APPLICATION OF FLOW COMPUTERS FOR GAS MEASUREMENT AND CONTROL EM 3020 Dave Shollenbarger Fisher Controls International, Inc.

1612 South 17th Avenue, Marshalltown, Iowa 50158

Introduction Electronic flow computers (EFCs) are rapidly becoming the standard for real-time gas measurement. As these devises become more and more capable, advanced control stratigies are becoming common place. As more and more EFCs are commissioned, customers sometimes learn hard lessons regarding electronic gas measurement. Many times these lessons could have been avoided if proper consideration was given to the selection of an EFC devise and the applications at hand. This paper will discuss, in general, gas measurement and control applied through EFCs. It will focus on the importance of AGA EFC configuration, API Chapter 21 historical archiving techniques, and the different control options available. EFCs and Gas Measurement The primary task for the EFC in a custody transfer application is to measure the gas flow accurately and reliablyln addition to performing the actual gas measurement, it is required to provide local data storage and the associated audit trail. Independent of whether the actual meter is a pulse type (PD, turbine, rotary, aultrasonic) or differential type (orifice) meter, these common functional blocks comprise gas flow measurement systems: the physical meter (primary device), the process transmitters (secondary devices) and the flow computer (tertiary device). Once we take a look inside the flow computer, there are other commonalties between the different types of meters. These commonalties may be apparent as you properly configure the flow equations and audit trail (historical database) for your application such that compliance with published industry standards are met. These standards include AGA3, AGA7, AGA5, AGA8, AGA9 and API Chapter 21 publications. Keep in mind that the term custody transfer suggests that the meter is used as a transfer of ownership between the buyer and seller. AGA and API have created guidelines, but no certification or accuracy mandates exist. To achieve the goal of accurate and reliable gas measurement, steps should be taken to eliminate as 326

many potential sources of error from the flow equation as possible. Primary devices. The primary device is probably the most likely, but overlooked cause of potential errors. A poorly installed and maintained primary device can contribute from 5% to 20% error for something as simple as a slightly deformed plate in an orifice meter. Even on a small run averaging 40 MCF per day at an estimated gas price of $2.00 per MCF, a 15% error could cost you over $4,000 a year in gas that is unaccounted for. Always be sure the primary device is in top notch condition. Note that the AGA9 standard that is now out addresses the proper installation of the meter and references AGA7 as the calculation. Secondary devices. Choosing the correct transmitters for your application can significantly reduce the long term ownership cost of your system by improving its accuracy and reducing maintenance costs. Today, "smart multi-variable transmitters" are by far the most popular. Stability, interchangeability, temperature effects, static pressure effects and repeatability are all important factors for good measurement. When you take into consideration the accuracy, stability, interchangeability, temperature effects, static pressure effects, repeatability, maintainability and initial cost of quality smart multi-variable transmitters, it is easy to see the long-term cost advantage they provide. Accuracy improvements over conventional transmitters alone can eliminate the potential for error in excess of $5,500 / year on a 10MM gas run. Combine this with lower maintenance cost, and the lower initial cost of a multi-variable transmitter, and you have an exceptional value. Tertiary devices. With EFCs, the responsibility to enter and maintain information used by the flow computer's flow calculations and the maintenance of the subsequent audit trail information is many times shifted from the office to the field. Other responsibilities being moved to the field are data editing and recalculation. The office still handles the data processing, accounting and archiving.

AGA configuration options. Older contracts based

on the 1985 AGA equations are still in place while new contracts have moved to 1992 standards. Does the flow computer allow the calculation options to be chosen by the customer and set up on a per run basis? Are there any hard-coded parameters? If so, ensure that they meet your contractual obligations.
U n d e r s t a n d i n g m e t h o d s o f compressibility Compressibility is the most math intensive operation the EFC will have to perform. AGA8 is the standard that addresses the calculation of compressibility factors for natural gas and other related hydrocarbon gases. The compressibility factor is referred to and appears as the Z factor in the AGA3 gas flow calculations.

Deciding which method to use should be a simple decision since the factors involved in determining which method to use are straight forward and easy to use. Unfortunately, if you select the wrong method for your application, you may be introducing as much as 1% error into your equations. To determine which method to use, first ask yourself if the operating pressure exceeds 1750 psia o ! the temperature could be less than 17 F o.__r,could be greater than 143 o F. If your application required you to answer yes to any of the above questions, then you need to use the detailed method. If you can answer no to all the above questions, then you need to look at the following table. Quantity Normal Range .554 -.87 477 - 1150 BTU/scf 18.7- 45.1 M J/m3 45 - 100 0 - 50 0-30 Expanded Range 0.07 - 1.52 0 1800 BTU/scf 0 - 66 M J/m3

Put in simple terms, Z (compressibility) is the factor that is used to account for differences in volumes calculated by the ideal gas law at different pressures and temperatures from what real test data actually shows. Remember, the ideal gas law PV=nRT where P, V and T are the pressure, volume and temperature, n is the number of moles (which deals with how many gas molecule are in the volume) and R is a gas constant used to balance the equation. The idea was that for a given gas sample, regardless of PV and T, the product nR would be a constant. PV/T = nR Therefore, in an ideal world, you could calculate volume at different pressures and temperatures if you knew some pressure, temperature and volume to relate it to. In real life, it was found that for the most part, as pressure rises, the volume would be less than the ideal law calculates. Thus much time and effort was invested in developing equations that could be used to calculate Z and match the empirical test data. Thus, the real world equation takes the form PV=nRTZ We now have severall ways to calculate Z. Prior to 1985, NX-19 was the most common way to calculate Z. Since 1992 when AGA3 was updated, most companies have adopted the 1992 AGA8 calculations since the 1992 AGA3 specifies the 1992 AGA8. BUT, the 1992 AGA8 has three different acceptable methods for compressibility. They are the: Detailed Method Gross 1 Method Gross 2 Method

Relative Density Gross Heating Value Gross Heating Value Mole % Methane 0 - 100.0 Mole % Nitrogen 0 - 100.0 Mole % Carbon 0-100.0 Dioxide Mole % Ethane 0 - 10 0 - 100.0 Mole % Propane 0-4 0 - 12.0 Mole % Total 0 - 1 0-6.0 Butanes Mole % Total 0 - 0.3 0 - 4.0 Pentanes Mole % Hexanes 0 - 0.2 0 - dew point Plus Mole % Helium 0 - 0.2 0 - 3.0 Mole % Hydrogen 0 - 10.0 0 - 100.0 Mole % Carbon 0 - 3 . 0 0-3.0 Monoxide Mole % Argon # 0 - 1.0 Mole % Oxygen # 0 - 21.0 Mole % Water 0 - 0.05 0 - dew point Mole % Hydrogen 0 - 0 . 0 2 0-100.0 Sulfide # The normal range is considered to be zero for these compounds. This is the same table found on page 3 of AGA Report 8. Now, if any of your components fall into the expanded range listed above, you need to use the DETAILED method. If the GROSS method is still an option, you will need to know the heating value, relative density and molar

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percent for carbon dioxide for GROSS METHOD 1 or you will need to know the relative density, and the molar percent for carbon dioxide and nitrogen for GROSS METHOD 2

Historical Averaging techniques. API Chapter 21 defines four different methods of historical averaging techniques. They are flow dependent linear flow dependent formulaic flow weighted linear flow weighted formulaic.
Will the flow computer support all of these techniques and are they user selectable? If it does not, what is the default and does it meet your contractual requirements

Understandina averaqinq techniques

The easiest way to understand averaging [.1][.2]techniques is to first understand a linear average versus a formulaic average, then understand a flow-dependent versus a flow-weighted average. Once these are understood, it is a simple matter to combine them into the 4 different methods. To start with, let's assume we have the following data: Sample 1 2 3 4 5 Temp 2 3 4 5 6 PF 14 15 16 17 18 HW 10 0 50 30 40 Sqrt(HW*PF) 11.83 0 28.3 22.6 26.8

whether there is flow or not, the sample is multiplied by either a one or a zero. (14"1+15"0+16"1+17"1+18"1) / 4 = 16.25 A flow-wei.qhted averaqe has a weighting factor applied to the sample before it is averaged. Since the flow is not known at the time of the sample period, the API Chapter 21 recommended flow weighting factor is the square root of the Differential Pressure (DP) for that sample. [(14*sqrt(10)+15*sqrt(0)+ 16*sqrt(50)+ 17*sqrt(30)+l 8 *sqrt(40)] / [sqrt(10)+sqrt(0)+sqrt(50)+sqrt(30)+sqrt(40)] = 16.54 These demonstrate the different ways to calculate averages per API Chapter 21. Unfortunately, there is no recommendation as which method would be of benefit under known flow conditions. This decision is up to individual companies and/or specific contracts.

Future expansion capability. How adaptable is the flow computer to different situations? Projects that start out as basic gas measurement systems may evolve into monitor and control applications, so always consider the I/O expansion capabilities of the EFCs. Also consider the additional load requirements being placed on the power system. You should address up front how to expand the system even though you may not plan to do it until later. Operating system storage. Flow computers that utilize newer technologies such as "Flash" ROM
storage rather than EPROM allow their firmware to be upgraded in the field or over remote communications links by a simple file download. Compare this capability to removing the unit from service and replacing or "burning PROMs". When multiplied by several hundred units, it is easy to see the savings that can be realized by not having to visit each site.

Linear versus example

formulaic

pressure

average

A linear average is the type of average that we are most familiar with: (14+15+16+17+18) / 5 = 16 A formulaic average for gas measurement purposes is computed by averaging the roots of the sample, then squaring the average. [{sqrt(14)+ sqrt(15)+ sqrt(16)+ sqrt(17)+ sqrt(18)} / 5 ]^2 = 15.97

Historical database format and configuration. Because historical requirements change from application to application, you'll want a unit that
allows you to define which points are archived. For instance, at one station you my want a history of the line pressure while another station may require the totalization of compressor run time for preventive maintenance. Look for flexibility in the flow computer. Units that provide multiple communication ports that are both hardware and software configurable provide tremendous flexibility by allowing connections to

Flow-dependent example

vs.

flow-weighted

average

For simplicity, we will use linear averages to demonstrate. A flow-dependent averaqe simply means you are to keep the sample if there was flow (based on the low flow cutoff) or toss it out if there was no flow for that sample. To keep track of

Communication port availability.

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several types of communicating devices. For example, such a unit can communicate to a host both through a radio or leased line, while at the same time communicate to an intelligent device such as a gas chromatography.

Additional I/O. Usually, the first question is "What

are the I/O expansion options and the cost?" The next question should be "how will I interface them to the real world?" Discrete inputs and pulse inputs are usually straightforward to implement. On the other hand, there are a few points to consider regarding discrete outputs, analog inputs and analog outputs.

Local keypad access. Keypads are not always a

requirement and, in some cases, may not be desired. When keypads are acceptable, access to information and calibration procedures can increase operator efficiency. Common activities such as changing orifice plate constants, verifying data values, calibration and setpoint changes can be done easily through a local keypad. If you choose a device with a keypad, be sure that it has and that you use proper security.

Discrete Outputs. Most EFCs provide a solid-state output that can source in the neighbor hood of 100 mA. If this is not adequate, an interposing relay will be needed. If external inductive loads are controlled by the EFC, adding a "snubber" diode across the load should eliminate any spike created when the coil is deenergized. This is sometimes helpful. Analog Inputs and Outputs. If you choose to use
4-20 mA transmitters, they add a substantial load to the power system. Also, their performance may be questionable on nominal 12 V solar systems unless the EFC has transmitter sourcing voltage available. Low-power 1-5 VDC transmitters add minimal overhead to the power system. Even though they usually cost more initially, the long term saving and performance are often justified.

Adding Control to EFC Installation

Most systems start out as basic electronic gas measurement systems. In the beginning, the EFC will simply measure gas flow. You can substantially increase the system's total value by adding enhancements such as communications, monitoring and control. If control is to be considered, look at a device that will support the type of PID or logic control, additional I/O and how the additional power requirements will affect your system. Some common control applications that the EFC can perform include: Basic Flow Control - Analog or discrete PID control to maintain a flow set point. Pressure Control - Analog or discrete PID control to maintain a pressure setpoint. Flow Control with Pressure Override. Volume Nomination - Flow to an allowed volume, then shut down. Price Optimization - at a header, flow the most profitable stream the hardest, while using less profitable streams as makeup. Compressor Control sequencing of compressors, coordinate loading between compressors. Odorant Injection - injection per volume of flow. Gas Sampler Control - obtain samples per volume of flow. Plunger Lift - implementation of plunger lift algorithm to reduce additional on-site electronics. Tank Level control - blow down of condensate tanks. Alarm Reporting spontaneous reporting of alarm conditions to an operator or host. Well Shutdown - shutdown of operation on safety exception.

Understanding solar power in control applications using EFCs

For a system to be reliable it must have a dependable power source. The common choices are between AC and solar powered systems. A properly sized power system must take into account both power consumption and autonomy.

Power consumption refers to the load on the power

supply and should take into account constant and peak loads. Once you have the load, you can determine the amp-hour per day requirement.

Autonomy is the battery backup time.

It is the amount of time the flow computer can operate on battery power without any external charging. The incorrect sizing of batteries and/or solar arrays for a required load is perhaps the BIGGEST factor for premature battery failure, resulting in higher overall system life-cycle cost. The most common battery type used with solar and line power backup systems is the sealed lead-acid gel battery. This battery has three characteristics that determine its life expectancy. First, when 80% of it rated capacity has been discharged, its voltage has probably dropped to an unacceptable level,

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usually less than 11 VDC. This is referred to as an 80% depth of discharge. Second, up to 70% of available battery capacity can be lost in sustained ambient temperatures of -30 degrees C (-22 degrees F). Third, frequent cycling to a depth of discharge in excess of 50% can reduce battery life by as much as a factor of three. The number of times that a battery can be cycled, depending on its depth of discharge per cycle, can range from 200 to 1500 cycles. On solar-powered systems, it is critical to ensure that battery capacity and panel size are sufficient to account for ambient temperature swings and typical winter conditions to prevent excessive daily discharge. Failure to do so means you will be replacing batteries prematurely which directly relates to higher lifetime cost. In a poorly designed application, if a high depth of discharge occurs on a daily basis, batteries can fail in as little as 200 cycles. This means you may be replacing several thousand dollars worth of batteries that would still be alive if they were properly sized to the application.

approximately 28 mA. The associated board electronics may contribute an additional 2 mA . Together the mA overhead can be close to 30 mAmps on the solar-powered system. Now we calculate the amp-hr per day usage of an analog output: 0.030 amps * 24 Hrs/day = .72 amp-hrs/day
Example - DO Control Power Consumption Assuming that the deadband is set so that control adjustments are made only 10 seconds out of every hour, and the load during that time is 2100 mA (2000 mA for the actuator and 100 mA for the relay) we have

2.100 Amps * 10 secs/3600secs/hrs*24 hrs/day = 0.14 amp-hrs/day This shows that even though a 2 amp load may seem like a lot at first, under certain operating conditions it can actually be less of an overall load than a 4-20 mA signal. To summarize, be sure to account for all the variables, including the additional load placed on the system when control is added, additional enclosures that may be required to house batteries, and geographical area. In a nutshell, don't skimp on power because the issue can come back to haunt you.
Communications

Control and Solar Power

There are two common ways to implement control with an EFC. One is to use a 4-20 mA analog output, the other is to use two discrete outputs. The analog output allows for much finer control but has a constant draw on the system. Discrete output (DO) control has virtually no overhead associated with the DOs except when energized. In both cases, be sure to include any overhead from the control device in your power system calculations. Surprisingly enough, when using DO control the power system can remain modestly small even when electrically operated actuators with substantial current draws are required and IF you set up the application properly. 12 VDC electric actuators can draw up to 2 amps of current when active. This is a huge load on the solar-powered system. In reality, if these types of actuators are used on fairly steady processes, and the process can tolerate a deadband around the setpoint, then the load can be tolerated as shown below.
Example - 4-20 m A m p Control Power Consumption Let's assume the process is set up such that an average of 14 mA is the average output. The EFC should provide a 24 VDC sourcing voltage, so on the 12 VDC side, a 14 mA signal has the overhead of 330

The most frequent enhancement to basic EFM, and the most beneficial, is the addition of communications to a host system. Communications allows measured data to be collected and parameters, such as gas analysis, to be remotely entered. For example, site data is made available to operators so that they can better plan their daily tasks. Alarms can be reported on sensitive installations so that corrective action can be taken and well control and nominations can also be handled. Common methods of communications are through dial-up modems, leased-lines (Bell 202), radio (licensed and unlicensed frequencies), microwave and satellite. Combinations of these can be used as well. Each method has its advantages and disadvantages. Frequency of polling and speed should be balanced with cost. Site requirements may dictate communications to be close to real-time or as seldom as once a month.

With radio systems, it is especially important that enough time and money be allocated to design and implement the most dependable system possible. Generally, communication speed and availability relate directly to cost. Some EFMs support a communications scheme that can substantially reduce power system requirements, resulting in a battery and panel size reduction of over 50%. Even a modest reduction of the power system of $100 dollars per site on a 100 site project can result in savings of $10,000 on the initial project cost. A poorly designed system can waste thousands of dollars in troubleshooting and maintenance cost.

Conclusion Do your homework when applying EFC to measurement and control applications. There is much to be gained from a well-designed and executed project, and there is much to lose when long-term plans are not carefully considered.

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