New USM Installation Procedure

PT.
CONTROL SYSTEMS
CUSTOMER PROJECT
FOR
: PETROCHINA INTERNATIONAL JABUNG LTD. : SUPPLY AND INSTALL ONE (1) UNIT USM CUSTODY TRANSFER ON BGP METERING SYSTEM : INSTALLATION PROCEDURE : 25-A094011-MT-Q01 : -
DOCUMENT DOC NO. CUST. DOC NO.
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PT. Control Systems
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Issued for Approval DESCRIPTION
DPJ PREPD
SH CHECKD
AT APPROVD
11-Feb-2010 DATE
PT. CONTROL SYSTEMS
PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES
INSTALLATION PROCEDURE
TABLE OF CONTENTS
SECTION 1 INTRODUCTION
1.1 1.2 1.3 1.4 Purpose Reference Tool Requirement Permit Requirement
SECTION 2
IMPLEMENTATION
2.1 2.2 2.3 2.4 2.5 Collect Flow Computer Data Process Isolation Electrical Isolation Instrumentation Process Isolation Replacement Flowmeter 2.5.1 Removing old Flowmeter 2.5.2 Installing new Flowmeter 2.5.3 Leak test new Flowmeter Re wiring Signal And Electrical Cable Re powering System Integration and Communication Test
2.6 2.7 2.8
SECTION 3
FIELD VERIFICATION
3.1 3.2
Zero Flow Verification Flow Verification.
Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01
Installation Procedure Page 2 of 18
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SECTION 1 INTRODUCTION
1.1 PURPOSE
This procedure shall be utilized for: 1. Dismantling the existing Ultrasonic Flowmeter 2. 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 tool requirement Laptop with software programming accessories Multimeter. Standard tool. Chain Block and accessories Personal Protective Equipment for S500, with
1.4
PERMIT REQUIREMENT
Mostly all main work will be done on Local Technical room, and related to Electrical system, some permit required. 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 computer 2. Upload configuration to maintenance pc/laptop 3. Update the configuration for new ultrasonic flowmeter if needed
2.2
PROCESS ISOLATION
Before starting the job 1. Check that the isolation valve upstream and downstream is fully closed 2. Slowly vent the entrapped gas on the meter by opening the vent valve at the vent line of the meter. 3. Ensure that pressure inside the meter indicated at pressure transmitter equal to atmospheric pressure and no gas flow at HMI indication. 4. Applied soap bubble test solution at the venting valve to ensure that isolation valve downstream and upstream not passing.
2.3
ELECTRICAL ISOLATION
1. Open Terminal Block on metering panel as per as built drawing for Pressure Transmitter, Temperature Transmitter and Ultrasonic Flowmeter 2. Open signal junction box and make sure no power applied to the instrument devices. 3. Disconnect all wiring termination on instrument devices and witness by DIMET 4. Pulling cable and add identification label if needed 5. Disconnect all wiring on flow computer, and keep flow computer turn on
2.4
INSTRUMENTATION PROCESS ISOLATION

Installation Procedure Page 4 of 18 25-A094011-MT-Q01
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1. Uninstall all instrument devices and accessories on the meter which will be replaced. 2. Give identification label and keep it in safe area 3. Uninstall isolation valve, SS tubing, bourdon tube, thermowheel, blind flange 4. 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 Flowmeter 1. Ensure that all electrical isolation work, process isolation work and instrumentation isolation work already done. 2. Prepare rigging material, verify sling sizes and length, check for damage 3. Dismantle pipe clamp or pipe support 4. Lift pipe spool and loosen all bolt 5. 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 Flowmeter 1. Prepare rigging material, verify sling sizes and length, check for damage 2. Ensure that the direction of the meter is correct. 3. Lift Flow meter 4. Install new gasket and temporary bolt to isolation valve and secure to pipe support 5. Align pipe flanges upstream and downstream to the isolation valve, fit and bolt up flanges 6. Check bolt tension on flanges and pipe support
Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01 Installation Procedure Page 5 of 18
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7.
Install all instrument devices and accessories. 8. Perform leak test if step 1 until 7 already done.
2.5.3 Leak Test Procedure

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

2. Pressurized the meter until the pressure reading of
3.
4. 5. 6.
7.
8.
the pressure gauge is 100 Psig. Visually check and record any leaks on the flange joints using soap bubble test. Record the pressure reading of the pressure gauge every 15 minutes, hold at these test pressure for 1 hour. If any leaks are founded, tightening the bolts after nitrogen inside meter is vented, and repeat this step. After step 2 is succeed, repeat the step 2 for test pressure = 500 Psig. After step 4 is succeed, repeat the step 4 for test pressure = 1000 Psig. After step 4 is succeed, increase the test pressure = operating pressure (1500 Psig). Visually check and record any leaks on the flange joints using soap bubble test. Record the pressure reading of the pressure gauge every 15 minutes at the start of this test period and end of this test period, hold at these test pressure for 1 hour. If any leaks are founded, tightening the bolts after nitrogen inside meter is vented, and repeat the step 1 to 6. If leak test is succeed, field installation already done
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 cable complete with cable glands and heat shrink into appropriate tag numbers or label. 2. Ensure that all cables have a spare for modification in 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 heat shrink, use heat gun tools to install it. And ensure that water and explosion gas cant entrapped in the transmitter body. 5. Apply thin layer of grease on transmitter cap and re-sealing by witness of DIMET.
2.7
RE-POWERING SYSTEMS
Step by step Power Up 1. Ensure that all field cable termination on transmitter already done and terminal cap cover already tight. 2. The USM, Pressure Transmitter, Temperature Transmitter can be power up by close terminal block on metering panel as per as built drawing for FT, PT and TT. 3. Check the related field transmitter working properly. 4. Re-connect all signal cables to existing flow computer that have been un-plugged before.
2.8
INTEGRATION & COMMUNICATION TEST PROCEDURE

1. Make wiring Connection between control panel and the USM. Existing cable will be used for 24 VDC power cable, and existing serial cable will be used for the same purpose. 2. Additional cable for Ethernet communication shall be provided 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 maintenance computer. 5. Set ethernet communication setting on the USM, based on the existing CUI setting on the maintenance computer. 6. After wiring connection and correct setting have been done. The USM can be powered up. 7. Check & record the communication status between USM and Flow Computer. Compare the data received by flow computer with the same data on the USM. Comparison can be 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 computer with the inside diameter of the installed USM. 9. Make communication to USM using Daniel CUI with Ethernet communication. Ensure that communication can be established.
SECTION 4
4.1
FIELD VERIFICATION PROCEDURE
ZERO FLOW VERIFICATION

1. After leak test has been completed, the meter tube is remained pressurized at operating pressure. The USM can be powered Up and connect TCP/IP Cable from USM into Laptop running CUI software.
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2. Run the CUI software and make sure CUI software can communicate with USM. Done the following item with CUI Software: a. Read the USM configuration and save as AsFound configuration file. Read the USM configuration file by select Read button on the Edit/Compare Configuration window. b. Verify the data in the AsFound configuration file same as configuration file during FAT. The configuration data shall be compare are: Metrology data: Chord Dimension, Pipe inside diameter, pipe outside diameter, Chord delay time, dry calibration coefficient, etc. Wet calibration meter factor Make sure that the above data same as data at calibration, except communication parameter. c. Basic Meter Diagnostic Below five basic diagnostic feature provides a comprehensive analysis of meters 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 be found 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 is in acceptance level, then the maintenance log file can be used as sources for the baseline value beside log file during Calibration.
APPENDIX A
THE PRIMARY PARAMETER WHICH PROVIDE THE USER WITH A WAY OF DIAGNOSING A METER PROBLEM
Parameter Profile Factor Velocity ratio of inner chords to outer chords: (Vb + Vc) / (Va + Vd)
Normal Under normal condition: 1.20 1.26 Piping configuration in actual field installation will affect this value. At low velocities (<2 3 ft/sec) value may deviate from the norm
Abnormal At velocities > 3 ft/sec, trended profile factor indicates shift from the norm or the factor when the meter was initially installed Trended shift to higher values of profile factor (increasing over time) probably indicate
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Swirl Determined from velocity ratio of inner chords to outer chords: (Vb + Vc) / (Va + Vd) Swirl angle is calculated from Profile Factor
For Profile factor 1.17, the swirl angle will be ~ 0 Degree.
contaminant of upstream piping. Typical variation in log file (or Monitor Screen) should be less then +/0.02. Excess variation could be an indication of flow conditioner blockage (or a constantly changing flow profile) Check turbulence if high this is a define sign of blockage or something that is causing significant profile changes. At velocities > 3 ft/sec, trended Swirl angle indicates shift from the norm or the factor when the meter was initially installed. Typical swirl is 2% or less if flow conditioner is used and installed properly. If a flow conditioner is not installed, or improper located, upstream piping
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Crossflow Velocity ratio of the chords in one plane to those in other plane
Under Normal condition crossflow factor ~ 1.00 +/- 0.02 At low velocities (<2 3 ft/sec) Crossflow value may change due to the inability of the flow conditioner to have much affect on the velocity profile or temperature gradient that may cause flow stratification
Symmetry Velocity ratio of the two upper chords to the two lower chords: (Va + Vb) / (Vc + Vd)
Under Normal condition factor ~ 1.00 +/- 0.02. At low velocities (<2 3 ft/sec) Crossflow value may change due to the inability of the
maybe a cause If flow conditioner is properly installed, a blockage may have occurred or the meter/upstream piping may be dirty. At Velocity > 3 ft/sec, trended crossflow value indicates a shift from the norm or the value when the meter was initially installed Typically the crossflow will not vary more than +/- 0.02 in the log file from the average. Variation in excess of +/0.02 should be considered abnormal and warrant further investigation. Check for blockage in piping or dirty meter/upstream piping. At Velocity > 3 ft/sec, trended symmetry value indicates a shift from the norm or the value when the meter was initially installed
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flow conditioner to have much affect on the velocity profile or temperature gradient that may cause flow stratification
Signal To Noise Ratio Comparison of noise from transducer to background noise in meter
At normal velocities (below 60 ft/sec) value are typically 2500 to 3000 with no control valve noise present. At high velocities (above 60 ft/sec) the value may be as low as 1000. If meter velocities exceed 100 ft/sec, SNR can drop to below 250.
Typically the crossflow will not vary more than +/- 0.02 in the log file from the average. Variation in excess of +/0.02 should be considered abnormal and warrant further investigation. Check for blockage in piping or dirty meter/upstream piping. At Velocity > 3 ft/sec, trended SNR value indicates a shift from the norm or the value when the meter was initially installed (at similar velocities) View waveforms to check for background noise due to differential device such as control valve. Implement stacking and / or filtering to improve SNR. Monitor transducer performance as meter should be running 100% up until close to
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full scale rating in velocities Speed Of Sound Comparison of meters reported SOS to AGA 10 SOS Typically 3 ft/sec different between the meters average SOS and the AGA 10 SOS. There may be increased variance at very low gas velocities At Velocity > 3 ft/sec, SOS different greater than 3 ft/sec probably indicates error in gas temperature or gas composition. Error can be due to sample analysis lag time (GC update time as well as time for gas to get GC). Error can be due to significant changes in gas composition from minute to minutes (check for steady meter SOS in monitor screen to confirm) Check for low flow gas velocity (<2 3 ft/sec) as thermal stratification may explain differences. At Velocity > 3 ft/sec, SOS different values indicate a shift from the norm or the value when the meter was initially installed (at similar
Installation Procedure Page 14 of 18 25-A094011-MT-Q01
Speed Of Sound Comparison of each chords SOS to meters reported SOS
Typically 1 ft/sec difference between each chords. There may be increased variance at very low high gas velocities
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Gain
Under the normal conditions gain values are a function of the fluid properties (primarily pressure and velocities) Under similar conditions, gain remain relatives constant and difference between chords will be small.
velosities) Check for dirty or faulty transducer on chord indicating the change. Check for ultrasonic noise which may be causing a peak switch. Check for low flow gas velocities (<2 3 ft/sec) as thermal stratification may explain the differences Trended gain values on all chords indicates a shift from the norm or the value when the meter was initially installed (at similar condition). If all have increased or decreased, check for significant change in operating condition such as pressure and velocity. Doubling the pressure changes gain about 6 for all chords. At velocities above 50-60 ft/sec gain value will increase and
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Signal Quality Performace
Normally the performance on all paths should be 100 %. At high velocities (near rated capacity) performances may be decrease to below 100%.
near rated capacity gain may be 6-10 higher on a Mark III. If individual transducer have high gain, check for fouling or deterioration of transducer (internal resistance). At normal velocities, trended performances value for all chords indicate a shift from the norm or the value when the meter was initially installed (at similar conditions) Check for transducer fouling or dirty meter. Performance may be less than 100% when control valve noise is present. Check SNR value to see if they are above 1000. Check for transducer fouling or deterioration on chord(s). Typically they will be increased gain if transducer is
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Turbulence Variability in each chord(s) velocity reading during a sample period
Normally 2-4 % on Chords A & D Normally 1-2 % on Chords B & C
Eta Peak Switch detection on acoustic wave
Normally has a value of 0 +/- 2 s
failing and causing low performance (SNR will usually be higher also), At normal velocities, turbulence value on oe or more chords indicate a shift from the norm or the value when the meter was initially installed. Check for obstruction upstream of the meter. Increase to 6% or more are strong indication of blockage of flow conditioner. Fluctuating flow from cyclic flow control valve can also cause an increase in the average. Variation of 1-2 % above and below the average of each chord are normal (can be checked in log file). Values of Eta are outside the range of 0 +/- 2 s. Values above may be in indication of peak switch (Typically above 5 s)
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Significant variance above and below 2 sis probably an indication of intermittent peak switching. Check for noise in meter, either flow induce or control valve. SNR should be low if peak switching is occurring due to control valve May occur at very high velocities, if waveforms becomes distorted.

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DOCUMENT DOC NO. CUST. DOC NO.

PT. Control Systems

Issued for Approval DESCRIPTION

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

2.6 2.7 2.8

Zero Flow Verification Flow Verification.

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

Installation Procedure Page 2 of 18

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

Installation Procedure Page 3 of 18

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

INSTRUMENTATION PROCESS ISOLATION

Betara Gas Plant PetroChina International Jabung Ltd.

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

REPLACEMENT FLOW METER

2.5.1 Removing old Flow Meter

2.5.2 Installing New Flow Meter

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

2.5.3 Leak Test Procedure

to ensure that no leaks at piping systems.

RE-WIRING SIGNAL AND ELECTRICAL CABLE

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

Installation Procedure Page 6 of 18

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

INTEGRATION & COMMUNICATION TEST PROCEDURE

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

Installation Procedure Page 7 of 18

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

FIELD VERIFICATION PROCEDURE

ZERO FLOW VERIFICATION

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

Installation Procedure Page 8 of 18

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

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

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

Installation Procedure Page 9 of 18

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

For Profile factor 1.17, the swirl angle will be ~ 0 Degree.

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

Betara Gas Plant PetroChina International Jabung Ltd. 25-A094011-MT-Q01

PT. CONTROL SYSTEMS

PROVISION OF SUPERVISION OF INSTALLATION NEW USM METER RUN SERVICES

Speed Of Sound Comparison of each chords SOS to meters reported SOS

Betara Gas Plant PetroChina International Jabung Ltd.

PT. CONTROL SYSTEMS