New USM Installation Procedure

7/30/2019 New USM Installation Procedure

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PT. CONTROL SYSTEMS

Prepared by:

PT. Control Systems

0 Issued for Approval DPJ SH AT 11-Feb-2010

REV DESCRIPTION PREP’D CHECK’D APPROV’D DATE

CUSTOMER : PETROCHINA INTERNATIONAL JABUNG LTD.PROJECT : SUPPLY AND INSTALL ONE (1) UNIT USM

FOR CUSTODY TRANSFER ON BGP METERING SYSTEM

DOCUMENT : INSTALLATION PROCEDURE DOC NO. : 25-A094011-MT-Q01CUST. DOC NO. : -



PT. CONTROL SYSTEMSPROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

I NSTALLATION PROCEDURE

TABLE OF CONTENTS

SECTION 1 INTRODUCTION

1.1 Purpose1.2 Reference1.3 Tool Requirement1.4 Permit Requirement

SECTION 2 IMPLEMENTATION

2.1 Collect Flow Computer Data2.2 Process Isolation2.3 Electrical Isolation2.4 Instrumentation Process Isolation2.5 Replacement Flowmeter

2.5.1 Removing old Flowmeter2.5.2 Installing new Flowmeter

2.5.3 Leak test new Flowmeter2.6 Re wiring Signal And Electrical Cable2.7 Re powering System2.8 Integration and Communication Test

SECTION 3 FIELD VERIFICATION3.1 Zero Flow Verification3.2 Flow Verification.

Betara Gas Plant Installation ProcedurePetroChina International Jabung Ltd. of 18

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SECTION 1 – INTRODUCTION

1.1 PURPOSE

This procedure shall be utilized for:

1. Dismantling the existing Ultrasonic Flowmeter2. Installation New Ultrasonic Meter Run.3. Integration between the new installations of gas flow

meter with existing flow computer.4. Field Verification of the new installation of gas flow

meter.

1.2 REFERENCE

1. AGA Report 9, AGA 2000;2. DTI Guidance Note for Petroleum Measurement Under

Petroleum (Production) Regulation, Issue March 2002;3. ANSI B16.34: 1996, B16.5: 1999;4. API RP 500: 1997, API Chapter 5, 6 and 21;

5. IEC 60331-11: 1999, 60197: 1965, 60654: 1993

1.3 TOOL REQUIREMENT

To carry out the upgrading job there is no special toolrequirement

• Laptop with software programming for S500, with

accessories

• Multimeter.

• Standard tool.

• Chain Block and accessories

• Personal Protective Equipment

1.4 PERMIT REQUIREMENT

Mostly all main work will be done on Local Technicalroom, and related to Electrical system, some permitrequired.

• Cold work permit with complementary

• Electrical Isolation


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SECTION 2 - IMPLEMENTATION

2.1 COLLECT FLOW COMPUTER DATA

1. Collect an existing configuration flow computer2. Upload configuration to maintenance pc/laptop3. Update the configuration for new ultrasonic

flowmeter if needed

2.2 PROCESS ISOLATION

Before starting the job

1. Check that the isolation valve upstream anddownstream is fully closed

2. Slowly vent the entrapped gas on the meter byopening the vent valve at the vent line of themeter.

3. Ensure that pressure inside the meter indicated atpressure transmitter equal to atmospheric pressureand no gas flow at HMI indication.

4. Applied soap bubble test solution at the ventingvalve to ensure that isolation valve downstream andupstream not passing.

2.3 ELECTRICAL ISOLATION

1. Open Terminal Block on metering panel as per as

built drawing for Pressure Transmitter, TemperatureTransmitter and Ultrasonic Flowmeter

2. Open signal junction box and make sure no powerapplied to the instrument devices.

3. Disconnect all wiring termination on instrumentdevices and witness by DIMET

4. Pulling cable and add identification label if needed5. Disconnect all wiring on flow computer, and keep

flow computer turn on

2.4 INSTRUMENTATION PROCESS ISOLATION


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1. Uninstall all instrument devices and accessories onthe meter which will be replaced.

2. Give identification label and keep it in safe area3. Uninstall isolation valve, SS tubing, bourdon tube,

thermowheel, blind flange4. Give identification label and keep in safe area.

2.5 REPLACEMENT FLOW METER

2.5.1 Removing old Flow Meter

Step by step of replacing Flowmeter1. Ensure that all electrical isolation work, process

isolation work and instrumentation isolation workalready done.

2. Prepare rigging material, verify sling sizes andlength, check for damage

3. Dismantle pipe clamp or pipe support

4. Lift pipe spool and loosen all bolt5. Remove meter from existing place (See : Lifting

Procedure)6. The old meter shall be keep in safe area and in

order not to disturbing installation new meter.7. During removing the meter, the existing meter skid

shall be closed by blind flange.

2.5.2 Installing New Flow Meter

Step by step of installing Flowmeter1. Prepare rigging material, verify sling

sizes and length, check for damage2. Ensure that the direction of the meter is

correct.3. Lift Flow meter4. Install new gasket and temporary bolt to

isolation valve and secure to pipe support5. Align pipe flanges upstream and downstream

to the isolation valve, fit and bolt up flanges6. Check bolt tension on flanges and pipe

support


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7. Install all instrument devices andaccessories.

8. Perform leak test if step 1 until 7 alreadydone.

2.5.3 Leak Test Procedure

1. Start to pressurize the meter stream with nitrogento ensure that no leaks at piping systems.

2. Pressurized the meter until the pressure reading ofthe pressure gauge is 100 Psig. Visually check andrecord any leaks on the flange joints using soapbubble test. Record the pressure reading of thepressure gauge every 15 minutes, hold at these testpressure for 1 hour.

3. If any leaks are founded, tightening the bolts afternitrogen inside meter is vented, and repeat this

step.4. After step 2 is succeed, repeat the step 2 for test

pressure = 500 Psig.5. After step 4 is succeed, repeat the step 4 for test

pressure = 1000 Psig.6. After step 4 is succeed, increase the test pressure

= operating pressure (1500 Psig). Visually check andrecord any leaks on the flange joints using soapbubble test. Record the pressure reading of thepressure gauge every 15 minutes at the start of thistest period and end of this test period, hold atthese test pressure for 1 hour.

7. If any leaks are founded, tightening the bolts afternitrogen inside meter is vented, and repeat the step1 to 6.

8. If leak test is succeed, field installation alreadydone

2.6 RE-WIRING SIGNAL AND ELECTRICAL CABLE

After installation of all piping systems and instrument

devices already done, signal cable and communication


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cable shall be re-install.

1. Install all signal cable and communication cablecomplete with cable glands and heat shrink intoappropriate tag numbers or label.

2. Ensure that all cables have a spare for modificationin the future with pigtail.

3. Termination all wire cables to terminal board,ensure that the polarity is correct.

4. Each cable glands complete with 6 inch long heatshrink, use heat gun tools to install it. And ensurethat water and explosion gas can’t entrapped in thetransmitter body.

5. Apply thin layer of grease on transmitter cap andre-sealing by witness of DIMET.

2.7 RE-POWERING SYSTEMS

Step by step Power Up

1. Ensure that all field cable termination ontransmitter already done and terminal cap coveralready tight.

2. The USM, Pressure Transmitter, TemperatureTransmitter can be power up by close terminal blockon metering panel as per as built drawing for FT, PTand TT.

3. Check the related field transmitter workingproperly.

4. Re-connect all signal cables to existing flowcomputer that have been un-plugged before.

2.8 INTEGRATION & COMMUNICATION TEST PROCEDURE

1. Make wiring Connection between control panel and theUSM. Existing cable will be used for 24 VDC powercable, and existing serial cable will be used for thesame purpose.

2. Additional cable for Ethernet communication shall beprovided and installed.


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3. Set serial communication setting on the USM port A,based on the existing flow computer setting.

4. Set serial communication setting on the USM port B,based on the existing CUI setting on the maintenancecomputer.

5. Set ethernet communication setting on the USM, basedon the existing CUI setting on the maintenancecomputer.

6. After wiring connection and correct setting have been

done. The USM can be powered up.

7. Check & record the communication status between USMand Flow Computer. Compare the data received by flowcomputer with the same data on the USM. Comparison canbe done on the following data:

• Velocity of gas for Chord A, B, C, D and the

average.

• Sound of Velocity for Chord A, B, C, D and the

average.

• Gain value for Chord A, B, C, D and the average.

• SNR data for Chord A, B, C, D and the average.

8. Update the inside diameter data on the flow computerwith the inside diameter of the installed USM.

9. Make communication to USM using Daniel CUI withEthernet communication. Ensure that communication canbe established.

SECTION 4 FIELD VERIFICATION PROCEDURE

4.1 ZERO FLOW VERIFICATION

1. After leak test has been completed, the meter tube isremained pressurized at operating pressure. The USMcan be powered Up and connect TCP/IP Cable from USMinto Laptop running CUI software.


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2. Run the CUI software and make sure CUI software cancommunicate with USM. Done the following item with CUISoftware:

a. Read the USM configuration and save as AsFoundconfiguration file. Read the USM configuration fileby select Read button on the Edit/CompareConfiguration window.

b. Verify the data in the AsFound configuration filesame as configuration file during FAT. Theconfiguration data shall be compare are: Metrology data: Chord Dimension, Pipe inside

diameter, pipe outside diameter, Chord delaytime, dry calibration coefficient, etc.

Wet calibration meter factor

Make sure that the above data same as data atcalibration, except communication parameter.

c. Basic Meter DiagnosticBelow five basic diagnostic feature provides a

comprehensive analysis of meter’s health:

• Individual path velocities

• Signal to noise for each transducer

• Individual path of speed and sound

• Gain of each transducer

• Accepted of pulse, in percentage of each

transducer

The acceptance criteria of above parameter can befound in the Appendix A.

4.2 FLOW VERIFICATION

1. After Zero Flow Verification indicates good result,gas can be flown through ultrasonic gas flow meter.Flow verification shall be done at this step.

2. Beside the five basic diagnostic as per zero flow

verification, below advance diagnostic parameter shall


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be verificated:

• Turbulence

• Swirl

• Symmetry

• Crossflow

• ETA (peak switch detection)

The acceptance criteria of above parameter can be

found in Appendix A.

3. After all above check have completed and the result isin acceptance level, then the maintenance log file canbe used as sources for the baseline value beside logfile during Calibration.

APPENDIX A

THE PRIMARY PARAMETER WHICH PROVIDE THE USER WITH A WAY OF

DIAGNOSING A METER PROBLEM

Parameter Normal Abnormal

Profile FactorVelocity ratio ofinner chords toouter chords:

(Vb + Vc) / (Va +Vd)

- Under normalcondition: 1.20 –1.26

- Piping

configuration inactual fieldinstallation willaffect this value.

- At lowvelocities (<2 – 3ft/sec) value maydeviate from thenorm

- At velocities> 3 ft/sec,trended profilefactor indicates

shift from thenorm or thefactor when themeter wasinitiallyinstalled

- Trended shiftto higher valuesof profile factor(increasing overtime) probably

indicate


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contaminant ofupstream piping.

- Typicalvariation in logfile (or MonitorScreen) should beless then +/-0.02. Excessvariation couldbe an indication

of flowconditionerblockage (or aconstantlychanging flowprofile)

- Checkturbulence – ifhigh this is adefine sign ofblockage orsomething that is

causingsignificantprofile changes.

SwirlDetermined fromvelocity ratio ofinner chords toouter chords:(Vb + Vc) / (Va +Vd)Swirl angle iscalculated from

Profile Factor

- For Profilefactor 1.17, theswirl angle willbe ~ 0 Degree.

- At velocities> 3 ft/sec,trended Swirlangle indicatesshift from thenorm or thefactor when themeter wasinitiallyinstalled.

- Typical swirlis 2% or less ifflow conditioneris used andinstalledproperly.

- If a flowconditioner isnot installed, orimproper located,

upstream piping


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maybe a cause

- If flowconditioner isproperlyinstalled, ablockage may haveoccurred or themeter/upstreampiping may bedirty.

CrossflowVelocity ratio ofthe chords in oneplane to those inother plane

- Under Normalconditioncrossflow factor ~1.00 +/- 0.02

- At lowvelocities (<2 – 3ft/sec) Crossflowvalue may changedue to theinability of theflow conditionerto have much

affect on thevelocity profileor temperaturegradient that maycause flowstratification

- At Velocity >3 ft/sec, trendedcrossflow valueindicates a shiftfrom the norm orthe value whenthe meter wasinitiallyinstalled

- Typically thecrossflow willnot vary more

than +/- 0.02 inthe log file fromthe average.Variation inexcess of +/-0.02 should beconsideredabnormal andwarrant furtherinvestigation.

- Check forblockage inpiping or dirtymeter/upstreampiping.

SymmetryVelocity ratio ofthe two upperchords to the twolower chords:(Va + Vb) / (Vc +Vd)

- Under Normalcondition factor ~1.00 +/- 0.02.

- At lowvelocities (<2 – 3ft/sec) Crossflowvalue may changedue to the

inability of the

- At Velocity >3 ft/sec, trendedsymmetry valueindicates a shiftfrom the norm orthe value whenthe meter wasinitially

installed


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flow conditionerto have muchaffect on thevelocity profileor temperaturegradient that maycause flowstratification

- Typically thecrossflow willnot vary morethan +/- 0.02 inthe log file fromthe average.Variation inexcess of +/-0.02 should beconsidered

abnormal andwarrant furtherinvestigation.

- Check forblockage inpiping or dirtymeter/upstreampiping.

Signal To NoiseRatio

Comparison ofnoise from

transducer tobackground noisein meter

At normalvelocities (below60 ft/sec) valueare typically 2500

to 3000 with nocontrol valvenoise present. Athigh velocities(above 60 ft/sec)the value may beas low as 1000. Ifmeter velocitiesexceed 100 ft/sec,SNR can drop tobelow 250.

- At Velocity >3 ft/sec, trendedSNR valueindicates a shift

from the norm orthe value whenthe meter wasinitiallyinstalled (atsimilarvelocities)

- View waveformsto check forbackground noisedue todifferentialdevice such ascontrol valve.Implementstacking and / orfiltering toimprove SNR.Monitortransducerperformance asmeter should berunning 100% up

until close to


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full scale ratingin velocities

Speed Of Sound Comparison ofmeter’s reportedSOS to AGA 10 SOS

- Typically 3≤ ft/sec differentbetween themeter’s averageSOS and the AGA 10SOS.

- There may be

increased varianceat very low gasvelocities

- At Velocity >3 ft/sec, SOSdifferent greaterthan 3 ft/secprobablyindicates errorin gas

temperature orgas composition.

- Error can bedue to sampleanalysis lag time(GC update timeas well as timefor gas to getGC).

- Error can bedue tosignificant

changes in gascomposition fromminute to minutes(check for steadymeter SOS inmonitor screen toconfirm)

- Check for lowflow gas velocity(<2 – 3 ft/sec)as thermalstratificationmay explaindifferences.

Speed Of SoundComparison of eachchords’ SOS tometers’ reportedSOS

- Typically 1≤ ft/sec differencebetween eachchords.

- There may beincreased varianceat very low highgas velocities

- At Velocity >3 ft/sec, SOSdifferent valuesindicate a shiftfrom the norm orthe value whenthe meter wasinitiallyinstalled (at

similar


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velosities)

- Check fordirty or faultytransducer onchord indicatingthe change.

- Check forultrasonic noisewhich may becausing a peak

switch.- Check for lowflow gasvelocities (<2 –3 ft/sec) asthermalstratificationmay explain thedifferences

Gain - Under thenormal conditionsgain values are a

function of thefluid properties(primarilypressure andvelocities)

- Under similarconditions, gainremain relativesconstant anddifference betweenchords will be

small.

- Trended gainvalues on allchords indicates

a shift from thenorm or the valuewhen the meterwas initiallyinstalled (atsimilarcondition).

- If all haveincreased ordecreased, checkfor significant

change inoperatingcondition such aspressure andvelocity.Doubling thepressure changesgain about 6 forall chords.

- At velocitiesabove 50-60ft/sec gain value

will increase and


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near ratedcapacity gain maybe 6-10 higher ona Mark III.

- If individualtransducer havehigh gain, checkfor fouling ordeterioration oftransducer

(internalresistance).

Signal Quality

Performace- Normally theperformance on allpaths should be100 %.

- At highvelocities (nearrated capacity)performances maybe decrease tobelow 100%.

- At normalvelocities,trendedperformancesvalue for allchords indicate ashift from thenorm or the valuewhen the meterwas initially

installed (atsimilarconditions)

- Check fortransducerfouling or dirtymeter.

- Performancemay be less than100% when controlvalve noise ispresent. CheckSNR value to seeif they are above1000.

- Check fortransducerfouling ordeterioration onchord(s).Typically theywill be increasedgain if

transducer is


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failing andcausing lowperformance (SNRwill usually behigher also),

Turbulence

Variability ineach chord(s)velocity readingduring a sampleperiod

- Normally 2-4% on Chords A & D

- Normally 1-2% on Chords B & C

- At normalvelocities,turbulence valueon oe or morechords indicate a

shift from thenorm or the valuewhen the meterwas initiallyinstalled.

- Check forobstructionupstream of themeter. Increaseto 6% or more arestrong indicationof blockage of

flow conditioner.- Fluctuatingflow from cyclicflow controlvalve can alsocause an increasein the average.

- Variation of1-2 % above andbelow the averageof each chord arenormal (can bechecked in logfile).

EtaPeak Switchdetection onacoustic wave

- Normally hasa value of 0 +/- 2µs

- Values of Etaare outside therange of 0 +/- 2µs.

- Values abovemay be inindication ofpeak switch(Typically above

5 µs)


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- Significantvariance aboveand below 2 µsisprobably anindication ofintermittent peakswitching.

- Check fornoise in meter,either flow

induce or controlvalve. SNR shouldbe low if peakswitching isoccurring due tocontrol valve

- May occur atvery highvelocities, ifwaveforms becomesdistorted.


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