Instrument Condition Based Monitoring.ppt

Offshore Workshop FLOWSIC600, April 2007  Page 1
Condition Based Monitoring (of Ultrasonic Gas Flow Meters)
Koos van Helden, B.ASc.
International Account Manager Eastern Hemisphere
SICK Engineering GmbH
(Member of SICK|MAIHAK)
in Co-operation with
Data Intelek Sdn. Bhd.

 CBM is an Acronym for “Condition Based Monitoring”
 This means the Performance of a Meter is monitored, and
validated, by using its internal Diagnostics
 Today’s ultrasonic Gas Flow Meters provide a wealth of Data
that can be used for Health Check
 They are f.i.:
 Path Velocities
 Speed-of-Sound
 AGC Levels/Limits
 The Intention is to Answer one basic Question:
”Is the meter still accurate?”
What Is CBM?

 The Problem is many don’t understand the
Diagnostics, since they have many different Meter
Designs to maintain, and often don’t have enough
Time
 Typically Users collect Log Files for Analysis monthly,
or less frequently, and often someone else analyzes
them
 This means a Problem may go undetected for the
entire Month, or more, before it’s identified, assuming
the operator understands what the Diagnostics are
saying
So What Does CBM Mean?

 Today being accurate has never been more
important
 Long-term accuracy of a USM is all User’s desire
 Proving the USM is accurate is a Challenge for
everyone
 Diagnostics have been the promise of USMs for
Years to help insure Custody Transfer Meter is
accurate
Understanding This New CBM Design

 The best Diagnostics are of no Value unless the
Users understand them
 Additionally, subtle Changes in a facility’s Operation
are often difficult to identify
 The Benefit of this Design? – It doesn’t rely on
Interpretation of Diagnostics by the User
Understanding This New CBM Design

 USMs provide several Diagnostics
 Traditionally many have relied on S-o-S Calculations
and Comparison to the meter’s S-o-S as an
Indication of Meter Accuracy
 This is a false Assumption – A meter’s S-o-S can be
accurate compared to AGA #10, but the Meter may
not be measuring accurately
What USM Diagnostics are Important?

4-Path Transducers
Single-Path
Transducers
CBM 4+1 Meter Design – Artist’s Drawing

4-Path
Transducers
Single-Path
Transducers
8-inch, CBM 4+1 Meter

4-Path
Transducers
Single-Path
Transducers
CBM 4+1 Meter Transducer Locations

CBM 4+1 Meter Dual Electronics

 This CBM design uses a single-path, center-line
Meter as a “real-time” Check of the fiscal Meter’s
Performance
 The single Path Meter’s Response will be
significantly greater than the 4-path when the Velocity
Profile changes. These changes can come from:
 Blocked Flow Conditioners
 Meter and Pipeline Contamination (dirty vs. clean)
 Pulsation (single Path samples at a different Rate)
 Potential Problem with Transducers or Electronics
 Any other Issue that is not common to both Meters
How This CBM Design Works

 TransCanada Pipeline (TCPL) has used this
Technique for many Years
 Their Implementation uses two separate Meters
 Upstream (Custody Transfer) Meter is a 4-path
 Downstream is a single-path, single-reflection Meter
 Both Electronics compared in the Flow Computer
History of This Concept

 Output from both Electronics is collected by the
Flow Computer or RTU
 Hourly uncorrected Volumes for the single and 4-path
Meter Electronics are then compared
 An Alarm is generated when the Deviation exceeds a
specified Amount (typically something like 0.2-0.4%)
 Provides “real-time” Analysis of Meter Operation with
alarming at the hourly Level
Using the CBM 4+1 Design

 CEESI tested the first CBM 4+1 meter, a 10-inch
 Conducted on January 15, 2007
 Baseline was 5 Flow Rate Points (3…36 m/s)
 Both the 4-path and single-path calibrated and PWL
implemented in both Electronics
Testing of First CBM 4+1 10-inch Meter

 A subsequent Test was conducted with Blockage of
the CPA similar to testing done on a standard 4-path
Meter
 Canada Pipeline Accessories markets the Nova 50E
(CPA 50E) Flow Conditioner.
 Results of this 4-path are consistent with that of the
12-inch Test presented at the CEESI USM
Conference in June 2006
Testing of First CBM 4+1 10-inch Meter

10-inch, CBM 4+1 Meter Testing at CEESI

10-inch CPA, 40% Blocked

As Found and As Left Results
-1.00
-0.75
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
0 20 40 60 80 100 120 140
Meter Velocity (ft/sec)
%
Error
As Left Verification Points Blocked Flow Conditioner
4-Path, 10-Inch Meter Results

As Found and As Left Results
-4.0
-3.5
-3.0
-2.5
-2.0
-1.5
-1.0
-0.5
0.0
0.5
1.0
0 20 40 60 80 100 120 140
%
Error
As Left Verification Points Blocked Flow Conditioner
Single-Path, 10-Inch Results

 Question: Do other Line Sizes provide similar
Results, and will this Design find much smaller
Blockage?
 To answer, two additional CBM Meters were shipped
to CEESI, one 8-inch and one 12-inch CBM 4+1
Meter
 Same 40% Blockage tested, but additional testing included
3 blocked Holes, and 1 blocked Hole
 3 blocked Holes tested at Bottom, and on Side of Meter
 Single blocked Hole tested only at Bottom of Meter
Additional Concept Validation

12-inch CPA , 40% Blocked

12-inch, 4-Path Meter - 40%Blocked Results
-1.00
-0.75
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
0 10 20 30 40 50 60 70 80
%
Error
Un-Blocked CPA 40 Percent Blocked CPA
12-inch, 4-Path Meter - 40% Holes Blocked

12-inch, Single-Path Meter, 40%Blocked Results
-4.0
-3.5
-3.0
-2.5
-2.0
-1.5
-1.0
-0.5
0.0
0.5
1.0
0 10 20 30 40 50 60 70 80
%
Error
Un-Blocked 40% Blocked
12-inch, Single-Path Meter - 40% Holes Blocked

12-inch CPA, 3 Holes Blocked

12-inch, 4-Path Meter - 3 Holes Blocked Results
-1.00
-0.75
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
0 10 20 30 40 50 60 70 80
%
Error
Un-Blocked CPA 3 Holes Blocked Results 3 Holes Blocked - Rotated 90 Degrees
12-inch, 4-Path Meter - 3 Holes Blocked

12-inch, Single-Path Meter, 3 Holes Blocked Results
-3.0
-2.5
-2.0
-1.5
-1.0
-0.5
0.0
0.5
1.0
0 10 20 30 40 50 60 70 80
%
Error
Un-Blocked CPA 3 Holes Blocked CPA 3 Holes Blocked - CPA Rotated 90 Degrees
`
12-inch, Single-Path Meter - 3 Holes Blocked

Flowing Velocity Ratios at 44.5 ft/s
0.921
1
.020
1
.01
7
0.91
5
0.80 0.85 0.90 0.95 1
.00 1
.05 1
.1
0
Path 1
Path 2
Path 3
Path 4
Average Flowing Velocity (ft/sec)
0.900
0.982
1
.027
0.997
0.80 0.85 0.90 0.95 1
.00 1
.05 1
.1
0
Path 1
Path 2
Path 3
Path 4
0.885
1
.000
1
.039
0.945
0.80 0.85 0.90 0.95 1
.00 1
.05 1
.1
0
Path 1
Path 2
Path 3
Path 4
0.968
0.989
0.994
0.987
0.80 0.85 0.90 0.95 1
.00 1
.05 1
.1
0
Path 1
Path 2
Path 3
Path 4
Baseline
3
Holes,
Bottom
3
Holes,
Side
40%
Holes
Profile Factor: 1.109 Profile Factor: 1.059
Profile Factor: 1.014
Profile Factor: 1.114
Path Ratios Path Ratios
12-inch, 4-Path Meter Path Ratios

Baseline
3
Holes,
Bottom
3
Holes,
Side
40%
Holes
12-inch, 4-Path Meter Profile/Asymmetry Factors

Baseline
3
Holes,
Bottom
3
Holes,
Side
40%
Holes
Average Turbulence: 4.02 Avg. Turbulence: 4.33
Average Turbulence: 2.44 Avg. Turbulence: 7.03
12-inch, 4-Path Meter Turbulence

12-inch CPA, 1 Hole Blocked

12-inch, 4-Path Meter - 1 Hole Blocked Results
-1.00
-0.75
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
0 10 20 30 40 50 60 70 80
%
Error
Un-Blocked CPA Single Hole Blocked - Botton CPA
12-inch, 4-Path Meter - 1 Hole Blocked

12-inch, Single-Path Meter, 1 Hole Blocked Results
-1.00
-0.75
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
0 10 20 30 40 50 60 70 80
%
Error
As Left Single Hole Blocked CPA
12-inch, Single-Path Meter - 1 Hole Blocked

Baseline
Baseline
1
Hole
Blocked
0.921
1
.020
1
.01
7
0.91
5
0.80 0.85 0.90 0.95 1
.00 1
.05 1
.1
0
Path 1
Path 2
Path 3
Path 4
0.898
0.994
1
.035
0.953
0.80 0.85 0.90 0.95 1
.00 1
.05 1
.1
0
Path 1
Path 2
Path 3
Path 4
1
Hole
Blocked
Profile Factor: 1.109 Profile Factor: 1.096
Average Turbulence: 2.44 Average Turbulence: 3.05

8-inch CPA, 40% Blocked

8 inch, 4-Path Baseline and 40% Blocked CPA
-1.00
-0.75
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
0 10 20 30 40 50 60 70 80
%
Error
Un-blocked CPA 40 Percent Blocked CPA
8-inch, 4-Path Meter - 40% Holes Blocked

8-inch, Single-Path 40% Blocked CPA Results
-4.0
-3.5
-3.0
-2.5
-2.0
-1.5
-1.0
-0.5
0.0
0.5
1.0
0 10 20 30 40 50 60 70 80
%
Error
Un-Blocked CPA 40% Blocked CPA
8-inch, Single-Path Meter - 40% Holes Blocked

8-inch CPA, 3 Holes Blocked

8 inch, 4-Path Baseline and 3 Holes Blocked
-1.00
-0.75
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
0 10 20 30 40 50 60 70 80
%
Error
Un-blocked CPA 3 Holes Blocked - Bottom 3 Holes Blocked - Rotated 90 Degrees
8-inch, 4-Path Meter - 3 Holes Blocked

8-inch, Single-Path, 3 Holes Blocked Results
-4.0
-3.5
-3.0
-2.5
-2.0
-1.5
-1.0
-0.5
0.0
0.5
1.0
0 10 20 30 40 50 60 70 80
%
Error
Un-Blocked CPA
3 Holes Blocked CPA
3 Holes Blocked CPA Rotated 90 Degrees CPA
8-inch, Single-Path Meter - 3 Holes Blocked

8-inch CPA, 1 Hole Blocked

8 inch, 4-Path Baseline and 1 Hole Blocked
-1.00
-0.75
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
0 10 20 30 40 50 60 70 80
%
Error
As Left Single Hole Blocked - Botton CPA

8-inch, Single-Path, 1 Hole Blocked CPA Results
-1.00
-0.75
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
0 10 20 30 40 50 60 70 80
%
Error
As Left Single Hole Blocked - Botton CPA
8-inch, Single-Path Meter - 1 Hole Blocked

 The single-path Meter is very sensitive to Changes in
Flow Profile where the 4-path is very insensitive
 If Velocity Profile changes occur, it is almost
impossible for the Effect to be the same Amount, and
in the same Direction, for both Electronics
Summary of CBM 4+1 Testing

 With little Blockage it is more difficult to detect using
conventional Meter Diagnostic Information
 This Technique can provide an Alarm within 1 Hour of
a Problem occurring
 Identification of a potential Measurement Problem
immediately can significantly reduce Meter Station
Uncertainty
 This Technique does not require any Technician
Analysis Time and is an automated Solution to
validate proper USM Operation
Summary of CBM 4+1 Testing

End of Presentation

Instrument Condition Based Monitoring.ppt

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