8 years experience in process automation and custody...
Transcript of 8 years experience in process automation and custody...
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DIVIN MADAKKARA Engineer Loss Control, KOC
• B. Tech in Instrumentation and Control. • 8 years experience in process automation
and custody metering. • Working in Export Tech Service Team , KOC • Worked as Metering Engineer in Daniel. • Worked as DCS Engineer with Emerson. • Worked in projects like RLOC in Qatar,
MOIP and NOP in KNPC , Crude Metering System at NPP in KOC and Bunker Metering System at KNPC.
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Custody Measurement Control System
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Introduction • Custody transfer using dynamic measurement of fluid
with flow meters offer accuracy of 0.25% or better.
• Devices and instrumentation installed play an important role in the measurement performance.
• Its the overall system that brings all the equipment together to ensure the required accuracy, sustainability, and reliability of the custody transfer measurement.
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What is a Custody Metering System?
• Metering system is an engineered solution to a measurement problem, with unique requirements.
• Different fluid properties , flow rates, measurement requirements , physical locations.
• Custody metering is not just about having a flow meter, components of a custody metering system include multiple meter runs, Quality systems, proving and calibration facilities and metering control system.
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What makes it Special ? • Metering system could be rendered inaccurate by a failed
component, internal damage caused by foreign material in the flowing stream, build-up of solids, calibration drift over time, or a number of other factors.
• Periodic maintenance on custody metering systems is critical to maximize overall accuracy and uptime.
• The frequency of scheduled maintenance on custody metering systems is often mandated in custody transfer contract agreements.
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• Even though there is established routine maintenance practices, still there are many who do not follow or follow less-than-optimal practices.
• A number of factors will affect the best possible maintenance practices for a custody metering system including: contract requirements, OEM recommendations, practical experience, and amount of financial risk to which improperly maintained measurement equipment might expose the operator.
• Custody Metering is special and requires special attention.
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Metering Control System – Components
• Flow Computers
• PLC
• Supervisory Computers
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Metering control systems – Legacy
• Single Stream Flow computers.
• Separate Prover Flow computers.
• Supervisory computers.
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Flow Computers - Primary Function • Actual Cash register of custody transfer system.
• Industry standard flow calculations.
• Retains the true fiscal totals.
• Directly connected to measurement devices.
• Generation of fiscal reports.
• Alarms and event handling.
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Flow Computers - Current
• Multi Stream Capability.
• Fast Processors with 32 Bit Math Co processor.
• Configurable or Programmable.
• HART Connectivity.
• WEB-Enabled interfaces.
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• The Metering Supervisory Computer is normally customized to each Fiscal Metering Station.
• The Concepts, the Hardware, software and the Functions differ from System to System.
Supervisory Computers
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Supervisory Computers
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• PC hardware and associated software drivers are frequently revised / updated.
• New operating systems are regularly released.
• Software patches are regularly released.
• Customized programming.
Supervisory Computers – Challenges
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• Stand Alone
• Dual Redundant
• Hot Standby
Redundancy
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Ethernet
Flow Computers
PLC
Supervisory
HMI
Reports
HUB
Ethernet Ethernet
RS232 or Ethernet
Flow Meter Inputs Turbines Temperature Pressure
Digital I/O
Alarms
DCS / SCADA Communications
Typical System Configuration
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Ethernet
Flow Computers
PLC
Supervisory
HMI
Reports
HUB
Ethernet Ethernet
RS232 or Ethernet
Flow Meter Inputs Turbines Temperature Pressure
Digital I/O
Alarms
DCS / SCADA Communications
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DanPac Measurement and Control System
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DCS Embedded Metering Control System
ERP SYSTEMS
Distributed Control System (DCS)
Field Instruments
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Benefits of New technology • Advanced network integration, scalability and ability to
embed various standalone applications, helps in real time interpretation of data for performance monitoring, quantitative and qualitative analysis.
• Enhanced real time diagnostic features, using benefits of smart instrumentation & various validation techniques.
• Use of controller based distributed architecture with standard hardware and software enhances the stability, redundancy features and makes it easier for upgrades and maintain.
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1. Not just another HMI in the control room.
• Typically MSC systems are like any other control system, keeping focus on normal operation, process data and access to historical reports.
• A system which can be used to monitor and control the quality of measurement.
• A system which can seamlessly embed the various standalone applications related to flow metering, supporting our maintenance, audit and management.
What We as an End User Looks For ?
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2. Ability to integrate the smart metering devices.
• Use of smart devices in metering , provide lots of information on their own health, ability to communicate with other device and more.
• MSC normally acquire process data required for operation, generate alarm if something is wrong with measurement, requiring specialist to travel to site and troubleshoot issue.
• A system which can provide remote access to wealth of diagnostic information provided by the smart devices, with ability to use this information in real time.
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3. Ability to store Measurement Data.
• Measurement data is about both quantity and quality.
• FCs store these data for a particular period, then flush these information and lost for ever.
• A System which can archive all crucial measurement data, including the periodic quantity reports or batch reports, calibration and validation reports , changes in configuration settings and any events related to metering system.
• A System which can encrypt these measurement data.
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4. Ability to detect the measurement deviations.
• A System which can continuously monitor the health of metering equipment and validate measurement data in real-time, e.g. by cross-checking redundant and parallel measurements and applying statistical control.
• A System which can apply self-diagnostics on both device and system and can warn the user in real-time for measurement issues.
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5. Ability to provide auto correction for error.
• Quantifying the measurement error and correcting the meter ticket is a time consuming and a specialist job.
• A system which can automatically replicate the flow computer calculations , using the concepts of virtual flow computer with high resolution metering data and sophisticated correction method and can quantify the loss or gain caused due to the error in measurement.
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6. Measurement Management
• Track the measurement management process and build a traceable measurement system.
• A System which can track the periodic validations for the instruments as per the standards or company policies , reports the abnormalities to the responsible persons in the hierarchy in case of deviations beyond the tolerance limits.
• A System which can help our Ship Shore difference investigations , with consolidated reports for all the events happened during a particular vessel loading and associated validation reports.
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7. Customized with Standardized Metering Package.
• Standardized metering packages with customized solution for our operational and fiscal requirements.
• A System which uses standard programming languages and avoid using custom scripting at the supervisory level.
• A System with inbuilt redundancy features.
• A System which can effectively control batch operations.
• Preference to integrated supervisory and flow metering technology.
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THANK YOU