DESIGN, CALIBRATION AND OPERATION OF FIELD STANDARD TEST MEASURES Class # 4040 Richard C.

Jordan Seraphin Test Measure Company P.O. Box 227 Rancocas, N.J. 08073

INTRODUCTION A field standard test measure is a graduated neck volumetric container, fabricated to stringent design criteria to deliver a specific volume of liquid when drained. To identify its true volume value, it is calibrated by an official agency such as the National Institute of Standards and Technology (NIST). The primary purpose of a field standard test measure is to provide a standardized volume, used for the calibration of displacement and tank provers, when calibrated by the water draw method. Field standard test measures are commonly referred to as test measures--for brevity and simplicity the term test measure or measures will be used in this paper for field standard test measures. Test measures can be either of the hand-carried or the stationary bottom-drain type (often referred to as "prover cans"). Hand-carried measures are usually small measures of less than 10 gallons, while the bottom drain measures are mounted on legs and are typically greater than 10 gallons. They can also be classified by their graduated neck resolution. Test measures of the same volume can have either a normal or high sensitivity neck. Normal sensitivity measures have a larger neck diameter and therefore have less resolution on the scale. High sensitivity measures have a smaller diameter neck and have much greater resolution. Since the neck length gets much longer when its diameter is reduced, as the volume gets larger it becomes increasingly impractical to have a highly sensitive neck. Generally, measures of less than 100 gallons can have high sensitivity necks and not be too excessively tall. DESIGN AND CONSTRUCTION Test measures are manufactured to the specifications and tolerances outlined in NIST Handbook 105-3. Test measures with bottom drains have a cylindrical body, a conical top, a cylindrical neck, a conical bottom and a drain valve.

They are designed in this manner to ensure a complete drain. There is a small diameter gauge glass and scale mounted to the side of the neck, which enables the operator to read the volume by the meniscus level in the glass. The nominal volume of the standard is determined from the drain valve at the bottom to the zero mark on the scale in the neck.

Neck

Adj ustingRod

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Spirit LeI

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U_9_perreinforcement band

Body
Lower reinforcement band

Drain Valve

FIELDSTANDARD TEST MEASURE Hand-carried test measures do not have a bottom drain. They are drained by picking them up by their bale handle and inverting them to within 15 degrees of vertical. Their bottom band is perpendicular to the vertical axis of the measure and when placed on a level surface, should be level.

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Bail Handle Gauge Glass

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standards have 2 spirit levels, usually mounted on the top cone, 90 degrees apart for determining whether the unit is level. Cones

Scale PI at

Yokes (ScaleBrackets)

ReinforcementBand~i

Standards < 10 gallons have a top cone of 35 degrees and a bottom cone of 20 degrees, while standards >10 gallons have a top cone of 25 degrees and a bottom cone of 20 degrees. These angles provide for appropriate drain characteristics. In the bottom cone, just above the center drain, an anti-vortex baffle plate is welded in place. This plate minimizes the circular liquid motion, which creates a vortex while draining. Drain Lines A gravity discharge line between the bottom of the bottom cone and the shut-off valve is considered the drain line. This drain line should be sloped downward at a minimum of 5 degrees from horizontal in order to provide an adequate drain. The drain valve is a very important component of the calibrated volume, which if replaced requires the recalibration of the test measure. A quick acting, full opening valve is the type that should be used. In order to indicate whether the valve has been either removed or replaced, a wire seal should be attached from the drain line to the valve. Some test measures are equipped with drain valves that are threaded on to the drain line. If removed and replaced the amount of turns on the threads could differ from its original position, which changes the volume. Gauge Glass Test measures are equipped with a gauge glass and scale assembly mounted on the side of the neck. The gauge glass should be made of borosilicate type glass. The glass must be removable and replaceable without breaking the seal on the scale and voiding the calibration. Any replacement glass must conform to the original inside and outside diameter specified by the manufacturer. The leak proof seal at the bottom of the gauge glass is performed by the compression of O-rings in the bottom bracket as opposed to using cement. Scale Plate and Graduations The scale plate is made of corrosion resistant metal, usually stainless steel or aluminum. It is mounted tangentially to the front of the gauge glass, no more than " from the glass. The scale

Concave JBottom

Hand-Carried Test Measure Materials and Fabrication The test measure is designed in such a way that it can be filled and completely drained without any obstructions or chances for air entrapment. During fabrication, any interior welded seams must be filled and ground smooth. There can be no dents, crevices, or pockets that may entrap air, liquid or foreign material. A horizontal cross section taken at any point on the standard must me circular. All parts of the main body of a test measure must be made of corrosion resistant series 300 stainless steel. Reinforcement Bands When full, the pressure from the liquid should not distort the standard or change its volume in any way. Reinforcement bands are used at the transition from the body to the top cone and from the body to the bottom cone to prevent this from happening. Large units will sometimes incorporate a band around the middle of the body for additional support.

Neck To prevent distortion or damage to the neck, the opening at the top shall be reinforced by a rolled bead or a welded band. The top surface of the reinforcement must be perpendicular to the vertical axis of the standard so that the level of the standard can be determined by laying a machinist's precision spirit level across it. Bottom drain

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graduations should not be less than 1/16" apart or the lines will be too close together to get a good reading of the meniscus. The zero mark on the scale, which is at the approximate center of the neck height, indicates the nominal volume of the test measure. The scales are mounted to yokes that are secured to adjusting rods that run parallel to the gauge glass, between the upper and lower gauge glass blocks. The scale is wire sealed in place upon calibration. The seal must be installed in such a way that the scale cannot be moved by the adjusting rod unless the seal is removed. If the seal is broken or missing the test measure must be recalibrated. Levels and Leveling The level of a test measure test measure can be determined by placing a precision machinist's spirit level across the top of the neck of the test measure. The level must me determined in two directions 90 degrees apart and can be used to verify the permanently mounted spirit levels. All test measures should be equipped with a minimum of two adjustable spirit levels, mounted at right angles to each other. The adjusting screws on these levels must be equipped with a means for wire sealing and the level must have a protective cover. Care and Protection of Test measures Test measures are precision liquid measurement instruments vital to the calibration of dynamic liquid meter provers and tank provers in the field. They must be kept free of debris, dents, and must be handled, transported, and stored with care to prevent jeopardizing the integrity of their calibrations. Depending on the size, a protective case is a good method of protecting and storing test measures.

Wetting down the test measure means to fill it initially with water to the zero mark on the scale, level it, and drain it in accordance with the drain time requirements on the calibration report. Test measures with no drain valve are drained, in accordance with NIST guidelines, for 10 seconds after main flow cessation, while test measures with bottom drain valves are drained for 30 seconds after main flow cessation. Wetting down the measure in this manner provides a consistent, repeatable "clingage" of water to the interior surfaces of the measure. This "clingage" amount will be left in the measure after each test. In accordance with API Manual of Petroleum Measurement Standards (MPMS) chapter 4, sect. 7, water is required to be used as the calibrating liquid because of its stability, low thermal coefficient of expansion, and high heat capacity. Calibration Frequency Field standard test measures must be calibrated by NIST at regular intervals. The calibration intervals are: prior to use of new test measures, every 3 years for test measures in regular use, every 5 yrs. for test measures in infrequent use, any time there is evidence of damage, distortion, repair, alterations or maintenance. It is a judgment call whether test measures should be calibrated upon change of ownership. The calibrated volume of all test measures should be reported to 5 or more significant digits. When NIST calibrates test measures they identify the true volume by the term Base Prover Volume, and document this important number on the calibration report. CALIBRATION METHODS

CALIBRATION Test measures are calibrated "to contain" or "to deliver". Test measures designed "to contain" are calibrated in an empty, clean and dry state. Measures designed "to deliver" are calibrated in a wet state. "To deliver" means that the measure will "deliver" its nominal volume when drained, even though there is residual water left in the measure when the drain valve is closed. In the field, when calibrating dynamic liquid meter provers by the waterdraw method, test measures are used in the wet down condition. It is impractical to dry and clean the test measure after each test in a field environment.

Calibration of test measures can be performed in one of two ways. Either by the Gravimetric or the Volumetric method. NIST has the ability to calibrate up to 100 gallon test measures gravimetrically,.due to the size of their scale. Large measures are calibrated by the volume transfer, or volumetrically.

Gravimetric Method In the gravimetric method the measure being calibrated is weighted empty from a "dry" state for the tare weight and then weighed full of distilled

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water. The measure is then drained and weighed again in the "wet" condition. The air temperature, relative humidity, and atmospheric pressure are recorded. At each filling the temperature of water is also recorded. The "to contain" condition is calculated via a formula by dividing the difference between the mass of the full measure and the mass or the empty dry measure by the difference between the air density and the water density. The "to delivered" volume is calculated by dividing the difference between the mass of the full measure and the mass of the drained "wet" measure by the difference between the density of the water and the density of the air. The volume of the measure adjusted to a reference temperature (60 degrees F, 15 degrees C ) i s then performed using a formula which takes into account the temperature of the distilled water, the standard reference temperature, and the volume coefficient of thermal expansion of the material of the test measure (for stainless steel: .0000265 per degree F). Repeat runs are performed for the "to deliver" volume. Volumetric Method In the volumetric method a known volume is transferred to the unknown test measure via gravity. To establish a "wet" condition the standard is filled with water and is then drained in accordance with the prescribed drain time. The unknown test measure is filled with water and drained in accordance with the prescribed drain time. Now that the measures have both been wet down, the actual volume transfer can begin. 1. The standard is filled with water to the zero mark on the scale plate and the water temperature is recorded. 2. The standard is drained into the unknown standard via gravity (the drain valve is closed after 30 seconds after main flow cessation). 3. The water level on the scale of the unknown measure (read from the bottom of the meniscus)is recorded as well as the water temperature. (If the volume of the standard is smaller than the volume of the unknown measure, steps 1 through 3 are repeated, the required number of times until the nominal volume of the unknown is reached.) 4. After one complete calibration or "run" is completed, additional runs may be performed. The volume in the unknown measure is corrected for temperature and the thermal coefficient of

expansion of the material construction using a formula commonly known as "Z60". Note: The formula for identifying the true volume value can be found in API MPMS Ch. 4, sect. 7 pg 8-10, as well as NIST Handbook 145. OPERATION AND USE The primary use of field standard test measures is to determine the volume of a meter prover when using the waterdraw method of calibration. Measures come in various sizes anywhere from 1 gallon up to 1500 gallons or metric equivalent. A test measure may be made in any convenient size and are often made to the exact size of small volume provers. Only test measures calibrated with a "to deliver" volume should be used in the calibration of meter provers. FIELD USE Field standard test measures are used in the waterdraw calibration of pipe provers, small volume provers, and tank provers. NOTE: Detailed procedures for field use of these test measures for waterdraw calibration can be found in API MPMS, Ch. 4.9.1 "Determination of the Volume of Displacement and Tank Provers by the Waterdraw Method". Three different techniques can be used to calibrate meter provers using test measures. 1. Fill each test measure to its exact certified (zero) capacity, and allow the final water level to be read on completion in the last test measure filled. 2. Slightly overfill each test measure and then bring the level back to the exact capacity (zero) by withdrawing some of the liquid. The liquid that is released is then put into the next test measure to be filled. 3. With graduated neck test measures it is not necessary to operate at the zero level. Therefore, the test measure may be filled to any location on its scale, the liquid level read, .and its certified capacity is then adjusted mathematically using a plus or minus scale reading. A minus signifies that the water level is below the certified volume, and a plus indicates that the water level is above the zero mark on the scale. NOTE: Method 3 is the typical method used in the field.

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PREPATORY CALIBRATION: 1.

STEPS

FOR

WATERDRAW

CONCLUSION Field standard test measures are precision liquid volumetric measurement instruments used to calibrate dynamic provers or tank provers by the waterdraw calibration method. They are designed and constructed to detailed specifications outlined by NIST and are calibrated "to deliver". They are carefully manufactured in order to ensure that there is no chance for air or liquid entrapment which could affect its volume accuracy or the repeatability of successive tests. Although very durable, they should be handled and transported with care, to avoid jeopardizing the integrity of their calibration. The Base Prover Volume outlined on the calibration report is the actual true volume and the key number to be utilized during calibration runs and compensating calculations. Field standard test measures are the reference standards from which the dynamic type provers are calibrated--providing a traceable link to NIST. These measures are an important tool to the petroleum measurement technician in helping ensure accurate liquid custody transfer in the field.

2.

3. 4.

Inspect all test measures to be used in the calibration for cleanliness, dents, unbroken sight glasses, scales and seals. All the test measures shall be leveled while they are in a water-filled condition, across at two axis 90 degrees apart. Check the measures for leaks Drain the measures and close the valve 30 seconds after main flow cessation. If a measure is of the hand-held type drain the measure for 10 seconds after main flow cessation, and return it to its upright condition. This establishes a repeatable clingage condition.

CALIBRATION RUN: When calibrating a meter prover by the waterdraw method, multiple fills of one or more field standard test measures are necessary for each run. For example: If you were calibrating a 750 gallon displacement prover: a) One 500 gallon prover could be used once, One 100 gallon could be used twice, and a 50 gallon could be used once. b) One 100 gallon could be used seven times, and one 50 gallon could be used once. NIST recommends that the number of fills be kept to a minimum and should not exceed 15 times, in order to keep the uncertainty of the calibration within reasonable limits. It is critical to account for every drop of water in order to get an accurate calibration. Simplified Calibration Procedure: 1. 2. The test measure is filled with water to an upper scale reading. The water level in the gauge glass, from the bottom of the meniscus, is read on the scale plate and is recorded as a (+) or (-) volume, depending on whether the reading is above or below the zero line on the scale. The level of the test measure is verified. The temperature of the water in the test measure is recorded by immersing a thermometer in the measure or by putting the thermometer in the stream of flow while it is draining. Drain the measure in the prescribed manner to reestablish the wet down condition, with the consistent amount of clingage, for the next run.

References: API Manual of Petroleum Measurement Standards (MPMS) Chapter 4, Section 7 Field Standard Test Measures Chapter 4, Section 8 Operation of Proving Systems Chapter 4, Section 4, Tank Provers Chapter 12, Section 2, Part 4 Calculation of Base Prover Volumes by the Waterdraw Method NIST, Handbook 105-3, Specifications and Tolerances of Graduated Neck Type Volumetric Field Standards. NIST Handbook 145, Handbook for the Quality Assurance of Metrological Measurements

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