SpiritIT_mCT_Petrolchimico_Final_rev1

Flow-X and eXLerate: flexible solutions for
high-accuracy custody transfer applications
G. Ciarlo, N. Bonavita – ABB Measurement & Analytics, mcT Petrolchimico – 25.11.2015

Flexible Solutions for High-accuracy Custody Transfer
Outline
© ABB Group
11/26/2015 | Slide 2
1. Custody Transfer: Needs and Opportunities
2. Tackling the Challenge through Innovation
3. Flow-X: latest technology for flexible yet secure
measurement
4. eXLerate: Data Integration and Management in
critical flow metering applications
5. Selected Success Stories

Custody Transfer: Need and Opportunities
Introduction
© ABB Group
11/26/2015 | Slide 3
 Custody transfer, also referred as fiscal metering, is a typical
practice in O&G any time liquids or gases are traded between
different parties (e.g. two different operators)
 Custody transfer is characterized by a payment, which is
function of the amount of the material exchanged.
 Accuracy in the measurement is of paramount importance
since even very little errors can generate consistent losses for
one of the parties involved
 Typically countries regulate Custody Transfer since it includes
also government taxation and agreements between parties
 Specific standards have been also developed by relevant
organizations (e.g. API, AGA, GERG, GOST, ISO, etc.).

Introduction
© ABB Group
11/26/2015 | Slide 4
 Custody transfer metering stations are highly engineered
systems comprising several components:
 Flow meters
 Temperature and pressure transmitters
 Gas chromatographs and other quality analyzers
 Provers for liquid meter calibration
 Flow computers
 Metering supervisory computer
PT
FT
TT
PT TT
PT TT
FT
FT
PT TT AT

Introduction
© ABB Group
11/26/2015 | Slide 5
 Metering station main function is to provide accurate
measurement, archiving and reporting functionalities for
the fluid transferred between the parties
 Historical data can provide relevant information for the
actual and prior quantities reported:
 To apply corrections to measurement errors
 To update calculations in case of standards changes
 To check if the measurement equipment is outside the
accuracy tolerances or has incorrectly recorded some
measurement parameter
 Data allows parties with different interest to independently
verify the correctness of the reported quantities.

Custody Transfer Needs and Opportunities
Custody Transfer Data – The old situation
Custody Transfer Data = Set of printouts
© ABB Group
11/26/2015 | Slide 6

Custody Transfer Data – Current situation
Custody Transfer Data = Set of electronic files
© ABB Group
11/26/2015 | Slide 7

What can be improved?
 Metering Control Systems are actually made for:
 Daily operation
 …and NOT for:
 Technicians
 Metering Specialist
 Auditors
 Accounting staff
 This means that current generation of metering systems is:
 Dumb
 Inaccurate
 Time-consuming
© ABB Group
11/26/2015 | Slide 8

Outline
© ABB Group
11/26/2015 | Slide 9
measurement

Tackling the Challenge through Innovation
Compelling Reasons for New Technology
© ABB Group
11/26/2015 | Slide 10
 Meters became intelligent with
diagnostics. Flow computers didn’t.
Data throughput increased significantly.
 Significant progress in today’s
mechanical & electronic components,
design, manufacture
 Offering high quality, scalable products
for various applications. Managing cost.
 Upgrade legacy systems with maximum
flexibility to interface old as well as new
technology.
 Integration of supervisory software &
flow computers to a high level.

Value Proposition
© ABB Group
11/26/2015 | Slide 11
 To help address such challenges ABB selected Spirit IT to become part of its family
 Spirit Innovative Technologies help improve customers business performance by providing
innovative technology and value adding solutions in the area of flow computers and metering
supervisory computers

Value Proposition
© ABB Group
11/26/2015 | Slide 12
 Spirit IT recognized:
 The fact that existing products are
based on ageing hardware platforms
that limit the ability to develop state-
of-the-art measurement systems.
 The need to address multiple
markets with a single, cost effective
and scalable solution without
compromise to performance.
 The needs of the systems Upgrade
projects which differ from New green
field projects requiring flexibility to
interface old and new technologies
without sacrificing performance.

Spirit IT Introduction
© ABB Group
11/26/2015 | Slide 13
 A product developing company, with
expertise in System Integration in oil & gas
 Main (R&D) office in the Netherlands
 Established in 2001
 Sales offices in Houston and Kuala Lumpur
 Hardware and software products
 Product design & production
 Software development
 Marketing & Sales
 Customer Support
 Services
 Training, on-site support
 Consultancy; additional services

Spirit IT interest fields
© ABB Group
11/26/2015 | Slide 14
 In its 15 years experience in the Oil and Gas sector, Spirit IT
has developed specific competences in Custody Transfer
applications
 Spirit IT focused on two critical components of metering
station applications:
 Flow Computers  Flow-X
 Supervisory Software  eXLerate
 Spirit IT know-how and solutions complete ABB portfolio,
enlarging the range of advanced products and solution
dedicated to O&G end-users.

Outline
© ABB Group
11/26/2015 | Slide 15
measurement

Flow-X: Latest Technology Flow Computers
Developments of the last 17 years
© ABB Group
11/26/2015 | Slide 16

A Series of Products
FLOW-X/S
Single stream for Rail mount
FLOW-X/R
19” Rack
1-8 flow computers
FLOW-X/P
Multi-stream panel with 1-4 flow computers
© ABB Group
11/26/2015 | Slide 17

Flow-X Main Features
 Flow-X is designed and tested for Custody Transfer
applications, providing the highest level of:
 Accuracy
 At room temperature analog input accuracy is better that 0.002%
 All data processing and storage is based on 64-bit resolution to
avoid any loss of accuracy.
 Security (prevention of unauthorized access)
 Traceability & Auditability
 Flow-X has implemented (and is certified for) the most
accurate calculations for Oil and Gas:
 API, AGA, GERG, GPA, ISO etc.
© ABB Group
11/26/2015 | Slide 18

Flow-X Main Features
 Flow-X is designed for single stream installations  1 Flow
computer per flow meter
 Each module is a complete flow computer with all the
standard functionalities plus advanced features:
 4 reporting periods (hourly, daily and 2 user-definable)
 Bi-directional flow
 GERG-2008
 Two provers
 Ticket recalculations
 With its standardized form, Flow-X/M is the only spare part with no
variety of expansion boards and/or I/O cards
© ABB Group
11/26/2015 | Slide 19

Flow-X Latest Technology Flow Computers
The SW Makes the Difference
 Flow-X modules can be easily configured through Flow-
Xpress SW platform
 Flow-Xpress SW provides large flexibility and simplicity
also for every user:
 Pre-configured standard applications
 Interfacing to legacy systems
 Freedom to develop your own field-upgradeable
applications
 Flow-Xpress allows to configure and test flow computer
operation from a WEB browser, providing remote access
for upgrades and modifications
 Full fledged liquid and gas applications
 FREE Software updates from website repository
© ABB Group
11/26/2015 | Slide 20

Outline
© ABB Group
11/26/2015 | Slide 21
measurement

eXLerate: Data Integration and Management
What it is
 Traditional SCADA packages are frequently used even if
they are not made for custody transfer application
 In custody transfer supervision is intended for
measurement (i.e. financial purposes) not for process
control
 Traditional SCADA require specific custom-made
development in order to manage fiscal metering stations.
 This makes difficult to have prompt technical support in
case of issues and malfunctioning
 Spirit IT developed eXLerate, the software platform,
specifically tailored for custody transfer applications
 eXLerate is totally independent from the supplier of the
instrumentation
© ABB Group
11/26/2015 | Slide 22

Main Features
 eXLerate provides all the functionalities needed in order to cover all the
requirements from the most challenging custody transfer applications:
 Scalable and flexible software environment
 Synchronized redundancy on Client and Servers
 Embedded flow equations, calculation, time averages, etc.
 High precision with 64-bit accuracy
 Real-time diagnostic and performance monitoring
 Integrated validation & calibration facilities for instrumentation
 Control capabilities for batches, sampling and proving applications
 Mis-measurement management with automatic recalculations of missing
data
 Automatic and custom report generation
 Web interface for system monitoring
© ABB Group
11/26/2015 | Slide 23

…for a Number of Supervisory Applications
Metering
Supervisory
& Control
(Virtual) Flow
Computing Systems
Validation &
Calibration
Pipeline Network
Management
Calibration
Management
Depot & Terminal
Automation
© ABB Group
11/26/2015 | Slide 25

eXLerate Added Value
BASIC AUTOMATION
• HMI (Human Machine Interface)
• Communication
• Basic reporting
• Control (flow control, valves, sampling, proving)
Traditional
Automates daily operations
CUSTODY TRANSFER SPECIFIC
• 100% Redundancy / transparency (bumpless)
• Shall work at least 99.999%of the time
• Sophisticated custody transfer reporting
• High precision (19286251442762 scf)
• …
Optimizes availability and accuracy & precision
MAKING IT SMART & COMPLETE
• Virtual flow computing
• On-line meter diagnostics
• On-line instrument & analyzer validation
• On-line custody transfer data validation
• On-line custody transfer data correction
• …
Automates maintenance, management and data
processing
(the work of metering technicians, metering engineers and
accounting)
© ABB Group
11/26/2015 | Slide 26

Flow-X + eXLerate – Power Package
Seamless integration for optimal management
 Flow-X and eXLerate can be combined in Power
Packages, pre-engineered automation solutions for:
 Flow metering control
 Liquid loading & unloading (ship, rail, truck)
 Calibration management
 This approach provides all the basic metering functions
together with advanced features in a single standardized
environment
 Power Packages offer the best of both worlds: the powerful
capabilities of the flow computer together with the flexibility
of the automation software.
© ABB Group
11/26/2015 | Slide 27

Selected Success Stories
#1 – Wheatstone Onshore & Offshore
© ABB Group
 Wheatstone Australia project (Chevron):
 Offshore processing platform used to produce
and separate gas and condensate
 Onshore facility to process, liquefy and store
natural gas for export
 Offshore
 2 Flow-X/R with 16 modules for produced and
flare gas
 1 Flow-X/R with 5 modules for fuel gas
 Redundant eXLerate supervisory system
 Onshore
 22 Flow-X/P with 58 modules with LNG and
GERG2008 calculations
 Redundant eXLerate supervisory system.
 Automated Coriolis self-verification, master
meter proving and transmitter validations
11/26/2015 | Slide 29

© ABB Group
11/26/2015 | Slide 30
#2 – Edmonton Terminal
 Edmonton terminal is one of the largest North
America’s oil storage hubs (around 8 million barrels)
 Butane and propane rail car loading and unloading
 Scope of the system was to accurately register the
transferred quantities and to control the loading.
 Complete system was made of:
 22 flow computer modules, included in 3 Flow-X/R
racks
 5 eXLerate systems in redundant configuration.
 Combined liquid and vapor return measurement and
reporting.
 Vapor calculations with GERG-2008
 Remote Factory Acceptance Test from Canada

#3 – Petronas
© ABB Group
11/26/2015 | Slide 31
 Petronas implemented a diversity of products and
solutions from many different suppliers
 Poor support, high maintenance & replacement cost
 Instabilities cause problems for operations
 Too many measurement errors
 Petronas chose Spirit IT in order to harmonize its
systems, basing on the eXLerate software platform:
 Reduced measurement errors from 0.3% to 0.1%
 Reduced cost of operation by high level of automation
 Automatic measurement error detection
 Uniformity across the company
 Effective remote assistance of the operators

SpiritIT_mCT_Petrolchimico_Final_rev1

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