spiritit_mct_petrolchimico_final_rev1

Flow-X and eXLerate: flexible solutions forhigh-accuracy custody transfer applications

G. Ciarlo, N. Bonavita – ABB Measurement & Analytics, mcT Petrolchimico – 25.11.2015

Flexible Solutions for High-accuracy Custody TransferOutline

© ABB Group11/26/2015 | Slide 2

1. Custody Transfer: Needs and Opportunities

2. Tackling the Challenge through Innovation

3. Flow-X: latest technology for flexible yet secure measurement

4. eXLerate: Data Integration and Management in critical flow metering applications

5. Selected Success Stories

Custody Transfer: Need and OpportunitiesIntroduction


Custody transfer, also referred as fiscal metering, is a typical practice in O&G any time liquids or gases are traded between different parties (e.g. two different operators)

Custody transfer is characterized by a payment, which is function of the amount of the material exchanged.

Accuracy in the measurement is of paramount importance since even very little errors can generate consistent losses for one of the parties involved

Typically countries regulate Custody Transfer since it includes also government taxation and agreements between parties

Specific standards have been also developed by relevant organizations (e.g. API, AGA, GERG, GOST, ISO, etc.).



Custody transfer metering stations are highly engineered systems comprising several components: Flow meters

Temperature and pressure transmitters

Gas chromatographs and other quality analyzers

Provers for liquid meter calibration

Flow computers

Metering supervisory computer

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Metering station main function is to provide accurate measurement, archiving and reporting functionalities for the fluid transferred between the parties

Historical data can provide relevant information for the actual and prior quantities reported: To apply corrections to measurement errors

To update calculations in case of standards changes

To check if the measurement equipment is outside the accuracy tolerances or has incorrectly recorded some measurement parameter

Data allows parties with different interest to independently verify the correctness of the reported quantities.

Custody Transfer Needs and OpportunitiesCustody Transfer Data – The old situation

Custody Transfer Data = Set of printouts


Custody Transfer Needs and OpportunitiesCustody Transfer Data – Current situation

Custody Transfer Data = Set of electronic files


Custody Transfer Needs and OpportunitiesWhat can be improved?

Metering Control Systems are actually made for:

Daily operation

…and NOT for:

Technicians

Metering Specialist

Auditors

Accounting staff

This means that current generation of metering systems is:

Dumb Inaccurate Time-consuming


Tackling the Challenge through InnovationCompelling Reasons for New Technology


Meters became intelligent with diagnostics. Flow computers didn’t.Data throughput increased significantly.

Significant progress in today’s mechanical & electronic components, design, manufacture

Offering high quality, scalable products for various applications. Managing cost.

Upgrade legacy systems with maximum flexibility to interface old as well as new technology.

Integration of supervisory software & flow computers to a high level.

Tackling the Challenge through InnovationValue Proposition


To help address such challenges ABB selected Spirit IT to become part of its family

Spirit Innovative Technologies help improve customers business performance by providing innovative technology and value adding solutions in the area of flow computers and metering supervisory computers

Tackling the Challenge through InnovationValue Proposition


Spirit IT recognized:

The fact that existing products are based on ageing hardware platforms that limit the ability to develop state-of-the-art measurement systems.

The need to address multiple markets with a single, cost effective and scalable solution without compromise to performance.

The needs of the systems Upgrade projects which differ from New green field projects requiring flexibility to interface old and new technologies without sacrificing performance.

Tackling the Challenge through InnovationSpirit IT Introduction


A product developing company, with expertise in System Integration in oil & gas

Main (R&D) office in the Netherlands Established in 2001 Sales offices in Houston and Kuala Lumpur Hardware and software products

Product design & production Software development Marketing & Sales Customer Support

Services Training, on-site support Consultancy; additional services

Tackling the Challenge through InnovationSpirit IT interest fields


In its 15 years experience in the Oil and Gas sector, Spirit IT has developed specific competences in Custody Transfer applications

Spirit IT focused on two critical components of metering station applications:

Flow Computers Flow-X Supervisory Software eXLerate

Spirit IT know-how and solutions complete ABB portfolio, enlarging the range of advanced products and solution dedicated to O&G end-users.

Flow-X: Latest Technology Flow ComputersDevelopments of the last 17 years


Flow-X: Latest Technology Flow ComputersA Series of Products

FLOW-X/SSingle stream for Rail mount

FLOW-X/R19” Rack

1-8 flow computers

FLOW-X/PMulti-stream panel with 1-4 flow computers


Flow-X: Latest Technology Flow ComputersFlow-X Main Features

Flow-X is designed and tested for Custody Transfer applications, providing the highest level of:

Accuracy

At room temperature analog input accuracy is better that 0.002%

All data processing and storage is based on 64-bit resolution to avoid any loss of accuracy.

Security (prevention of unauthorized access)

Traceability & Auditability

Flow-X has implemented (and is certified for) the most accurate calculations for Oil and Gas:

API, AGA, GERG, GPA, ISO etc.


Flow-X: Latest Technology Flow ComputersFlow-X Main Features

Flow-X is designed for single stream installations 1 Flow computer per flow meter

Each module is a complete flow computer with all the standard functionalities plus advanced features:

4 reporting periods (hourly, daily and 2 user-definable)

Bi-directional flow

GERG-2008

Two provers

Ticket recalculations

With its standardized form, Flow-X/M is the only spare part with no variety of expansion boards and/or I/O cards


Flow-X Latest Technology Flow ComputersThe SW Makes the Difference

Flow-X modules can be easily configured through Flow-Xpress SW platform

Flow-Xpress SW provides large flexibility and simplicity also for every user:

Pre-configured standard applications

Interfacing to legacy systems

Freedom to develop your own field-upgradeable applications

Flow-Xpress allows to configure and test flow computer operation from a WEB browser, providing remote access for upgrades and modifications

Full fledged liquid and gas applications

FREE Software updates from website repository


eXLerate: Data Integration and ManagementWhat it is

Traditional SCADA packages are frequently used even if they are not made for custody transfer application

In custody transfer supervision is intended for measurement (i.e. financial purposes) not for process control

Traditional SCADA require specific custom-made development in order to manage fiscal metering stations.

This makes difficult to have prompt technical support in case of issues and malfunctioning

Spirit IT developed eXLerate, the software platform, specifically tailored for custody transfer applications

eXLerate is totally independent from the supplier of the instrumentation


eXLerate: Data Integration and ManagementMain Features

eXLerate provides all the functionalities needed in order to cover all the requirements from the most challenging custody transfer applications:

Scalable and flexible software environment

Synchronized redundancy on Client and Servers

Embedded flow equations, calculation, time averages, etc.

High precision with 64-bit accuracy

Real-time diagnostic and performance monitoring

Integrated validation & calibration facilities for instrumentation

Control capabilities for batches, sampling and proving applications

Mis-measurement management with automatic recalculations of missing data

Automatic and custom report generation

Web interface for system monitoring


eXLerate: Data Integration and ManagementFlexible System Architectures …


eXLerate: Data Integration and Management…for a Number of Supervisory Applications

Metering Supervisory

& Control

(Virtual) Flow Computing Systems

Validation & Calibration

Pipeline Network Management

Calibration Management

Depot & Terminal Automation


eXLerate: Data Integration and ManagementeXLerate Added Value

BASIC AUTOMATION• HMI (Human Machine Interface)• Communication• Basic reporting • Control (flow control, valves, sampling, proving)Trad

ition

al

Automates daily operations

CUSTODY TRANSFER SPECIFIC• 100% Redundancy / transparency (bumpless)• Shall work at least 99.999% of the time• Sophisticated custody transfer reporting• High precision (19286251442762 scf)• …

Optimizes availability and accuracy & precision

MAKING IT SMART & COMPLETE• Virtual flow computing• On-line meter diagnostics• On-line instrument & analyzer validation• On-line custody transfer data validation• On-line custody transfer data correction• …

Automates maintenance, management and data processing

(the work of metering technicians, metering engineers and accounting)


Flow-X + eXLerate – Power PackageSeamless integration for optimal management

Flow-X and eXLerate can be combined in Power Packages, pre-engineered automation solutions for:

Flow metering control

Liquid loading & unloading (ship, rail, truck)

Calibration management

This approach provides all the basic metering functions together with advanced features in a single standardized environment

Power Packages offer the best of both worlds: the powerful capabilities of the flow computer together with the flexibility of the automation software.


Selected Success Stories#1 – Wheatstone Onshore & Offshore

© ABB Group

Wheatstone Australia project (Chevron): Offshore processing platform used to produce

and separate gas and condensate

Onshore facility to process, liquefy and store natural gas for export

Offshore 2 Flow-X/R with 16 modules for produced and

flare gas

1 Flow-X/R with 5 modules for fuel gas

Redundant eXLerate supervisory system

Onshore 22 Flow-X/P with 58 modules with LNG and

GERG2008 calculations

Redundant eXLerate supervisory system.

Automated Coriolis self-verification, master meter proving and transmitter validations

11/26/2015 | Slide 29

Selected Success Stories


#2 – Edmonton Terminal

Edmonton terminal is one of the largest North America’s oil storage hubs (around 8 million barrels)

Butane and propane rail car loading and unloading

Scope of the system was to accurately register the transferred quantities and to control the loading.

Complete system was made of: 22 flow computer modules, included in 3 Flow-X/R

racks

5 eXLerate systems in redundant configuration.

Combined liquid and vapor return measurement and reporting.

Vapor calculations with GERG-2008

Remote Factory Acceptance Test from Canada

Selected Success Stories#3 – Petronas


Petronas implemented a diversity of products and solutions from many different suppliers Poor support, high maintenance & replacement cost

Instabilities cause problems for operations

Too many measurement errors

Petronas chose Spirit IT in order to harmonize its systems, basing on the eXLerate software platform: Reduced measurement errors from 0.3% to 0.1%

Reduced cost of operation by high level of automation

Automatic measurement error detection

Uniformity across the company

Effective remote assistance of the operators

Selected Success Stories#3 – Petronas


Thank You!


spiritit_mct_petrolchimico_final_rev1

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