CORIOLIS METER FOR CUSTODY TRANSFER APPLICATION PERFORMANCE OF THE FOXBORO CFS20 CORIOLIS METER AND CFT50 TRANSMITTER WITH SMALL VOLUME PROVER

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1 CORIOLIS METER FOR CUSTODY TRANSFER APPLICATION PERFORMANCE OF THE FOXBORO CFS2 CORIOLIS METER AND CFT5 TRANSMITTER WITH SMALL VOLUME PROVER Robbie M. Lansangan, Invensys Foxboro Michael Reese, Invensys Foxboro Manus Henry, Oxford University 1 INTRODUCTION In the oil & gas industry, custody transfer is a form of transaction that involves the hand-off of the physical commodity from one operator to another. A custody transfer transaction, for instance, is performed between the well operator and the first transportation operator. Examples of the first transportation operator include pipeline, truck or ship. Subsequent custody transfer transactions for the crude commodity may take place until the product arrives at the refinery. Flow meters used in custody transfer measurements normally require a means of performance verification. This is generally referred to as meter proving. There are different types of meter provers that are used in the industry. These include bi-directional ball prover, compact piston or small volume prover (SVP). Generally, large bi-directional ball provers are used for high volume custody transfer operations. Small volume provers are typically part of a mobile truck-mounted system that travels from site to site in order to prove meters on a scheduled periodical basis. Meters are proven by determining the repeatability over consecutive proving runs, typically at a flow rate close to the normal operating conditions of a Lease Automated Custody Transfer (LACT) unit. Typical performance requirements for a meter are.5% repeatability and.25% between scheduled proving events. Mechanical meters, such as turbine or positive displacement, have long been the meters of choice in liquid custody transfer operation. Over the last 1-15 years, Coriolis meters have gained acceptance due to, among other things, the lack of moving parts that could wear out over time. However, questions around the ability of a Coriolis meter to have acceptable repeatability with numerous issues involved such as meter zero stability, installation, pulse output delay, etc., seems to have lingered. In terms of the issue of pulse output, one approach used to improve repeatability is to filter the pulse output from the transmitter. While this approach has oftentimes worked, it has somewhat the characteristics of a black box. This paper presents the performance of an all-digital Coriolis technology, particularly on the improvement of repeatability performance, without relying on pulse output filter tuning. The Foxboro CFS2 3 Coriolis meter and the CFT5 mass flow transmitter were tested at a flow laboratory using a small volume prover, over the entire flow capacity of the meter. With a prover volume of 2 gallons at the high end of the flow range, single pass runs were completed in approximately 1.5 seconds. Repeatability values obtained ranged from.3%-.4%. These results were obtained with no filtering applied to the meter s pulse output. Two operating companies have recently installed the Foxboro Coriolis meter in custody transfer for crude oil. In one instance, the CFS2/CFT5 was proven with a 15 gallon Small Volume Prover. Runs were performed using a single-pass, three-pass and ten-pass method at the same flow rate, which is about % of nominal maximum flow for the meter. The single pass runs were less than 2 seconds. Repeatability for each set of proving data was.35%,.42% and.22%, respectively. In another installation, the Foxboro Coriolis was proven with a 21 gallon bi-directional ball prover. The flow rate was around 25% of the meter s nominal maximum rate, with a resulting trip time of around 11 seconds. The repeatability obtained was.28%. 1

2 In both cases, the base K factor was set at 1, pulses per barrel. The pulse output damping was set to.. 2 FIELD PROVING OF CORIOLIS METERS WITH SMALL VOLUME PROVERS Today, the field (in-situ) proving of Coriolis meters, particularly with small volume provers, or SVP, seems to be well accepted and best practice methods have been learned and established over the years. In 16, Whitman presented a paper that attempted to address the topic of how to successfully prove a Coriolis meter in the field using small volume provers [1]. He concluded that Coriolis meters can be properly calibrated, or proved, using small volume provers, both in mass or in the more stringent volume method, citing the commonly quoted good practice requirements of piping installation, zeroing and flow conditions. Around the same time, the Weights and Measures Division (WMD) of the National Institute of Standards and Technology (NIST) published a three-part series of articles on the subject of Small Volume Provers [2]. This was an apparent response to an increase in the use of SVPs in numerous state officials jurisdiction. As a result, there was a swell in the number of questions coming from the field regarding the design, use, operation and implementation of SVPs in the inspection, testing and calibration of commercial measuring devices. The first article in the NIST papers provides a reference for the often confusing and interchangeably used terminology used to describe these provers. NIST defines an SVP, also referred to as Compact, Piston, or Ballistic prover as a type of conventional pipe prover in which a displacer travels through a very short section of a pipe or cylinder, requiring less than 1, pulses to be generated for a prover run. Whitman [3] and Vandiver [4] offers guidelines on when to prove a Coriolis meter as well as good practice procedures and methodologies for a Coriolis meter to prove. An interesting comment from reference [4] is Make sure the meter response is appropriate for the prover size. The pulse output damping value should never be set higher than.8 second. The pulse output damping has its origin from the commonly held assumption that due to the Coriolis meter s pulse output being manufactured, there exists an inherent delay time between the process event and the transmitted pulse output carrying the flow measurement information. This issue has gathered sufficient momentum in the measurement community and has often been cited as one of the reasons why a Coriolis meter failed to prove. Last year, an API Task Group was formed to investigate the Effect of Microprocessor Generated Pulse Output Delay on field proving of meters including Coriolis and Ultrasonic meter using SVPs. Assuming that the prover size selected (or often times what is available) gives the proper meter response time and the correct pulse output damping has been chosen, there is always the question of the number of proving runs to perform for a proving point and the number of passes that constitutes a run. The API Manual of Petroleum Measurement Standards, Chapter 5, Section 6 on Metering, Measurement of Liquid Hydrocarbons by Coriolis Meters [5], provides a concise, yet essentially complete guideline for Coriolis meters in custody transfer of hydrocarbon liquids. Table 1 of the above document, reproduced below, provides a guideline for the typical number of proving runs as well as the number of passes per run for different types of provers, including SVP. 2

3 Table 1 Typical Number of Proving Runs [5] Proving Method Conventional Pipe Prover Small Volume Prover Tank Prover Master Meter Number of Runs 5 consecutive bi-dir. runs 2 5 runs of multiple passes each 2 consecutive runs 2 consecutive runs A closer inspection of these documents, however, reveals that guidelines and good practice recommendations are still open to numerous interpretations. For instance, questions often arise as to how many passes per run are permitted, what pulse output damping to use, what constitutes a minimum acceptable run time, etc, not to mention the installation issues. These topics become more pressing particularly when the Coriolis meter in question fails to prove. As a consequence, the community practicing the art, from the providers to the operators, have often developed their own version of how to prove a Coriolis meter. 3 CORIOLIS METER FOR CUSTODY TRANSFER A Coriolis meter can be partitioned into two sections: the sensor and the transmitter. The sensor is essentially a mechanical component providing the pipework through which the process fluid flows, including the measurement section which is able to vibrate, along with (usually) coil-based sensors and driver(s) to monitor and maintain the sensor vibration. The transmitter is essentially an electronic device with electrical connections to the sensors and drivers of the sensor. The tasks of the transmitter are to initiate and maintain sensor vibration and to extract mass flow, density and possibly other process data from the sensor signals. The process data is typically then communicated to the outside world either in analog or digital form. In custody transfer application, the pulse or frequency output is the often preferred carrier of the measured quantity of mass or volume information. Several studies and published papers have shown that the major source of delay in this flow of information from the sensor to the pulse output lie in the transmitter [5]. 3.1 The Foxboro CFT5 Transmitter The Foxboro CFT5 transmitter is an all-digital design which eliminates certain classes of fault (e.g. stalling with two-phase flow) and which offers a much improved dynamic response. The transmitter is digital in that all components, other than elementary front end circuitry, are digital devices. Specifically the drive waveform used to initiate and maintain sensor oscillation is synthesised digitally. Following is a brief technical discussion of the CFT5 transmitter. The transmitter uses a Field Programmable Gate Array (FPGA) a programmable logic chip - for all real-time aspects of sensor control, for example drive waveform synthesis. A third useful digital technology is the audio codec (combined stereo ADC and DAC two sensor channels in and two drive channels out) providing 24bit data at 4kHz. An estimate of the dead time of the prototype transmitter is as follows. Although the codec samples at 4kHz, there is a 61 sample group delay between input and output, equivalent to 1.5ms dead time. Filtering in the FPGA takes 1ms. For a typical drive frequency of 8Hz, there is a delay of approximately 6ms (per half-cycle) for data acquisition. The processor required a further 1.5ms to perform the measurement calculation. The pulse output is updated immediately after each measurement calculation has been completed, and there are negligible delays (<1ms) in propagating a step change in flowrate through to the pulse output, even for low 3

4 flowrates. As discussed below, the high precision of the measurement calculation and frequency generation means that no averaging or filtering is required to provide a smooth measurement output, which results in a much improved dynamic response. Overall, this analysis suggests a total dead time of 1-16ms from sensor signal input through to pulse output, depending on where in the half-cycle a step change occurs. In their ISA 22 paper [6], Wiklund and Peluso explain the growing importance of the dynamic response of flowmeters. The dynamic response indicates how rapidly a meter is able to track changes in flowrate, for example during a batching process. The authors of [6] modelled the dynamic response of several flowmeter technologies (differential pressure (DP) with orifice plate, electromagnetic, vortex and Coriolis), testing the products of several manufacturers. Figure 1 shows, for the fastest meter in each class, the response to an instantaneous unit step change in the true flowrate, based on the parameter values reported in [6]. As can be appreciated from Fig 1, there are two aspects to the dynamic response an initial deadtime where there is no change in output, and then a first or second-order response towards the new steady-state value. In [6], DP and orifice plate is shown to have the fastest response, while Coriolis has the slowest response. While this finding aligns with other user experience [7], recent studies [8] have shown that Coriolis meters can have a response time in the order of 5-6 ms for the similar conditions in [6]. Nonetheless, the fastest response curve in Fig 1, superimposed on the data from [6], is the performance of Foxboro Coriolis meter. The dead time is 1-16ms, and the new steady state value is achieved within a further 2-3ms. Figure 1: Nominal Step Response of Different Flow Meters 3.2 API Task Force on Microprocessor Generated Pulse Output The manufactured pulse output derives its origin in comparison with the way a mechanical meter generates a pulse output. Briefly, a turbine meter s blades, or a gear within a PD meter passes near a Hall Effect sensor coil. As the blades, or gear teeth rotate and pass this stationary pickup coil, a pulse is generated, the output rate of which is proportional to the turbine rotation speed, and the flow rate of the fluid. With the turbine or PD meter each pulse represents a discrete volume of fluid. Coriolis meters can output a derived pulse rate proportional to mass or volume flow which can be termed Microprocessor Generated Flow Pulses (MGFP). A feature of MGFP is that the transmitter processing has a finite delay time, and together with measurement and output signal filtering, the reported mass flow may lag the true measurement. In 21 API formed an ad hoc task group to investigate what impact (if any), MGFP had on the measurement process, especially when the flow meters were being proved. Preliminary testing on a number of microprocessor based flow meters (Coriolis and Ultrasonic) showed that the flow pulse output by the flow meters did in fact lag the flow measurement and that under certain circumstances this could cause additional uncertainty to be introduced during the proving operation. API subsequently formed the 'Microprocessor Based Pulse' TAG, and funded flow lab research to investigate the issue more fully. At least eight different flow meters with pulse multiplying electronics were used, including Coriolis, ultrasonic, and helical turbines, from a number of flow meter vendors 4

5 A brief description of the Foxboro CFS2 3 Coriolis meter performance from the TAG trials follows. The Task Force is in the process of finalizing the test results and this paper will defer to the API report for the full results. Flow disturbances were deliberately introduced during the proving cycle, each trial was repeated 1 times and repeatability assessed. The SVP electronics used had the ability to add a delay to the gating signal used to count pulses for the response test meter. With the Foxboro Coriolis meter, it was discovered that it is possible to tune this delay for each filter setting so that the resulting prove result correlated with the reference master turbine meter. It was observed that the delay time tuning was very predictable to the point that it can be mathematically predicted. This level of performance is attributed to the CFT5 dynamic response characteristics discussed above. The very fast responding CFT5 flow transmitter electronics was then subjected to the rigors of liquid custody transfer proving requirements with a small volume prover. The following sections present the results of laboratory and field performance of the Foxboro Coriolis meter. 3.3 Proving the Foxboro Coriolis Meter Repeatability is used as an indication of whether the proving results are valid. Two generally accepted methods of calculating repeatability are the Average Pulse Data Method and the Average Meter Factor Method. In this paper, the Average Meter Factor Method is used because it eliminates the changing fluid density and prover reference volume due to changes in pressure and temperature during the runs. Typical requirement for a meter to prove is.5% repeatability during a prove and.25% between scheduled proving events. For successive runs at a fixed flow rate, repeatability, expressed in percent, is calculated as follows: Repeatability = (MAX ƒ i MIN ƒ i )/MIN ƒ i (1) where ƒ i is the net meter factor for each run. Note that Equation (1) uses the minimum value instead of the average value for the divisor, resulting in a more stringent test of repeatability. A study was undertaken to determine the performance of a 3 Foxboro CFS2 Coriolis meter and the CFT5 transmitter using a small volume prover. Tests were conducted in an industrial testing facility engaged in the calibration and proving of flow meters for liquid custody transfer, both in the field and in the laboratory. The prover loop where the study was conducted employs the chain-driven Calibron small volume prover. The flow loop capacity ranges from.2 to 1,4 gpm. The prover volume used in the study is 2 gallons. Figure 2 shows the laboratory installation. The pulse output from the CFT5 was connected to laboratory flow computer with the output damping set at zero (), with a meter factor of 1, pulses per barrel. Figure 2: Laboratory Prover Loop Testing of Foxboro Coriolis Meter Five consecutive single pass proving runs were conducted from 2% to the nominal 1% meter capacity of 7 bph. The repeatability obtained at each point is shown in Figure 3, 5

6 which is well within the.5% line over the entire flow range. The average net meter factor ranged from.88 to 1.41 resulting in a meter linearity of.15%. At the top end of the flow range, the run time per prover pass is about 1.5 seconds. CFS2 3 in + CFT5 - Custody Transfer Small Volume Prover.8%.7%.6%.5%.4%.3%.2%.1%.% % 2% 4% 6% 8% 1% 12% % of Nominal Full Scale Flow Range Repeatability Figure 3: Repeatability Performance of the Foxboro Coriolis Meter 4 FIELD EXPERIENCE The results obtained in the laboratory environment can be argued as ideal when compared to in-situ or field proving. A question can then arise as to whether a similar performance can be obtained in the field. With performance obtained in the laboratory setting, two operating companies in the USA became interested in the Foxboro Coriolis meter and wanted to find out whether, in fact, a similar performance can be obtained in their field operation. Company A installed two CFS2 3 meters labelled South and North meters along with the CFT5 transmitters. Figure 4 shows the field installation of both meters. Figure 4: Two Foxboro Coriolis Meters in Crude Oil Custody Transfer with Operator A Shortly after the meters were installed, they were proven with a 15 gallon Brooks Compact prover. Figure 5 shows the field proving truck with the SVP. A base K factor of 1, pulses per barrel was used with zero () damping on the pulse output. Five consecutive single pass and triple pass runs were conducted for each meter. 6

7 Figure 5: Foxboro Coriolis Meter Proving with a Small Volume Prover Table 2 and Table 3 show the proving data for the South and North meters, respectively. Good repeatability results were obtained for both meters for this installation, as evidence from the data shown below. In the case of North meter, repeatability showed an improvement with the 3 pass per run data compared to the single pass runs. Note that for all the data points, the run time per prover pass is approximately 1. seconds. A second installation with another operator involves 2 Foxboro CFS2 3 Coriolis meters. One of the meters is installed on a LACT unit with crude going into a pipeline, show in Figure 6 below. The second meter was installed on LACT unit for truck loading. Figure 6: Foxboro Coriolis Meter in Crude Oil Custody Transfer with Operator B Both meters were proven with a Maloney 1 bi-directional pipe prover. Similar to the previous installation, the pulse output was connected to the prover flow computer, using a base K factor of 1, pulses per barrel and zero () pulse output damping. Five consecutive bi-directional runs were conducted at a flow rate of 175 bph which corresponds to approximately 25% of the meter s nominal maximum capacity. Pressure and temperature for both the prover and the meter remained constant at 11 psig and 7ºF, respectively. The average round trip time was 13. seconds. The repeatability obtained from the first set of five consecutive runs was.3% with an average meter factor of.82. The witness from the operating company deemed no further runs were required based on the results obtained from the first run. 7

8 Table 2-- Case 1 Foxboro Coriolis Meter Proving Data with a SVP South Meter Prover Data Volum e bbl Temperature (F) 86.5 Pressure (psig) Meter Data Base K 1, P/bbl Size (in) 3 Pulse output damping Temperature (F) 86.5 URV 7 bbl/hr Pressure (psig) Product Data Fluid Generalized Crude Densit y.852 g/cc API 6 F 1 Pass Proving Data Run Prover Meter Meter Flow Rate Meter Meter Net K Volume Volume Factor Pulses (Sbbl) (Sbbl) (Sbbl/hr) (P/bbl) Average SD Dev.5%.3%.35%.118%.35%.35% Repeatability.35% Avg Net Meter K Average Pass Time 1.5 sec 3 Pass Proving Data Run Prover Meter Meter Flow Rate Meter Meter Net K Volume Volume Factor Pulses (Sbbl) (Sbbl) (Sbbl/hr) (P/bbl)

9 Average SD Dev.1%.37%.42%.186%.42%.42% Repeatability.42% Avg Net Meter K Table 3- Case 2 Foxboro Coriolis Meter Proving Data with a SVP North Meter Prover Data Volume bbl Temperature (F) 86.6 Pressure (psig) Meter Data Base K 1, P/bbl Size (in) 3 Pulse output damping Temperature (F) 86.6 Nom URV 7 bbl/hr Pressure (psig) Product Data Fluid Generalized Crude Density.852 g/cc API 6 F 1 Pass Proving Data Run Prover Meter Meter Flow Rate Meter Meter Net K Volume Volume Factor Pulses (Sbbl) (Sbbl) (Sbbl/hr) (P/bbl) Average SD Dev.5%.7%.7%.182%.7%.7% Repeatability.7% Avg Net Meter K

10 Average Pass Time 3 Pass Proving Data 1.6 sec Run Prover Meter Meter Flow Rate Meter Meter Net K Volume Volume Factor Pulses (Sbbl) (Sbbl) (Sbbl/hr) (P/bbl) Average SD Dev.5%.55%.5%.87%.5%.5% Repeatability.5% Avg Net Meter K CONCLUSIONS This paper has presented results, both from laboratory testing and early field installations, on the performance of the Foxboro CFS2 3 Coriolis meter and the CFT5 flow transmitter. It is noted that in both cases, the excellent results obtained in terms of repeatability and linearity (from the laboratory tests) were obtained with single pass runs and with no damping on the pulse output from the CFT5 transmitter. Furthermore, it has been demonstrated that the above performance can be obtained using a small volume prover, with single pass time of less than 2 seconds. It is also noted that the performance obtained can be attributed to the all-digital CFT5 platform which utilizes state-of-the-art microprocessor and microchip technologies. The novel drive architecture, coupled with the all-digital design allows for very fast dynamic response to transients. While longer term results are certainly needed to build statistical confidence on the Foxboro Coriolis meter s performance, it is hoped that the product offers the hydrocarbon flow measurement community with a device that takes away some of the uncertainties related to in-situ Coriolis meter proving, by taking the pulse output filter tuning out of the process. 6 NOTATION f i Parameter used to calculate repeatability; can either be the net meter factor or pulse count K meter pulses per barrel 7 REFERENCES 1

11 [1] Whitman, S. K. Operational Experiences Proving Mass Flow Meters with Small Volume Provers, presented at the Energy Week Conference and Exhibition, February 16 [2] Lee, G. D. Part 1: Small Volume Provers -- Identification, Terminology and Definitions, March 25; Part 2: Small Volume Provers History, Design and Operation, June 25; Part 3: Small Volume Provers (SVPs) Mathematical Determination of Meter Performance Using SVPs, August 25, National Institute of Standards and Technology Publications, accessible at the web site [3] Whitman, S. K. API Coriolis Standard for Mass Measurement of Crude Oil, presented at the International School of Hydrocarbon Measurement (ISHM), Class 716. [4] Vandiver, M. Proving Coriolis Flow Meters, presented at the International School of Hydrocarbon Measurement (ISHM), Class CT413. [5] Henry M. et al. The Dynamic Response of Coriolis Mass Flow Meters : Theory and Applications, presented at the 24 ISA Show Technical Conference Symposium, Houston, TX. [6] Wiklund, D. and Peluso, M. Quantifying and Specifying the Dynamic Response of Flow Meters, presented at the 22 ISA Technical Conference. [7] Reizner J. R. Coriolis Mass Flow Meters in Batching Applications --- The Good, The Bad and the Ugly, presented at the World Batch Forum North American Conference, Chicago, May 24. [8] Clark C. and Cheeseright, R. Experimental Determination of the Dynamic Response of Coriolis Mass Flow Meters, Flow Measurement and Instrumentation 17 (26). 11

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