2
show the measurement accuracy profile. Shown in Table 1 are potential annual revenue losses due
to lack of proper accuracy, precision and accountability.

FIG. 2 - MEASUREMENT ACCURACY PPROFILE

 TABLE 1- POTENTIAL ANNUAL LOSSES FOR CRUDE AND HYDROCARBON
PRODUCTS.

Crude Oil = 8 MMBPD 0.5 % Error = 40 MBPD @

PETROLEUM LOSS
HYDROCARBON PRODUCT LOSS
TOTAL POTENTIAL ANNUAL LOSS
$ 15.00 / BBL = $ 600,000.00/ D
Liquefied Petroleum Gas 0.5 % Error = 3 MBPD@
LPG = 600 MMBPD $ 12.00 / BBL = $ 36,000.00 / D
Natural Gas 0.5 % Error = 13.5 MMSCFD @ $ 0.50
NG = 2,700 MSCFD. / MSCF = $ 6,750.00 / D
Gasoline 0.5% Error = 3 MBPD @
Diesel = 600 MBPD $ 22.00 / BBL= $ 66,000.00/D
Jet Fuel
+ 0.5% Measurement Error $ 255,150,000.00 which is non
recoverable .

• Measurement Precision. The primary purpose for better precision is to achieve and maintain proper
accountability, insurance of flow measurement systems integrity and above all satisfaction between
customer or client and supplier.
• Proper Accountability. We cannot be held accountable for what we cannot measure. Proper
accountability can be achieved by the application of:
- Proper control: effective monitoring and utilization of measurement procedures, traceable to
primary standards, to ensure accurate design and correct installation of measurement facilities.
- The optimization of measurement systems: minimizing loss and providing more efficient
operation and measurement facilities.
- Application of cost effective measurement equipment and technologies.

TYPES OF FLOW MEASUREMENT DEVICES

There are fundamentally two types of flow measuring devices:

• Direct Measurement Devices. Direct measuring devices are devices that use the fluid properties as
direct measuring parameters to determine the fluid flow rate. Such parameters are mass, density,
viscosity temperature, pressure etc. Examples are: Positive Displacement Meters and Mass Flow
Meters.
• Inferential Measurement Devices. Inferential measuring devices use parameters other than the
fluid properties, such as electronic pulse counts, meter factors, system factors, linear and rotational
velocities components of measuring devices to infer the fluid flow rate. Examples are: Turbine,
Hellicoidal, Orifice Plate, Vortex, Venturi and Ultra Sonic Flow Meters. Other measurement devices
associated with fluid flow are: Temperature, Static and Differential Pressure Measuring Devices
(Transmitters, Chart Recorders, Manometers, DP Cells), Densitometers, Viscometers and so on.
 PRINCIPALES AND APPLCATION OF MEASUREMENT TECHNOLOGIES

Crude and hydrocarbon product measurements consist of two types. Volumetric and Mass Flow.
Accuracy and precision play the key role in influencing the current applications of volumetric and mass
measurement technologies when applied to royalty and custody transfers for exports and domestic
consumption. Amongst the technologies being applied are, the use of the master meter in certifying
crude and product meter provers as an alternate to conventional prover certification method using
waterdraw; the principles and sciences of the various water- in- crude detection instruments currently
under evaluation in Saudi Aramco and the new mass and hellicoidal flow meters and their application in
well heads and viability in custody measurement applications where accuracy requirements are far more
stringent than those of process applications.
• Volumetric Flow.
Master Meter for Meter Prover Certification. The standard method of calibrating any pipe prover
involves a determination of the volume, displaced between detectors at standard conditions (15 Deg
C/ 60 Deg F, and 101.325 kPa/14.73 Psia). The details are given in the A.P.I. (Manual for Petroleum
Measurement Standards Chapter 4 " Proving Systems " 1997). Displacer is made to move from the
launch chamber toward the detector switch by the action of the 4-way valve. The measured volume is
the volume displaced by the displacer, starting from the instant the displacer activates the first
detector to the instant it contacts the second detector on the other side of the prover. This is called
one pass. The 4-way valve is reversed and the same procedure is repeated in the opposite direction
for the second pass. The sum of the two passes or round trip is the measured volume of the prover.
Figure 3 shows a graphic representation of a Bi-Directional U-Shaped Pipe Meter Prover.

FIG. 3 - BI-DIRECTIONAL U-TYPE PIPE METER PROVER

Fluid is introduced into the master meter, master prover (or master certified test measure) and the
prover to be calibrated. Trial runs of the master meter are made against the master prover or master
test measure to calculate its meter factor. This is achieved by comparing pulse counts generated by
the pulse generator of the meter against the known volume of the certified test measure, for several
trial runs. The prover volume is then determined in the same fashion.
The pulse generator starts pulse count as soon as the displacer gates the detector and continues to
count pulses until the second detector is gated and the pulse counts stop. This is considered a pass or
half trip. The sum of the pulse counts of the two passes or round trip is translated into volume and
corrected for standard conditions. Figure 4 shows a graphic representation of a prover certification
using the master meter method and Figure 5 shows a graphic representation of a Master Meter Skid.

FIG. 4 - MASTER METER PROVER CERTIFICATION FIG. 5 - MASTER METER

Water cut Meter. The dielectric constant and conductivity of water are much higher than that for
oil. This difference can be utilizes to measure the water content of oil/water mixtures. The water cut
meters measures the microwave dielectric properties of mixtures using the resonant cavity method.
The density of a material in the tube affects the natural vibration frequency of a tube. By measuring
the frequency, one can measure the density of the material. A resonant cavity is a metal structure,
which confines an electric field and causes it to reflect back and forth within the cavity. If the
wavelength of the electromagnetic waves equal one of the dimensions of the cavity, then the multiple
reflecting waves constructively interfere and generate a standing wave: electric field resonance. If
one fills a resonant cavity with a material, the resonant frequency of the cavity will shift by an
amount directly related to the dielectric constant of the material. The width of the resonant peak is
related to the conductivity of the material in the cavity. Thus by measuring the resonant frequency
and peak width, one measures the dielectric properties of a material in the cavity. Figure 6 shows a
graphic representation of a Water cut Meter.

FIG. 6 - WATER CUT METER

Helicoidally Flow Meter. The hellicoidal flow meter operates in a very similar fashion to the
turbine flow meter, except that the conventional turbine meter requires straightening vanes upstream
to laminate the fluid flow. The main difference is that the blades of the helliciodal meter are as the
name implies. The Fluid flowing through the hellical blades causes rotation at a speed directly
proportional to the flow (within certain limitation of flow and viscosity); each revolution thus
corresponding to a precise and constant volume throughput. A magnet (one or two) mounted in the
rotor induces electrical impulses in an adjacent pickup coil. These are then processed by an electrical
converter and displayed as a flow rate. Figure 7 shows a graphic representation of a Hellicoidal Flow
Meter.

FIG. 7 - HELLICOIDAL FLOW METER

Sonic Flow Meter. The use of highly sophisticated techniques enables us to detect very small time
differences. These small time differences make it possible to reach a measuring resolution as low as
1mm/s. the ultra sonic flow meter takes advantage of the principle that an ultrasonic pulse travels
faster downstream while slower upstream. The larger the difference in time between the two pulses
the more fluid passes by. Because ultrasonic meters do not rely on kinetic energy from the fluid, very
low flow rates can be detected. This results in a very high turn down (typically 50:1) and no pressure
drop. Figure 8 shows a graphic representation of a Sonic Flow Meter.

FIG. 8 - SONIC FLOW METER

Orifice Plate Flow Meter. The most widely used head device in the gas industry is an orifice meter.
The primary element is installed in the pipeline carrying the fluid and consists of a meter run, or
tube, and an orifice plate inside an orifice fitting. The orifice that is bored through the plate creates
the restriction. The fitting has pressure taps drilled into the flanges on either side of the orifice plate.
 The upstream tap senses static, or flowing pressure usually expressed in psia or psig. The
downstream tap senses the pressure of the flowing fluid after it passes through the orifice. Under
normal conditions, downstream pressure at the tap is lower than upstream pressure. Since the
pressure on one side of the orifice is different from pressure on the other side, a difference in
pressure exists. This pressure difference is termed “differential pressure” usually expressed in inches
of water. Differential pressure is expressed in inches of water when a U-tube, or manometer, with
water in it is used. Water in a U-tube moves if pressure is applied to either end of the U. If a scale, or
ruler, marked in inches is placed alongside the U-tube, the number of inches of water movement
caused by pressure can be noted. Very small amounts of pressure cause a relatively large amount of
water movement within the tube. In some cases, however, a water manometer cannot be used
because the pressure of the flowing fluid in the line exceeds a manometer’s pressure rating. Gauge
lines, which are usually small-diameter lengths of stainless steel tubing, come out of the pressure
taps and transmit upstream and downstream pressure to the secondary element. The secondary
element contains pressure-sensing devices and a flow recorder or other type of recording instrument
to record static and differential pressure. The pressure-sensing device may be a bellows meter or a
pressure transducer that puts out an electrical signal. A bellows meter is shaped like a very small
accordion. Pressure causes the bellows to move back and forth, and the movement is linked to the
recorder. A pressure transducer senses pressure changes and transmits them electrically to computers
or other electronic devices. The dynamic flow equation for the orifice plate is derived from the basic
mass and energy conservation laws and Newton’s laws of motion. This equation can be expressed as
Qv = Cv(hwp)1/2 where Qv is the volumetric flow through put in cubic inches or feet per second or
minute, Cv orifice discharge coefficient, hw static pressure in inches of water column and p is the
dynamic pressure difference in psia or psig which creates the flow through the orifice bore. Figure 9
shows an orifice meter installation.

FIG. 9 - ORIFICE METER INSTALLATION

• Mass Flow.
Coriolis Mass Flow Meter. Assume you are standing in the center of a merry-go-round rotating with an
angular velocity w (for clarity one revolution per minute). You start to walk at a constant speed from the
center to the edge of the merry-go-round. When passing A you are covering the distance A’ and when
passing B you are covering the distance B’ both in the same one minute. It is clear that the distance B’ is
much greater than the distance A’. Apparently you have been accelerating . You have a certain mass and
 from Newton’s second law Force = mass x acceleration. So there must be a force. This force and
acceleration is named after Coriolis and are the basis for the mass flow meters. The Coriolis force Fc
prevents you from arriving at the point you were originally heading for. The resulting deflection D is a
measure of the Coriolis force and as such the mass. The faster you walk the larger the deflection. This
type of meter measures the mass of the fluid flowing through vibrating “U or S” shaped tubes. As the
fluid flow through the vibrating tubes, the naturally occurring Coriolis force causes a slight rotation of
the meter tube about it’s axis, which is proportional to the amount of mass flowing in the tube. These
meters can also measure density as function of the tubes natural frequency. Figure 10 shows a graphic
representation of the principle of the Coriolis Force. Figure 11 shows a graphic representation of the
Coriolis Mass Flow Meter. Table 2 shows some attributes of the flow measurement devices mentioned
throughout this paper.

FIG. 10 - CORIOLIS FORCE Fc FIG. 11 - CORIOLIS FORCE MASS FLOWMETER

TABLE 2 - ATTRIBUTES OF FLOW MEASUREMENT DEVICES.

TECHNOLOGY ACCURACY COST SAVINGS ADVANTAGES DISADVANTAGES

MASTER Comparable To $25,000 $500,000.00 & Accurate. Traceable to Secondary
METER Waterdraw Volume, 15,000.00 Man Repeatable. Standards.
±0.05% Deviation. Hours Annually. Calibration with
0.02% Repeatability. Process Fluid.
WATER CUT ± 0.05% For 0 to 1% $50,000 Labor, Operation, In Line Reading. Requires Mixer
METER Water In Crude. & Maintenance Minimum Pressure Upstream.
±0.5% For 1 to 20% Cost. Drop.
Water In Crude. Temperature
± 1.0% For 20 to 50% Compensated.
Water In Crude. Easy Calibration.
± 5.0% For 50 to
100% Water In Crude.
HELLICOID ± 0.25% Of Reading. $65,000 Labor, Operation, Single Rotating Poor Performance On Dry
METER 0.02% Repeatability & Maintenance Element. Waxy Crude.
Cost. Low Press. Drop.
Linearity Unaffected
by Viscosity.
SONIC METER ± 0.25% Of Reading. $ 5,000 Labor, Operation, Bi Directional Flow Works Well Only On Dry
0.02% Repeatability. & Maintenance Capacity. Fluids.
Can Detect Flows As Cost. Repeatable.
Low As 1mm/s. No Press. Drop.
No Moving Parts.
ORIFICE METER ± 0.5-1.0% Of $3,500 Labor, Operation, No Moving Parts. Requires Flow
Reading. 0.02% & Maintenance Flow Expressed In Conditioner Upstream.
Repeatability. Cost. Volume or Mass. Secondary Standard
Traceable.
MASS METER ± 0.2% Of Rate $60,000 Labor, Operation, Direct Mass Measure. High Pressure
Operated At Fluid & Maintenance No Moving Parts. Drop for Low
Velocities Between Cost. Unaffected by Flow Rates.
0.12 & 12. m/s Temperature.
(0.4 and 40 f/s).

CONCLUSION

In conclusion to this paper “ Crude and Hydrocarbon Measurement Technologies” the main point are
briefly summarized and recommendations are offered.
• Summary of Main Points.
- Measurement: The Philosophy and Science.
A reference standard used for the quantitative comparison of properties. The quantitative and
numerical assessment of the dynamic and static properties of naturally occurring phenomena and
substances.
- The role of Saudi Aramco in the national and international arena of crude and hydrocarbon
measurements. Effective monitoring, enforcement and compliance with government
guidelines (Ministry of Petroleum and Mineral Resources) as well as international measurement
standards and requirements to ensure proper design, installation, and operation of royalty and
custody metering facilities.
- Need for better accuracy and finer precision for proper accountability.
“ We cannot be held accountable for what we can not measure”. Through finer precision and
higher accuracy, proper accountability can be achieved and tremendous cost savings realized.
- Types of Flow Measuring Devices.
Direct and Inferential Measurement Devices.
- Principles and application of measurement technologies.
Volumetric and Mass Flow Meters.
• Recommendations.
- Better accuracy and finer precision through application of new and more cost effective
measurement technologies.
- Continued participation and proactive representation in national and international measurement
engineering and loss control institutions.
- Effective monitoring and application of measurement and loss control standards to measurement
facilities for compliance and quality assurance.
- Monitoring and continued development of measurement training programs.
 ACKNOWLEDGEMENTS

• Ministry of Petroleum and Mineral Resources.

• Custody Measurement Unit, Consulting Services Department, Saudi Aramco.
• Petroleum Loss Control Unit, Terminal Operations Department, Saudi Aramco.
• Juaymah Gas Plant Engineering Division ,Juaymah Gas Plants Department, Saudi Aramco.
• Ras Tanura Refinery Operations Department, Saudi Aramco.

REFERENCES

• American Petroleum Institute 1993; Manual of Petroleum Measurement Standards, Washington; API
• Miller R.W. 1996; Flow Measurement Engineering, New York; McGraw-Hill.
• Spink L.K. 1972; Flow Measurement Engineering, Massachusetts; The Foxboro Company.