MULTIBEAM ULTRASONIC FLOWMETER for a Custody transfer application at a tank farm - a long term trial project T. Leenhoven, H.

Danen, KROHNE, The Netherlands

Copyright OMC 2001. This paper was presented at the Offshore Mediterranean Conference and Exhibition in Ravenna, Italy, March 28-30, 2001. It was selected for presentation by the OMC 2001 Programme Committee following review of information contained in the abstract submitted by the authors. The Paper as presented at OMC 2001 has not been reviewed by the Programme Committee.

Abstract
Accurate volume measurements are essential for the transport and trade of oil and oil products. High demands are put on flowmeter performance, especially when it concerns custody transfer or fiscal metering applications. Inaccuracies in volume measurements when buying or selling can cost much money and customer credit. A multibeam ultrasonic flowmeter forms an interesting new flowmeter technology for custody transfer applications where highly accurate measurements are required. It is the first liquid ultrasonic flowmeter to meet the stringent requirements stated in the guidelines of OIML and NPD for custody transfer. The uncertainty range lies within 0.15% of rate over a wide flow range and the flowmeter has a repeatability of 0.02%. In addition the multiple beam ultrasonic flowmeter has several benefits: operates independent of viscosity, is negligible effected by distorted flow profiles and swirl, can perform bi-directional measurements; gives much information on the flow profile over the cross section of a pipe. has no moving parts and therefore no wear and is nearly maintenance-free as e.g. frequent and costly periodic calibrations or re-calibrations after product-change are not necessary.

The Forties Pipeline System (FPS) installed a 12 5 path KROHNE ultrasonic flowmeter at the Dalmeny Export Terminal for an extended trial period of nearly 15 months. Approximately 800,000 barrels of stabilised crude oil are transferred to Dalmeny Terminal each day for transfer to tankers. The customer decided not to make it a research project but the duration of the trial the ultrasonic flowmeter replaced one of the 12 -helical bladed- turbine meters. It was used as an integral part of a fiscal metering system, accounting for the custody transfer measurement of oil to tankers. The Forties Pipeline System is a shared pipeline system with some 50 customers each entitled to their share of the export quantities. The primary purpose of the trial was to establish whether the meter, in particular the transducer ports, would be liable to suffer from wax or particulate deposition. Secondly, the aim of the project was to verify the accuracy, repeatability and long term stability of the multiple beam flowmeter. Accuracy and repeatability were tested using the bi-directional pipe prover and reliability was closely monitored to ensure there was no adverse impact on measurements. The trial was a success. The KROHNE 5 path liquid ultrasonic meter performed to a perfectly acceptable standard for the fiscal standard measurement of Forties Blend stabilised crude oil. Strong points:

No significant long term drift. The meter was reliable and repeatable. Virtually all prove results within +/- 0.10% of the mean. The meter always met the criteria that five consecutive runs were run within +/- 0.05% repeatability. The meter showed no signs of deposition of wax or particles. After 15 months in the line the meter did not have even a thin film of oil its on surface. The meter did not require any intervention for maintenance or calibration during the 15-month trial period.

Introduction
Major improvements in accuracy led to the first ultrasonic liquid flowmeter able to meet the stringent requirements set by end-users and institutions like OIML and NPD for custody transfer of oil products with regard to uncertainty and repeatability. An increasing number of Boards of Weight and Measures has approved the use of the multibeam ultrasonic flowmeter for fiscal metering applications. Various laboratory and field tests have demonstrated that the uncertainty range lies within 0.15% of the measured value and a repeatability of 0.02%. The ultrasonic flow measurement technology has some important benefits over other measurement principles commonly used for custody transfer i.e. turbine meters and positive displacement meters. It is expected that the multiple beam ultrasonic flow meter will largely impact the custody transfer market, not only because of its highly accurate measurements, but also because of its low operational and maintenance costs. The multiple beam ultrasonic flow meter operates independent of viscosity and is negligible effected by distorted flow profiles and swirl. The multiple path design, with five beams, gives all the required information on the flow profile over the cross section of a pipe. The meters have no moving parts, therefore no wear and are nearly maintenance-free. Frequent and costly periodic calibrations or re-calibrations after productchange are not necessary. This means that a permanent prover installation is not required. This paper describes long term tests that have been carried out at a British storage tank farm of Dalmeny. A large number of customers are involved as it concerns a storage facility of the Forties Pipeline System whereby various offshore fields feed into pipeline system. The initiator of the tests, BP Amoco, was interested in testing the multi-beam ultrasonic flowmeter, as it concerns a new flowmeter technology in which several customers showed interest. Another reason for the trial was that the meter causes no pressure drop and consequently could dramatically lower the pumping costs and allows for higher pipeline capacity. An 12 150 lbs flanged multi-beam ultrasonic flowmeter was installed in the metering installation of Dalmeny in July 1999. The purpose was to test the flowmeter on its long term stability and whether the meter would be liable to suffer from wax or other depositions.

Developments Ultrasonic FLowmeters

Ultrasonic flowmeters are one of the fastest growing precision measurement technologies in the world. Their popularity has increased as they have become substantially more accurate compared to ten years ago. The number of applications where ultrasonic flow meters are being used is growing. Ultrasonic flow meters are gaining full acceptance through recognition of their unique abilities. Important benefits include their nonintrusiveness, their lack of moving parts, inherent low pressure drop, their wide rangeability and low maintenance.

The developments started with clamp-on ultrasonic flow meters in the 1960s. Although they are quite flexible in use, in-line ultrasonic flow meters have proven to be more accurate. Improvements in highly accurate transit time measurements formed a new breakthrough for ultrasonic flow meters in the early 80s. Another step forward was reached with improved signal processing in the early 90s, resulting in the ability to measure fluids not totally clean. In the petroleum industry ultrasonic flow meters are in use since the 1980s. Single and double beam ultrasonic flow meters are used for applications like multiple product pipeline systems, (crude oil) blending systems, loading and offloading crude oil, crude oil from oil test separators, for liquid identification by sound velocity, detection of an underground leakage, and on floating production and offloading units (FPSOs). The experience gained in these applications contributed to the development and introduction of the first multiple beam ultrasonic flow meter for liquid applications. Multiple beam ultrasonic flowmeters for gas applications had already been successfully introduced to the market a few years earlier. The five beam ultrasonic liquid flowmeter has an uncertainty and repeatability within custody transfer specifications set by OIML for a wide range of viscosities, densities, temperatures and pressures. The multiple beam ultrasonic flow meter system already proved its ability to comply with the requirements for custody transfer of high value liquid hydrocarbons in various applications and tests. At the moment the market is dominated by turbine and PD meters. The ultrasonic flow meter has the important advantage over turbine meters that it operates independent of the mediums physical characteristics, and thus no longer requires product specific calibrations, and low maintenance as it has no moving parts. Compared to PD meters, ultrasonic flow meters are less bulky, can handle higher flow rates, and there is no danger the flow meter will obstruct the flow.

Higher Accuracy with Five Channels

Oil products can have a range of viscosities from e.g. 0.5 cSt for super gasoline to 120 cSt for fuel oil and higher. In addition, in large size pipelines laminar flow profiles can occur. The average flow velocity across a pipe is not uniform but has a certain distribution. In principle two main areas of flow velocity distribution, i.e. flow profiles, can be distinguished, laminar and turbulent flow. In theory for Reynolds numbers higher than 4000 there will be a turbulent flow profile (flattened shape), whereas for Reynolds numbers below 2300 a laminar profile (parabolic shape) will be established. Practice and theory, however, are not always the same, which has resulted in the definition of, a more undefined, flow profile called the transition area, existing in a Reynolds range from 2300 to 4000. In case of a single beam ultrasonic flow meter the average flow velocity is measured over the measurement path between two transducers, thereby crossing the centre of the pipe. High inaccuracies can occur when flow changes from turbulent to laminar. Research performed in the late 70s revealed that the measurement paths could better be located towards the pipe walls in order to become less dependent on the flow profile. To decrease the effects of the flow profile and changes in viscosity two or more beams are used.

Major improvements in accuracy are reached with the introduction of five measurement channels. By placing five channels in parallel a large range of the flow profile is covered across the metering section. This approach results in a wealth of information on the flow profile both in laminar and in turbulent flow conditions. Even in case of non-symmetrical flow profiles and swirl five measurement beams ensure accurate flow measurements. In addition five beams allow for better handling of the effects of changing flow profiles and or viscosities.

Ultrasonics for custody transfer

The KROHNE multiple beam ultrasonic flow meter is developed for custody transfer applications. For custody transfer both seller and buyer, require highly accurate volume measurements. An uncertainty of for example of for example 0.1% can lead to substantial profit losses and customer credit. If a flow meter is used for fiscal measurements also the government requires highly accurate measurements. During the development and testing of the multiple ultrasonic flow meter the requirements as stated in internationally recognised standards were taken as the minimum requirements to which the flow meter should be able to perform. The guidelines of OIML (Organisation Internationale de Metrologie) and NPD (Norwegian Petroleum Directorate) specify uncertainty and repeatability requirements with which flow meters must comply where used for custody transfer and fiscal measurements. These requirements are considered to be the most stringent in the world. OIML Uncertainty (OIML) 0.2% (10:1 measuring range) Linearity (NPD) Repeatability 0.06% NPD 0.15% (1:2 measuring range) 0.25% (1:10 measuring range) 0.02% (laboratory conditions) 0.025% (field conditions)

FORTIES PIPELINE SYSTEM

Two years ago discussions started with BP Oil, now BP Amoco Ltd, to carry out a trial with the multibeam ultrasonic flowmeter for the Forties Pipeline System in the United Kingdom. The fiscal standard metering system of the Dalmeny tank farm was chosen as the location for the field trial. The FPS comprises of two sections of a 36" pipeline, the offshore network and the landline section, which

together add up to more than 600 km of pipeline. Between the offshore production fields Forties Charlie and Unity and the Marine Terminal 'Hound Point' on the river Forth, there exist a complex transportation (pumping), oil stabilisation/gas separation processing and storage facilities. From Crooned Bay, North of Aberdeen, where the subsea pipeline comes ashore, the landline section passes through three booster stations before arriving at the Kinneil Plant in Grangemouth. At the Kinneil Plant crude oil and raw gas are produced. From the Kinneil Plant a proportion of the crude oil is going to the Grangemouth refinery, the rest is pumped to the Dalmeny tank farm. Approximately 800.000 barrels of crude oil are transferred to the Dalmeny Terminal each day. Stabilised crude oil is loaded to tankers at one of the two loading berths of the 'Hound Point' Marine Terminal. Dalmeny has eight storage tanks with a total capacity of 4.1 million barrels. The Dalmeny Terminal has a fiscal metering skid comprising of turbine meters and a 30 bi-directional prover with a total capacity of 14 m3. A total of 12 turbine meters with flow straighteners are installed in heated insulated lines. Each stream also has a strainer on the upstream section to eliminate the danger of damage from all kinds particles finding its way into the pipeline. Density and water content are determined on a flow proportional sample taken during the loading of each vessel. Typically the Forties blend at Dalmeny has the following medium properties: density @ 150C: 817.7 kg/m3 temperature: 32.6 0C pressure: 2.5 bar viscosity @ 300C: 3.0 cSt pour point: -150C. In general the Forties Blend does not show a great variation in temperature, pressure or density. The flow rate, however, varies significantly and during the trial period had a maximum of 3024 m3 and a minimum of 573 m3/hr.

Reasons for BP trial

Over 30 offshore fields feed into the Forties Pipeline System (FPS), which is a shared pipeline system with some 50 participants. Each participant is entitled to a share of the export quantities. Even a small uncertainty in flow measurements or repeatability has an impact on all participants in the FPS. One of the reasons for the interest in a trial on the customer's side was that as it concerns a new flow meter technology it would probably not be long before a multibeam ultrasonic flowmeters becomes the metering choice of a number of the participants in the FPS. Already there was a request by a customer of the FPS to use ultrasonics for fiscal measurements. Because the overall allocation metering system is very complex, a new flowmeter technology cannot be introduced without the acceptance of all parties involved. Another reason for FPS's interest in the multibeam ultrasonic flowmeter is the possibility of reducing pressure loss and pumping costs by using ultrasonic flowmeters. The Forties Pipeline is running close to its maximum capacity at approximately 1.000.000 barrels per day. At this level the pumping costs are high and the replacement of a number of turbine meters on the metering skid could reduce the pressure drop and consequently pumping costs and allow for a higher pipeline capacity in the future. At the moment high costs are involved resulting the injection of drag reducing agent at each booster station on the pipeline and the use of gas oil per booster station by the turbine driven pumps.

PURPOSE of the TRIAL

Prior to the test the customer defined two purposes for the set-up of the trial: The primary purpose of the trail was to establish whether the meter, in particular the transducer pockets, would be liable to suffer from wax or particulate deposition. In addition the test formed an opportunity to also verify the accuracy, repeatability and the reliability of the ultrasonic flowmeter over the trial period. Accuracy and repeatability were tested using a bidirectional pipe prover. BP decided not to deal with the trial as a research project. One of the existing twelve turbine flowmeters in the fiscal metering skid was replaced with a multibeam ultrasonic flowmeter. The test period for field trial was set for one year. The multibeam ultrasonic flowmeter would be subject to the same operating conditions as the turbine flowmeters. This also implied the ultrasonic flowmeter would be accounting for the custody transfer measurement of oil to tankers. The main reasons for KROHNE to participate in the trial at Forties Pipeline Systems were: Firstly, the long-term project formed a very nice opportunity to the test KROHNE's multibeam ultrasonic flowmeter on uncertainty, repeatability and long term stability in real life conditions. And secondly, it was an attractive project, because of the large number of (potential) customers directly and indirectly involved in the trial.

TEST SET-UP and installation

In July 1999 a multiple beam ultrasonic flowmeter of the type ALTOSONIC V with a diameter size 12" (DN 300) was installed replacing one of the turbine meters of the metering skid, as this stream could be switched to either of the two loading berths. Under normal operating conditions tankers are loaded directly from the production form the oil stabilisation plant at Kinneil. For the first three cargoes with the multibeam ultrasonic flowmeter, BP decided to load the tankers from the standing tanks. If the multibeam ultrasonic flowmeter would not perform to fiscal standards or became defective during the ship's load charge, the tank management functioned as a back up for the quantities delivered and the Bill of Lading. After three loadings the multibeam ultrasonic flowmeter built up enough confidence level, as it demonstrated an acceptable reliability and no discrepancies, to perform future loadings from production without the necessity of the tank management system as a backup. The same proving criteria would be used for the ultrasonic flowmeters as for the turbine meters. Five consecutive runs were used required within 0.025% repeatability. If this was not achieved within 10 runs by the bi-directional prover than the fiscal status of the flowmeter was not valid and the ultrasonic flowmeter would not be lined up for use. This is in accordance with the UK Department of Trade and Industry Oil and Gas Office guidance notes. The stream filter was removed. The existing flow straightener was retained with a short spool piece inserted between it and the meter to take up the space left from the removal of the strainer. As mentioned earlier BP was interested in the long-term stability of the meter and had concerns that the Forties crude could build up in the sensor pockets and on the internal surfaces of the meter. As a result of the customer's concerns as mentioned above the strainer was removed and the line was left unheated and without insulation to thoroughly test the meter. Should a drift in the meter factor be observed, lagging and heat tracing would be installed in stages.

The pulse output of the multibeam ultrasonic flowmeter was set to mimic that of the turbine meter removed from the line at 85.6329 p/m3. This was necessary to ensure the fiscal computer did not reject the multibeam ultrasonic flowmeter data as out of specification. In addition a performance curve was generated for the multibeam ultrasonic flowmeter over five points between 950 m3/hr and 2,900 m3/h.

multibeam uLTRASONIC Flowmeter System

The ultrasonic flow meter system uses the well-known transit time or time-of-flight principle to measure the volumetric flow rate of oil and oil products. In addition the flow meter measures the sound velocity, which can be used for e.g. product identification, gives an indication of the flow direction and an indication of the medium viscosity. Next to these data the flow meter system can provide valuable status and process data. The ultrasonic flowmeter system installed at BP Dalmeny comprises of four basic components: 1. a 12 150 lbs flanged primary head or flow sensor; 2. a field mounted signal converter; 3. a 19" rack version flow processor; and 4. as an extra option a Kepware software package.

The primary head or flow sensor has ten transducers, together forming five measurement channels. The multiple beams are used for the optimal identification of the flow profile. It is possible to replace a sensor during operation. Because the distance between the sensors remains unchanged, re-calibration afterwards is not required. The construction of the primary head is symmetrical and therefore the ultrasonic flow meter is able to perform bi-directional flow measurements. Cones, welded to the middle part, are important for the symmetrical shaping of the flow profile in the measurement section of the primary head. The angle of the cones is chosen such that negligible pressure drop occurs. A field mounted signal converter controls the five acoustic transducer pairs and performs the actual flow measurement. Raw data of each of the five measurement channels, including the average flow velocity per channel, average sound velocity and status data are sent to a flow-processing unit. The flow processor calculates the average volumetric flow based on flow measurements from the five sensor pairs. In addition, the flow processor computes the Reynolds number and swirl effects. As a result of these (corrected) computations, the system is insensitive to viscosity changes and distorted flow profiles. KROHNE holds a patent for these (corrected) computations. The flow processor can be either installed in the field or in the control room. For the Dalmeny installation the 19" rack version is chosen, which is installed in the control building. For flow computations the flow processor processes inputs from a temperature and a pressure transmitters installed in the flow line. The flow processor calculates nett oil volume according to API 2540 / IP 200 / ASTM D 1250. The volume correction factors are based on API chapter 11.1; the hydrocarbon compressibility is based on API chapter 11.2.1. The API standard 2540 @ 150C equals the ISO standard ISO 91.1 and API standard 2540 @ 200C equals the ISO standard ISO 91.2. The multibeam ultrasonic flowmeter is hooked up via an RS 422 full duplex serial link to a Kepware Scada software package for the logging of various parameters. The Scada package makes available for example data storage, trending, historical trending, alarm requests. Tools for internal diagnostics For custody transfer purposes the customer requires not only the volumetric flow and flow computations to e.

g. API standards, but also the reliability of the measurement system should be guaranteed. Therefore the multibeam ultrasonic flow meter system continuously monitors the integrity of the data and the system itself and, if necessary, provides alarms. Next to a low measurement uncertainty rate, the five measurement channels also represent a certain redundancy. In case one or two of the five measurement paths fail(s), the electronics will indicate which of the measurement channels is out of order and the system will give a warning. Based on the flow profile, the value will be interpolated, allowing the system to continue to measure within custody transfer requirements. The system continuously checks the shape of the flow profile. The program identifies and gives an alarm if, for example, the flow is out of range or if there is a too high concentration of air or gas bubbles or a communication failure is identified. Comparison of the sound velocity measured per channel allows the supervisory system to detect failures of the driving electronics, if not already detected by the driving electronics themselves.

Test PROCEEDIngs
The multibeam ultrasonic flowmeters was installed in the line in July 1999 and removed from the line on the 31st of October. During the initial trial period the meter was taken out of service a few times by the operators due to invalid proves and in a couple of instances excessive noise on the output of the meter. By the end of September the problems had been identified and steps put in place which eliminated re-occurance. One of the steps was that proving at flow rates, above the meter range specifications, was stopped. This led to extremely short proving times in the order of 7 seconds in each direction. The repeatability limit was to 0.05% within the fiscal computer. Another step taken was that the meter was stopped being used under gravity fill conditions. The meter is brought into service only when the pumps are in use because this gives a higher line pressure. Dalmeny is situated on top of a hill approximately 60 metres above the loading berths and the start/finish of loading is always under gravity. Unfortunately they start with all control valves fully open and let the system find its own level. With the strainer removed, the multibeam ultrasonic flowmeter was subjected to 50% higher flow rates than the turbine meters and at pressures of approximately 0.5 bar. This led to cavitation in the meter. During the test it was found out that the Scada system package gave significant information on the cavitation problems occuring in the metering system. By setting the proper opening and tuning the pump speed this problem was solved. The ultrasonic flowmeter was able to provide these data, which is not possible with a turbine meter. Avoiding cavitation in metering systems highly increases the accuracy and repeatability.

TEST Results
The meter factors were calculated as the average of at least five consecutive proving runs during which the repeatability must be within 0.03% and within 0.1% of the meter factor stored from the performance curve. The same criteria were used for the multibeam ultrasonic flowmeter as for the turbine meters. After the initial issues mentioned in the paragraph above were solved, the meter proved to be very reliable and repeatability, there was no significant long-term drift. The meter proving data demonstrated that all proofs done with the multibeam ultrasonic flowmeter fell within +/- 0.1% of the mean. There was one exception when the meter was used at the extreme values of the flow rate. During the trial no intervention was required for calibration or maintenance purposes. In addition there was no impact on, or disruption to routine operations.

After the trial was completed, the multibeam ultrasonic flowmeter sensor was taken out of the line and inspected. There was no evidence of disposition anywhere. Bear in mind that there have been periods the flowmeter was filled with oil, when the stream was not in use and the meter was neither heat traced not lagged. After being installed in the line for fifteen months the meter did not have even have a thin film of oil on its surfaces.

Conclusions
A multibeam ultrasonic flowmeter, with a diameter size of 12", was subject to a long term stability test at the Dalmeny tank farm which forms part of the Forties Pipeline System over a period of more than one year. The trial was not carried out as a research project. The ultrasonic flowmeter fulfilled the standard requirements for fiscal measurement of Forties Blend stabilised crude oil during normal operation. The flowmeter showed an excellent performance with regard to reliability, accuracy, and repeatability. The ultrasonic flowmeter sensor also showed no signs of deposition of wax or particles after the fifteen months trail period. No intervention for calibration or maintenance has been taken place during the trial. Both the customer and KROHNE were very happy with the results. The final conclusion drawn by the customer was: the trials were a success there was no impact on, or disruption to routine operation there was no adverse impact on FPS customer. -

References
Leenhoven, T., Danen, H.C.M., KROHNE Altometer, "Multibeam ultrasonic flowmeter for custody transfer of liquid custody transfer of liquid hydrocarbons", PEMEX Conference Mexico, 2000. Hogendoorn, C.J. and Boer, A.H.B., KROHNE Altometer, "Experience with Ultrasonic Flowmeters in Fiscal Applications for Oil", North Sea Flow Measurement Workshop, 1999 Moon, C. B., BP Amoco Exploration - Forties Pipeline System, "Field Trial of the KROHNE 5-path meter on Forties Blend at Dalmeny Export Terminal",

APPENDIX: TRANSIT TIME Ultrasonic Flow measurement principle

Imagine two canoes crossing a river over the same diagonal line, one going downstream with the flow and one going upstream against the flow. The canoe going with the flow takes less time to reach the other side of the river than the one moving against the flow. The difference in transit times directly relates to the flow velocity of the medium. Ultrasonic flowmeters use the transit times of acoustic pulses sent through the medium in order to establish the flow velocity and the volumetric flow rate. The time the acoustic pulses take to travel across, with and against the flow, is measured very accurately.

A pair of transducers, A and B, is positioned on either side of a pipeline. The measuring path AB has a length L. The average velocity of the medium over this measuring line is Vm. Measuring path L makes an angle with the velocity vector of the medium. C0 is the sound velocity.

Figure 3: Ultrasonic measurement principle

The transit time in downstream direction, from transducer A to B, is: (1) The transit time in upstream direction, from transducer B to A, is: (2) From equation (1) and (2), the difference in transit times can calculated: (3) T= The difference in transit times is proportional to the medium's mean flow velocity. Based on the above defined equations the formula for the average velocity vm can be deducted: (4) Vm = * is known as meter k-factor GK. GK is a constant and can be defined by calibration.

From the last equation it can be concluded that with the ultrasonic flow measurement principle, the flow velocity over the acoustic path is measured independent of: density, viscosity, and sound velocity. -