Tank Storage Istanbul 11/2010 LPG loading operations management

Automation & metering solutions

Agenda
1. 2. General configuration of an LPG depot Flow metering considerations and requirements Health & Safety requirements Loading authorization and security systems management Case study Presentation of an optimized supervisory and MECI automation and supervision system for the management of 14 LPG depots including 7 unmanned depots

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Automation & metering solutions

Flow meter requirements

LPG transactional bulk transfers can be carried out using standard volume or mass.

LPG Custody Transfer measurement primary meter must meet an accuracy of 0.6% (OIML R117 - MID)

Measure Accuracy depends on maintaining a single phase liquid flow through the flow meters

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Automation & metering solutions

Flow (volume and mass) metering

Volumetric flow metering (liters) PD meter, turbine meter Ultrasonic flow meter Mass flow metering Coriolis (kg, tons)

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Automation & metering solutions

Flow (volume and mass) metering

Benefits

Primary measurement in volume (PD and turbine meters) Primary measurement in mass (coriolis meters) Lack of moving parts, no mechanical wear (coriolis)

Disadvantages

Liquid phase assurance: Pressure drop can cause vapor breakout (flash point) Mechanical wear due to poor lubricity of LPG (PD and turbine meters) Units conversion uncertainty problems (mass to volume, volume to mass) Difficult calibration with volumetric devices (coriolis) Vibration sensitivity (coriolis)

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Automation & metering solutions

Volume conversion to Mass

Conversion from mass to volume and calculation of standard volume require accurate knowledge of the properties of LPG mixtures.

Mass =Volume * Density Density must be determined ! 1- Using an on-line densitometer (expensive solution); the densitometer is directly connected to the flow computer 2- Using LPG conversion tables, 24E and 23E, (produced and published by The Gas Processors Association (GPA) under the designation TP25), or other standards. The electronic flow computer will convert the volume to standard volume V15 and will compute the transactionnal mass = V15 * D15

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Automation & metering solutions

Measurement by weighing full truck

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Automation & metering solutions

Measurement by weighing full truck

Benefits

Primary measurement in mass Vapor phase measurement unnecessary Balance in weight easier Easy weighting instruments calibration

Disadvantages

Very expensive solution (weighting bridges, on-board weighting sensors) Tank trucks volume overfilling not controlled Tank truck traffic in the loading terminal heavier, more complex supervision system Safety problem; LPG gas retention on in weighting bridge installation gap
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Automation & metering solutions

LPG flow meters operation requirements

1 - Loading arm and hose must be constantly full of product in service operation 2 - Liquid phase assurance; LPG gets a high Vapor Pressure. Pressure drop can cause flashing change to two phase conditions, which can distort the measure accuracy. LPG Vapor Pressure is a mathematical equation Antoine formula, Vapor Pressure in relative bar unit function of temperature: VP = exp(a-b/(c+t)))-1 Butane C4 H10 Propane C3 H8 a:9,6382297 a:8,8258087 b:2321,2682 b:1897,6525 c:256,64 c:262,79

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Automation & metering solutions

LPG flow meter requirements

Vaporization depends on temperature and pressure of measured product How to maintain pressure and avoid vaporisation and maintain the liquid phase ? Cooling the temperature of the LPG (expensive) Maintaining the LPG all over the pipe at a pressure higher than its own Vapor Pressure: Holding constant pressure though P > LPG Vapor Pressure at max service temperature Holding adjusted pressure though P > LPG Vapor Pressure + 1 bar (dynamic regulation)

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Automation & metering solutions

Truck loading operation (1)

LPG is pushed in the piping in order to: Push out gas pockets To cool the piping installation in order to avoid gas formation during loading operation

Cooling process

Storage

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Automation & metering solutions

Truck loading operation (2)

The required quantity is pumped under pressure and loaded into the tank truck. In some configuration, the gas phase in the tank is either condensed or returned to the LPG storage. The site system or the batch controller control : The flow pressure regulation The flow rate regulation

Storage

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Automation & metering solutions

Tank unloading operation (1)

Gas phase of the storage is used to push out the liquid of the tank truck

Empty tank gas recovery Gas phase

Liquid phase

Storage

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Automation & metering solutions

Tank unloading operation (2)

The direction of the compressor is inverted in order to recover the gas phase of the tank truck.

2)

Gas phase recycling

Gas

Storage

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Automation & metering solutions

H&S requirements - Overall LPG site

General site gas, flame and smoke detections (emergency alarms)

Synchronization of the valves and pump status (emergency shut down valves)

Over & under pressure sensors

Overflow probes

Tanks level control

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Automation & metering solutions

H&S requirements - LPG loading position

Loading arm safety break Loading arm settled valve Loading arm pressure switch Vehicle grounding system Overfilling detection sensors Dead-man control Metering defaults

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Automation & metering solutions

H&S requirements - operator cabinet

Truck overfilling sensor: In addition to visual rotating gauge, tank truck can be equipped of an overfilling sensor (optical, magnetic , radar) The safety control system automatically stops the filling process when the overfilling level is reached Earthing connection; A specific grounding control device does not allow loading operation if not connected

Dead Man safety device: At a regular time interval, the operator must manifest its presence on the site actuating the dead - man device. In case of non presence action, a sound alarm is actuated. If the situation last, the general safety alarm is actuated for the site safety and alarm to safety services

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Case study : Optimization of metering, automation and supervisory for LPG depots

Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Overview

Final user Location Application

A French Major Oil Company France

-Supervision and automation of 15 butane, propane & LPG depots including 7 unmanned facilities (without permanent employee) -Automation of loading & unloading of LPG, butane, propane local and distant tank farm supervision, remote maintenance
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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Overview Headquarters Main depots Unmanned depots

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Overview

Headquarters

Remote maintenance Possibility to control all the depots Stock reconciliation in mass

Main depots

150 500 m3 Supplied by rail or tank trucks

Unmanned depots 100 m3 maxi Supplied by tank trucks Controlled by related main depot

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Overview: unmanned depot
Access control for trucks and drivers

Operator cabinet

Unloading area Loading area

Operator cabinet

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Depot access control

Driver identification

Biometric identification at the inlet of the depot Fingerprint readers are used to allow only accredited drivers to enter the facility

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Depot access control

Trucks identification at the inlet of the depot

Semi passive tag technology

Microwave based communication The tag echoes its identification code when receiving a 2.45 GHz carrier emitted by the antenna

Hand free detection

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Loading operations : operating procedure

The driver is identified via a smart card reader

The driver key-in loading data via MMI - mass preset value and medium - Actual tank filling rate -Truck plate number

The system calculates and display the maximum allowed quantity to be loaded The driver must then connect security devices (grounding system, tank level switch) He will then be allowed to press the Dead-man & the Start loading buttons
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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Loading operation : operator cabinet

Total mass display

Card reader Man Machine Interface Start loading button

Emergency stop button Tank truck level detection

Grounding detection

Dead-man detection

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Metering systems

1-Measuring system with turbine meter -Measurement of volume at operating pressure & temperature -Measurements of operating pressure and temperature -Calculation of operating density from P, T & API MPMS 11.2.2.M table -Calculation of masse Advantage: Easy to calibrate (volume against ball prover, P, t)

Weak point:

Not a direct mass measurement Can lead to error if product quality is not constant

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Metering systems : ball prover calibration

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Metering systems

2-Measuring system with massflowmeter

Advantage:

Direct measurement of mass No need for P & T custody transfer approved measurements

Weak point:

Calibration against prover needs also measurement of reference density

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Metering system: typical mass metering skid

Massmeter converter Massmeter transducer

Motor valve Control valve for line pressure adjustment

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Metering systems : flow computer (FC) functionalities

1-Calculation of loaded quantities, batch control, transactions data storage,

2-Blending control for LPG preparation The driver enter the quantity of LPG to be loaded The FC calculates the quantities of butane and propane to be loaded The batches of butane and propane are loaded successively

3-Communication

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Metering systems : flow computer functionalities

4-Additive injection control Injection of ethyl mercaptan for odour or of proprietary compounds for road fuels

5-Line pressure control The FC calculates the saturation pressure of LPG from P & T measurements It defines a pressure set point (Psat + 1 bar) controlled by control valve

6-Calibration operation management

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

Automation and supervisory system functionalities

1-Automation of loading and unloading operations Management of loading/unloading cycles Loading authorization according to company quotas Security devices management

2-Communication with the truck driver Operating instructions, error and warning messages

3-Communication with headquarters and dispatching

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

System architecture for main depot
Supervisory PC and data base Remote maintenance
PSTN

Printer PLC Truck indentification Badge reader Printer events

Printer Bill of lading

Fingerprint reader Scurity dev.

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Automation & metering solutions

2-Case study : Automation of loading & unloading stations

System architecture

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Automation & metering solutions

Thank you for your attention, Q & A ????

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