orifice plate diagnostics and prognosis presented by jennifer ayre, swinton technology on behalf of...
TRANSCRIPT
![Page 1: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/1.jpg)
Orifice Plate Diagnostics and Prognosis
Presented by
Jennifer Ayre, Swinton Technologyon behalf of
Mark Skelton, BP Exploration Operating Co.
Slide 1
Oil and Gas Focus Group MeetingWeds 11th May 2011, Norwich
![Page 2: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/2.jpg)
BP CATS Metering Teamhave a Vision
Slide 2
![Page 3: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/3.jpg)
Less Expensive Auditing
Less Calibration
Less Frequent Inspections
Slide 3
![Page 4: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/4.jpg)
4
The Vision
Preventative Maintenance, Accuracy Assurance, Mismeasurement Alerts
![Page 5: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/5.jpg)
So Here is the Story...
Slide 5
![Page 6: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/6.jpg)
1st Orifice Plate Inspection
5167 years B.C
Slide 6
![Page 7: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/7.jpg)
Since then, nothing changed…
Slide 7
![Page 8: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/8.jpg)
… until now!• 2008 & 2009: DP Diagnostics described
diagnostic methods for DP meters
• 2010: Swinton Technology developed “Prognosis” with DP Diagnostics
• BP CATS have given Prognosis an extensive field trial & CoP TGT have given Prognosis an initial field trial
• This presentation discusses the results of these field trials
Slide 8
![Page 9: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/9.jpg)
A Brief Review of the Diagnostic Methods• 3 DP’s give 3 DP pairs ,each pair
provides a DP ratio and 2 mass flows.
Ideally 6D downstream
Slide 9
![Page 10: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/10.jpg)
The Diagnostic Methods & Presentation ● 1 DP pair gives 1 DP ratio and 2 mass flows
● The difference between the DP ratio and an ISO calculated value is divided by a comparable uncertainty (y-axis)
● The difference between the 2 mass flows is divided by an assigned uncertainty (x-axis)
● The DP pair y and x coordinates form one point in the diagnostics box .The other 2 DP pairs provide 2 more points in diagnostics box
(-1,1) (1,1)
(1,-1)(-1,-1)
Slide 10
![Page 11: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/11.jpg)
• The diagnostic software can be applied via the meter’s flow computer
Field Data
Flow Computer
Metering Supervisory PC
+ Diagnostics Software
Additional I/O
Metering Supervisory PC
Applying the Diagnostic Solution
Diagnostics PC
• The diagnostic software can be applied via the meter’s flow computer OR via a separate I/O device to a dedicated PC
• DCS,• Historians• Maint
Scheduling• Email etc
Slide 11
![Page 12: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/12.jpg)
The Trials
Testing at CEESI Colorado
Testing at CEESI Iowa
BP CATS Field Trial
CoP TGT Field Trial
Slide 12
![Page 13: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/13.jpg)
Slide 13
![Page 14: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/14.jpg)
• BP operates CATS in Teesside, UK
• The terminal receives gas from multiple operators including BP & ConocoPhillips
• BP CATS has metering stations with multiple large orifice meters in parallel
•
• Field trials of Prognosis were carried out on one flange tapped 16”, 0.596 beta ratio orifice meter in a BP CATS metering station
• The stations natural gas flow was averaging (approx) 525 tonnes /hr
BP CATS
Slide 14
![Page 15: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/15.jpg)
BP CATS, May 2010
• Pipe ID 13.738”
d=8.195” (0.596 beta)
Slide 15
![Page 16: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/16.jpg)
BP CATS Field Trial Examples• Baseline (correct operation)
• Incorrectly entered inlet diameter
• Incorrectly entered orifice diameter
• Saturated DP transmitter
• Incorrectly calibrated DP transmitter
• Reversed plate
• Worn orifice edgeSlide 16
![Page 17: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/17.jpg)
Baseline Results at BP CATS
• First baseline test results were inside the NDB (as required)
• The theoretical correction factor was applied due to downstream tap >6D & thermowell upstream of this tap
Slide 17
![Page 18: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/18.jpg)
18
Keypad Diameter Orifice Errors (d= 8.195”)
d=8.100” -2.6% flowrate error
d=8.295” +2.9% flowrate error
Slide 18
![Page 19: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/19.jpg)
19
Keypad Diameter Inlet Errors (D = 13.738”)
ID=13.938” (sch 100)-0.5% flowrate error
ID=13.562” (sch 120)+0.4% flowrate error
Slide 19
![Page 20: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/20.jpg)
Saturated DP Transmitter (DPt=17.5kPa)• DP transmitter stack:
Low range transmitter, 0–15kPa, saturated
• If used it induces a -6.2% flowrate error
• Pattern indicates a DP problem & that it’s a traditional DP problem
• Also: kPakPa 2.112.67.15 Slide 20
![Page 21: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/21.jpg)
21
DP Transmitter Calibration Issues (Correct Calibration: 4mA-0kPa & 20mA-62kPa)• 20mA – 60kPa -1.6% flowrate error
• 20mA – 64kPa +1.6% flowrate error
Slide 21
![Page 22: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/22.jpg)
22
Reversed Orifice Plate
• A reversed plate in stream 5 produced a -15% error. Streams 2,3 & 5 were on line
• However all meters stated the same flowrates!?
• Meter 5’s flow resistance is reduced, & flow favours stream 5 by +15%, so error cancels this!
• Similar equilibrium existed for all other stream combinations tried
• It is not possible to monitor orifice meter performance in parallel runs by inter-comparing the parallel meters
Slide 22
![Page 23: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/23.jpg)
Reversed Orifice Plate (cont.)• Stream 5’s reversed
plate diagnostic result
• All meters read the same however..,
• Prognosis indicated the error
Slide 23
![Page 24: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/24.jpg)
Worn Orifice Edge• Stream 5’s plate was
deliberately worn, inducing a -2% error
• Streams 1,2 & 5 on line
• Again all meters showed same flow
• Prognosis alone indicated the error
Slide 24
![Page 25: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/25.jpg)
25
ConcoPhillips TGT
• CoP operates TGT in Lincolnshire, UK
• The terminal is co-owned by BP & CoP
• It receives gas from multiple operators
• Initial field trials of Prognosis were carried out on a corner tap 36”, 0.5997 beta ratio orifice meter at TGT
• The natural gas flow was averaging (approx) 400 tonnes /hr
Slide 25
![Page 26: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/26.jpg)
Baseline Results at CoP TGT
• A slight bias in the diagnostic baseline was found due to the downstream tapping configuration
• A small zeroing factor was therefore applied
Slide 26
![Page 27: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/27.jpg)
27
Keypad Diameter Inlet Errors (D =850.335mm)
ID=870.335mm-0.65% flowrate error
ID=830.335mm+0.75% flowrate error
Slide 27
![Page 28: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/28.jpg)
28
Summary• Swinton Technology have developed the DP
Diagnostics orifice meter diagnostics concept into a practical industrial product (‘Prognosis”)
• Field tests at BP CATS & CoP TGT were successful and are ongoing
• Prognosis is designed to warn of orifice meter system malfunctions, hence reducing costly exposure
• Most orifice meter errors could be seen at ≤ 1% error
Slide 28
![Page 29: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/29.jpg)
Reduced Carbon Footprint (orifice)
Assurance of Compliance and Accuracy
Less visits to remote operations
Less Frequent Meter Inspections
Reduced safety risks Proof of meter
performance over time
Observed Benefits
![Page 30: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/30.jpg)
Realisation
Slide 31
![Page 31: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/31.jpg)
The Future.....Wow look at this!!
Centralised Remote Diagnostics at a
Glance !!!
Slide 32
![Page 32: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/32.jpg)
DECC Statement
"DECC actively supports the use of two or three different DP measurements and associated software for diagnostic purposes on DP meters as introduced by Dr Richard Steven in [1] and [2]
as it has the potential to detect measurement errors as they arise, and to therefore greatly reduce the required frequency of
maintenance activities associated with DP-based measurement systems. Operators of relevant systems are encouraged to
approach DECC with a view to adopting condition-based monitoring strategies featuring this method.”
[1] 2008 NSFMW paper: Diagnostic Methodologies for Generic Differential Pressure Flow Meters
[2] 2009 NSFMW paper: Significantly Improved Capabilities of DP Meter Diagnostic Methodologies
![Page 33: Orifice Plate Diagnostics and Prognosis Presented by Jennifer Ayre, Swinton Technology on behalf of Mark Skelton, BP Exploration Operating Co. Slide 1](https://reader038.vdocuments.net/reader038/viewer/2022103022/56649cff5503460f949d0075/html5/thumbnails/33.jpg)
Thank You
QUESTIONS?
Slide 34