Remote Automation SolutionsRemote Automation Solutions

HYDROCARBON LIQUIDS FLOW MEASUREMENT

CAPABILITIES

John CulpRemote Automation Solutions

Liquid Industry Marketing Manager

Sept 30, 2009

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Table of Contents

1. Introduction to Capabilities.........................................................................41.1 Product Overview.....................................................................................41.2 Preset Vs Liquid Metering........................................................................41.3 Liquid Measurement.................................................................................51.4 Measurement Standards Used.................................................................51.5 Liquid Calculations Methodology..............................................................61.6 Standard (Base) Conditions.....................................................................71.7 Other Standards.......................................................................................7

2. The ROC800L............................................................................................82.1 Basic Configurations................................................................................82.3 General Features.....................................................................................8

2.3.1 Firmware............................................................................................82.3.2 Software............................................................................................82.3.3 Liquid Calculations.............................................................................92.3.4 Batch Control.....................................................................................92.3.5 Proving..............................................................................................92.3.6 Reporting and Printing.....................................................................102.3.7 Sample Control................................................................................112.3.8 Extended Programming...................................................................112.3.9 Development Suite 800 Workbenches............................................112.3.10 Distributed Control and Redundancy...............................................122.3.11 ROCLINK.........................................................................................12

2.4 Product Hardware..................................................................................132.4.1 Environmental Considerations.........................................................13

2.5 Hardware Architecture............................................................................132.5.1 Pulse Input Module..........................................................................142.5.2 Advance Pulse Module....................................................................142.5.3 AC-IO Module..................................................................................152.5.4 Analog Input.....................................................................................152.5.5 Analog Output..................................................................................152.5.6 RTD Input........................................................................................162.5.7 HART Module..................................................................................172.5.8 Discrete Input (DC)..........................................................................172.5.9 Discrete Outputs..............................................................................182.5.10 Measuring Mass..............................................................................192.5.11 Displays...........................................................................................19

2.6 Understanding ROC800L Applications...................................................192.6.1 The Leased Asset Custody Transfer Application.............................192.6.2 The Digital Net Oil Computer (DNOC).............................................232.6.3 The Pipeline Application..................................................................242.6.4 Other Applications...........................................................................27

3. S600.........................................................................................................293.1 Introduction............................................................................................293.2 PC Boards..............................................................................................29

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3.3 The software..........................................................................................304. FloBoss FB107.........................................................................................31

4.1 Functionality...........................................................................................314.2 Embedded Calculation...........................................................................314.3 I/O Options.............................................................................................31

5. PRESETS.................................................................................................325.1 Introduction............................................................................................325.2 Preset Flow Computer............................................................................32

5.2.1 IO Modules......................................................................................355.2.2 Reporting and Printing.....................................................................35

5.3 Definition of Blending Methods...............................................................365.3.1 The Ratio Blending System.............................................................375.3.2 The Sequential Blending System.....................................................385.3.3 Side Stream Blending......................................................................38

5.4 Additive Systems....................................................................................396. Summary..................................................................................................40

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1. Introduction to Capabilities

1.1 Product Overview

Emerson Process Management Remote Automation Solutions Division has been measuring and controlling the flow of hydrocarbon gases and liquids for 25 years. This effort has resulted in the development of many products for many applications in the industry. The Remote Automation Solution (RAS) Division is responsible for the development, manufacture and sale of Electronic Flow Computers. Some products have been extended to include Programmable Logic Controllers (PLC) and Remote Terminal Unit (RTU) functions to provide complete remote flow measurement and control solutions. The RAS division has several lines of flow computers for many different liquid hydrocarbon flow measurement applications. They Include: The ROC800 Line of RTU type flow computer is designed for remote field

operation with robust RTU and PLC capabilities, with low power consumption, rugged construction for with standing difficult environments and expanded capabilities to communicate over wireless and hardwired connections to Host systems such as Delta-V, DanPac, AMS and other SCADA systems. Typical applications involve proving and control of remote pipeline installations

The S600 Panel Mount Flow Computers with high density I/O capabilities and, strong customer programming capabilities for the installation requiring more highly complex installations.

The FloBoss Line of EFM flow computers (FB103/FB107) is a simpler solution designed for specific limited applications to create highly efficient solutions for applications that are remote and custody transfer accuracy is not required.

Presets are a line of Loading Controllers designed for the Loading Terminal industry where efficient and accurate loading of trucks, railcars and ships is needed. Presets also have the capability to blend products such as Ethanol and Gasoline at the point of loading, control the addition of special chemicals such as oxygenators and coloring indicators.

Earlier products included the PetroCount of which there are 15,000 installed and Danload 6000 of which there are 5000 installed. The latest in the line of Presets, intended for a replacement of the DanLoad 6000 is the DL8000 which shares hardware from the ROC800 line and thus reduces complexity in training, and spare parts.

1.2 Preset Vs Liquid Metering

The Preset is usually installed in a loading rack and is used to measure the flow of multiple products through a loading arm. Our devises are able to measure the flow of multiple products (up to 4) feeding a single loading arm.

The main difference between a liquid meter and preset is that a liquid meter will encounter continuous flow and well as discontinuous, will be installed in a Class 1 Div 2 area, and usually has minimal user interface.

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The Preset on the other hand in always discontinuous and usually involve the blending of multiple products, the injection of additives and safety monitoring. The preset is commonly requested in an explosion proof enclosure.

1.3 Liquid Measurement

All RAS Flow Computers measuring the flow of liquid hydrocarbons use exacting and thoroughly tested calculations for the volumetric corrections necessary to convert volume measurements to standard conditions

The calculations are based on a set of application programs designed to measure the flow and calculate the volume corrected to standard condition for the following hydrocarbons:

Crude Oils (API Group A) Refined Products (Gasoline, Jet Fuel) (API group B) Specialty Products (Ethanol and Bio-diesel with user agreed to standards)

(API Group C) Lubricating Oils (API Group D) Light Hydrocarbons (LPGs and NGLs) (API Group E) User defined products

Known thermal coefficient of expansion Compressibility Density

Other applications programs are available for measuring the flow of Water and Steam (IAPWS standards) Ethylene Propylene Butadiene MTBE (Methyl tertiary butyl ether) ETBE (Ethyl tertiary butyl ether) Toluene Para-Xylene

The applications may require custom engineering to fit the needs of the customer

1.4 Measurement Standards Used

The standards used to measure liquid flow are listed below and all of which are included in the ROC800L and the S600.

API 2450-(1980) ASTM –D1250-04, IP200/04 (Same as MPMS Chapter 11) API Manual for Petroleum Measurement Standards (MPMS)

o Chapter 4.6 Pulse Interpolation (small volume proving) o Chapter 5.5 Double Pulse Integrity (ISO 6551, IP252)o Chapter 11.1 Correction for Temperature Calcso Chapter 11.2.1, 11.2.1M Pressure Correction (M is for metrics)o Chapter 11.2.4 Light Hydrocarbons - GPA TP-27 (2007) o Chapter 12.2. Resolution for displays and printed reports

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o Chapter 21.2 Electronic Liquid Flow Measurement NIST Handbook 44 IP-2 (Now EI) (1980) Pressure Effects on density IP-3 (Now EI) (1988) Corrects Temp to 20°C IEEE Standard 754(1985) and API 11.1 (2004) Double Math Floating Point

precision (64 Bit)

The following table lists the temperature, pressure and specific gravity ranges covered by the API specifications.

  Crude OilRefined Products

Lubricating OilsLight Hydrocarbon

Density, kg/m³ @ 60°F 610.6 to 1163.5 800.9 to 1163.5 349.6 to 687.3

Relative Density @ 60°F 0.61120 to 1.16464 0.80168 to 1.1646 0.3500 to 0.6880

API Gravity @ 60°F 100.0 to -10.0 45.0 to -10.0  

Kg/m³ @ 15°C611.16 to 1163.79

611.16 to 1163.86

801.25 to 1163.85351.7 to 687.8

Kg/m³ @ 20°C606.12 to 1161.15

606.12 to 1160.62

798.11 to 1160.71331.7 to 683.6

Temperature, °C -50.00 to 150.00 –46 to 93

°F -58.0 to 302.0 –50.8 to 199.4°

Pressure, psig 0. to 1,500.0. to 1.034´1040. to 103.4

kPa (gauge)Bar (gauge)A60, per °F 230.0´10-6 to 930.0´10-6 N.A.

Per °C 414.0´10-6 to 1674.0´10-6 N.A.

1.5 Liquid Calculations Methodology

The volumetric corrections to standards are calculated using variations of the two basic algorithms shown below.Using K (K0, K1, K2) factors assigned to each product group (table - grouped according the densities) we can calculate a value for the temperature coefficient of expansion per degree (α). The K factors are identified, for each group) in MPMS Chapter 11.

Where:K0, K1 are liquid specific constantsRHO density at standard conditions

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Using α we can calculate the Volume Correction Factor or CTL using the following relationship.. Where:

Coefficient of thermal expansion at base conditionsTp temperature of the liquid at the proverTb base temperature

The purpose of these formulas is to convert the measured or indicated flow to standard conditions.

1.6 Standard (Base) Conditions

In the API standards standard conditions are defined as: United States Customary (USC) Units:

o Pressure: 14.696 psia (101.325 kPa)o Temperature: 60.0°F (15.56°C)

International System (SI) Units:o Pressure: 101.325 kPa (14.696 psia)o Temperature: 15.00°C (59.00°F) OR 20.00°C (68.00°F)

For light hydrocarbons, having a vapor pressure greater than atmospheric pressure at base temperature, the base pressure shall be the equilibrium vapor pressure at base temperature.

1.7 Other Standards

Other standards used include: Double Math PrecisionAll volume calculations are conducted using double precision math as defined by IEEE Standard 754(1985) is an API 11.1 (2004) and GPA TP27 (2007) requirement. Pulse FidelityThe pulse processing for Turbine Meter Pulse Integrity is done in accordance with API MPMS Chapter 5.5, which is equivalent to ISO 6551 published in 1982 the Institute of Petroleum (now the Energy Institute) standard, IP252. And BS 6439: 1983 or API Ch 5 Sec 5, there are five levels of pulse fidelity (A, B, C, D and E). We check to level B

2. The ROC800L

2.1 Basic Configurations

There a two basic configurations for the ROC800L The ROC809 that contains a CPU, Power supply (12 vdc or 24 vdc), a

back plane with slots for up to 9 I/O modules The ROC827 that contains a CPU, Power supply (12 vdc or 24 vdc), a

back plane with slots for up to 3 I/O modules and expansion units that

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hold up to 6 I/O modules each that can be added to create a Control with 9, 15, 21 or 27 I/O slots.

2.2 The CPU series 2

The CPU consists of:

8720 - 32 Bit 66 MHz (was 50 MHz)

Flash 16 MB (was 4 MB)

SRAM 2 MB (was 1 MB)

Flash 16 MB (was 4 MB)

SDRAM 64 MB (was 8 MB)

2.3 General Features

2.3.1 Firmware

The firmware in the ROC800 provides the capabilities that include: Real Time Operating System Task Execution Real Time Clock Establish and maintain communications Self Testing

2.3.2 Software

The Capabilities of the ROC for liquid measurement are contained in five user programs. The ROC800L liquid application package is based on a suite of four user programs written in C language and compiled for the processor in the ROC800L. The basic software is developed with the intention that after deployment the calculations for liquid volume are not alterable by the customer and all options and variations are all handled by a “fill-in-the blank” configuration. Control functions, reporting and other non-measurement functions can be programmable and under the control of the customer to provide a limited means of customizing.

The core programs written and compiled by Emerson RAS engineering are not field modifiable. They are configurable via a fill in the blank approach (Product type, units desired etc.) and consist of four modules Liquid Calculations Batching Proving Reporting and Printing

2.3.3 Liquid Calculations

These calculations are the same in a Preset or Liquid metering systems. Liquid calculations perform the flow measurement in accordance with API standards and measure temperature, pressure and density to correct the

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flowing volume to standard conditions. The ROC800L can measure up to 6 meter runs of liquid flow. It can also measure of to 6 meter runs of gas flow in the same device.

2.3.4 Batch Control

In the liquid calculations application are easily configured to record and control the flow for a quantity run of a liquid. A batch can be started and stopped on demand or run for a fixed quantity of fluid, a fixed period of time and scheduled on a daily, weekly, monthly or an accumulated to basis. Batches can also be stopped based on a sensor input such as total accumulated flow, level or other user configured event. Batches are contiguous in that when one batch is stopped the system immediate starts a new batch. Fluid base density and meter data parameters for up to 24 products can be stored and can be used to automatically define the next batch. Data for up to 10 batches can be stored in the Batch Queue program. This queue can be re-ordered by the operator to change the data available for the next queue.

A new batch is always initiated on start up and batch report is printed for unterminated batches in the system. This is so that in the event of a power failure all batches are terminated and when power is restored a batch report is printed and a new batch started. Unless a defined batch has been initiated, the batch is classified as an unauthorized or unknown product and can be defined later.

2.3.5 Proving

This module controls the valves and operations when using a meter prover.A Meter Prover is a piece of equipment used to verify the accuracy of a meter. Presently, meter provers (or more simply “provers”) refer to manually or electronic and/or computer controlled equipment used to calculate accuracy of a meter. Typically used in many facilities, provers work by comparing a known volume to a meter volume and can be expressed by the equation below. A series of mathematical computations are utilized to produce what is called a Meter Factor (MF). A meter factor is a numeric value given to represent the accuracy of the meter as compared to the known volume used during the test and is also used to calculate Gross Volume (GV). Many present day provers are capable of computing a meter’s proof result and displaying it on a computer screen.

MF = During a meter proving operation, detector switch inputs start and stop the accumulated pulse counts. A positive-to-negative transition on either detector input generates a time- stamped interrupt with the 30-megahertz on-board processor. This interrupt is used in the pulse accumulation between the detectors as well as the pulse interpolation calculations for use with small volume provers.

Users can configure the proving operations to include a selected number of successful runs in a sequence (up to 10), and set various timing limits in accordance with the desire repeatability standards.

Corrected Prover Volume Corrected Meter Volume

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The software will also perform Meter Factor and K-Factor linearization for up to 12 points based on flow rate.

Unidirectional and Bi-directional provers (>10,000 pulses) and Small Volume Prover (SVP) (<10,000 pulses are supported as is Master Meter Proving. The user can designate channel 4 on the Advanced Pulse Module (APM) as a pulse input or a solid state pulse output for remote totalizing.

Multiple proving cycles are run and during each proving cycle the flow computer will record the following:

1. Measure an indicated volume (IV)2. Monitor the temperature and pressure in the prover.3. Monitor air temperature (Small volume Prover – if required)4. Correct the indicated flow to standard volume at the meter5. Correct the prover volume to stand volume in the prover6. Calculate the meter factor for the cycle7. The flow computer will also monitor the variation in pressure and

temperature and calculate the standard deviation over all of the cycles run.

8. Number of prove cycles9. Number of pulses (greater than 10,000 per prove) for a large volume

prover and less than 10,000 per prove for a small volume prover.10.Save the prover report

Proving runs continue until at least a minimum of 3 or 4 runs are made where the repeatability, pressure variation and temperature variation are all acceptable. At that time the following data are recorded.

Proving is covered in more detail in another course.

2.3.6 Reporting and Printing

There are standard reports that are available for batch reports and proving reports and the system has the ability for the user to develop a custom report to meet the customer's own needs. The data available for reports meets the requirements of:

Batch Reports are per API MPMS Chapter 12,2,2

Proving Reports are per API MPMS Chapter 12.2.31. The ROC800L can print to a local ASCII printer or to a network printer via

the Ethernet. Reports can also be saved to internal memory in the ROC800L. The current batch and the most recent batch are available

2.3.7 Sample Control

Another user program available is the sampling control module. The sampling module can range from a simple regularly schedule command to take a sample to a complete sample system control that includes:

a. Batch numberb. Batch size c. Sample Can Size

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d. Enter fill percent of Can e. Enter sample (Grab) size f. Calculate number of bites, based on bite size, can fill amount and

flow rate g. Sampler Status (Running/Not Running) –DI h. Sampler L/R Local Remote – DI i. Sampler Start Stop – DOR          j. Issue sample command – DOR k. Sampler Can Valve Open Confirm– DI l. Sampler Can Valve Close Confirm– DI m. Sampler Can Valve Control DOR n. Sampler  Can weight – AI o. Standard Alarms on Weight ( Hi-Hi, Hi, Low, Low-Low, Signal Fail) p. Sampler over pressure shut down – DI

The deviation allowed in base density measurement is 0.5 API (xxx.x kg/m3). Currently this capability is being developed as a separate user program module that can beaded to the ROC800L.

2.3.8 Extended Programming

The control capabilities of the flow computer can be extended through several levels of programming:

1. Simple Function Sequence Tables – editor is provided and user can be trained

2. IEC 61131 Programming using the DS800 programming tool and includes:1. Ladder Logic2. Function Blocks3. Structured Text4. Instruction Lists5. Sequential Function Chart

3. User C customer firmware programmed by Emerson engineering

2.3.9 Development Suite 800 Workbenches

The DS800 tool is available in two packages based on• I/O limitations• Distributed Architecture Support• All other functionality remains is the same

Other Features include tag based algorithms, simulation, on line debugging

2.3.10 Distributed Control and Redundancy

An example of extended programming is redundancy. Currently two installations have been designed with a redundant architecture. The system consists of basically two independent ROC800Ls dedicated to flow measurement. In one case there is a third ROC assigned to handle most of the control activity. The Application is written using the IEC Programming tool DS800. This program runs

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on a host machine with a core program client program running on each ROC800L.

The redundancy program is developed for the customer by the LBP or the by the customer himself to meet the needs of the specific installation. For RAS Redundancy is a special program developed designed using the programming tool DS800 and is customized for each location.

2.3.11 ROCLINK

All liquid products based on the ROC or the FloBoss use the configuration tool ROCLINK, ROCLINK is a software application that runs on a laptop or desk top and facilitates communications with the ROCLINK, FLOBOSS or Preset. It is a windows base application compatible withWindows 2000 and Windows XP it has not yet been tested with Windows 7

The application is a point a click; fill in the blanks type of applications that makes configuring the ROC or Floboss an easy and quick task.

2.4 Product Hardware

2.4.1 Environmental Considerations

The ROC800L has been designed for the rugged field installation or can be used in a controlled environment. The features we have selected for the design include:

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2. Ruggedness for more extreme environments,3. Low power consumption, (solar power levels) 4. Protection against lightening and power surges5. Manage 200 to 500 I/O points. 6. Operation in a hazardous area7. Perform all the functions of a PLC8. Perform functions of an RTU and communicate with a host or SCADA

system Be able to stand alone as a flow computer system.

2.5 Hardware Architecture

The Hardware used in the ROC800 series is built on two basic backplanes

1. The ROC809 that contains a CPU, Power supply (12 vdc or 24 vdc), a back plane with slots for up to 9 I/O modules

2. The ROC827 that contains a CPU, Power supply (12 vdc or 24 vdc), a back plane with slots for up to 3 I/O modules and expansion units that holds up to 6 I/O modules that can be added to create a Controller with 9, 15, 21 or 27 I/O slots.

Other modules include:

2.5.1 Pulse Input Module

The PI module provides two channels for measuring either a low speed or high speed pulse signal. The PI module processes signals from pulse-generating devices and provides a pulse number to be used in calculating rate or an accumulated total. The PI is most commonly used to interface to relays or to open collector or open drain type solid-state devices. The Pulse Input can be used to interface to either self-powered or ROC800- Series powered devices. The high speed input supports signals up to 12 KHz, while the low speed input is used on signals less than 125 Hz.

2.5.2 Advance Pulse Module

To improve integrity of measurement, some turbine meters and PD meters provide dual pulse train. (Two pulses in one revolution.) This enable the flow computer to check for signal quality from the flow meter by comparing the two pulses received. First API recommends a voltage of 1 to 5 volts, or higher up to 30 volts for the pulse level.

The AMP module is able to handle up to two dual pulse trains in accordance with. API MPMS Chapter 5.5, or the Institute of Petroleum standard, IP252 or the ISO 6551 published in 1982 and checking the pulse up to level B integrity.

When a coriolis meter is used the flow is measured in mass units (pounds, kilograms or other mass/weight unit) and if volume is needed a conversion must be made.

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One pulse input on the APM module can be used as an input for a densitometer frequency input.

One pulse input can be set up as a pulse output to prove a pulse output for an external totalizer.

There ROC800 series is capable of accepting inputs from:

1. The Solartron 7835/45

2. The Solartron 7830/40

3. The USG Densitometer or

4. Analog input from a densitometer

The system reads density; temperature and pressure from the densitometer as well as the velocity of sound. The user can also input correction factors from calibrations for density, temperature and pressure.

After proving or calibrating a flow meter, it is found that sometimes K Factors or M Factors are not linear over the entire range of flow. Under these cases either the M factor or the K factor can linearize the factor.

2.5.3 AC-IO Module

The AC-IO module has six channels each can be configured as an input or an output. When configured as an output, a channel uses a solid-state, normally-open relay. Each AC output switches the AC input source ON or OFF. Using ROCLINK™ 800 Configuration Software you can configure a channel as latched, toggled, momentary, or Timed Duration Output (TDO). Other parameters report the approximate load, over current conditions, and AC input status. Discrete outputs can be configured to retain either the last value on reset or a user-specified fail-safe value.

When configured as an input, a channel can detect the presence of an AC signal between 90 and 245 V AC at 47 to 63 Hz. In standard discrete input mode, the module monitors the status of various AC sources. Each channel can also be software-configured to function as a latched DI, which remains in active state until reset. Other parameters can gather statistical information on the number of transitions and the time accumulated in the on or off state. Each channel within the module can be read up to 20 times per second.

2.5.4 Analog Input

The 12-bit Analog Input (AI-12) module and 16-bit Analog Input (AI-16) module for the ROC800-Series Remote Operations Controller (ROC) provide the ROC with the ability to monitor various analog field values. The AI modules provide four analog input channels. The AI channels are scalable, but are typically used to measure either a 4-20 mA analog signal (using a switch-selectable precision resistor that is built into the module) or a 1-5 V dc signal. If required, the low end of the AI module’s analog signal can be calibrated to zero. AI modules can provide isolated +12 V dc or +24 V dc field transmitter power (jumper selectable).

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For example, one module can provide +12 V dc for powering low-power analog transmitters, while another module in the same ROC800-Series can provide +24 V dc for powering conventional 4-20 mA transmitters.

The most common use of the analog input is to measure pressure. For proving the allowable deviation in the pressure measurement at the meter or at the prover is 3 psig (20 kPag)

Other analog inputs also measure

Valve Position

Level detection

2.5.5 Analog Output

The Analog Output (AO) module for the ROC800-Series Remote Operations Controller provides the ROC with the ability to control various analog field values.

The AO module provides four Analog Output channels. Each channel provides a 4 to 20 mA current signal for controlling analog current loop devices or dc voltage for control devices, with ranges starting at 0 and going to a maximum of 5 to 10 V dc.

The need for fuses has been eliminated on the Input/output (I/O) modules through the extensive use of current-limiting, short-circuit protection, and surge protection techniques. This results in less maintenance for remote locations. The I/O modules are self-resetting after a fault clears.

The AO module provides isolated loop-power (+T) sources with integrated short-circuit protection. This protection limits the amount of current (+T) during a short-circuit and auto-recovers after the fault clears.

2.5.6 RTD Input

The Resistance Temperature Detector (RTD) module for the ROC800-Series Remote Operations Controller (ROC800) provides the ROC with the ability to monitor various RTD sensors.

The RTD input module monitors the temperature signal from an RTD sensor within a fixed range. The RTD input module provides two channels for measuring the resistance of 2-wire, 3-wire, or 4-wire, 100-ohm, platinum RTD sensors with an alpha equal to 0.00385 or 0.00392 Ω/Ω/°C.

The extensive use of current-limiting short-circuits protection and surge protection techniques eliminate the need for fuses on the Input/output (I/O) modules. This reduces maintenance for remote locations. The I/O modules are self-resetting after a fault clears.

The modules each have their own integrated short-circuit protected isolated power supply. This power supply allows the field circuitry to be completely isolated from the backplane and the Central Processor Unit (CPU).

Each module provides isolation from other modules and the backplane, including power and signal isolation.

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There are many temperatures the flow computer needs to track. One is the temperature of the flowing fluid, another is the temperature of the fluid in the prover, and if so equipped the temperature of a sampling system is tracked. In some cases there are redundant temperature sensors to enable the flow computer to detect a sensor failure. The temperature is usually sensed by an RTD (Resistance Temperature Device and the flow computer senses a voltage or resistance that is proportional to the temperature. Sometimes the device is a thermocouple that provides a millivolt level signal directly proportional to the temperature. The temperature sensor can also be a temperature transmitter that senses the temperature and converts the signal to an analog (4 to 20 milliamps) or digital signal for transmission to the flow computer.

For proving the allowable deviation in a temperature measurement at the meter is 0.5° F (0.25° C)

For proving the allowable deviation in temperature at the prover is 0.2°F (0.1°C)

Please note that the ROC800 series Liquids program is not compatible with a thermocouple input.

2.5.7 HART Module

The HART (Highway Addressable Remote Transducer) Communication module allows a ROC800-Series Remote Operations Controller to communicate with HART devices using the HART protocol. The HART module receives signals from and transmits signals to HART transmitters. With the addition of a HART Pass-Through license key, a HART Card provides ROC800-Series controllers with Plantweb® Smart Remote Automation functionality. This includes the ability to pass HART data bidirectionally through the ROC network to AMS Suite: Intelligent Device Manager software.

The module has four input/output channels. Switches on the module board allow each channel to be set as an input or output channel. A channel set as an input can be configured for use in point-to-point or multi-drop mode. A channel set as an output can be configured for use in point-to-point mode only. Each channel has analog input capability intended for diagnostic and backup use, not for primary process variable measurement. HART superimposes Frequency Shift Keying (FSK) signals on the analog signal. This technique allows digital information to be passed to and from the transmitter on the 4 to 20 milliAmp analog signal. In point-to-point mode, the milliAmp signal is still representative of the primary variable. This mode allows communications with one HART device per analog channel. In multi-drop mode, as many as five HART devices can be connected (in parallel) to each analog input channel. Like the point-to-point mode, digital communications are superimposed on the 4 to 20 milliAmp signal; however, the analog signal is used only to power the end devices and does not represent any process variable value. With all four analog inputs in the multi-drop mode, the ROC can support a maximum of twenty HART devices.

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2.5.8 Discrete Input (DC)

The Discrete Input (DI) module for the ROC800-Series Remote Operations Controller provides the ROC with the ability to monitor various discrete input field values.

The DI module provides eight channels for sensing discrete inputs. The module monitors the status of relays, open-collector or open-drain type solid-state switches, and other two-state devices.

Each DI channel can also be software configured to function as a latched DI. A latched DI remains in the active state until reset. Other parameters can invert the field signal and gather statistical information on the number of transitions and the time accumulated in the on or off state. Each channel within the module can be read up to 250 times per second.

The need for fuses has been eliminated on the Input/Output (I/O) modules through the extensive use of current-limiting short-circuit protection and surge protection techniques. This results in less maintenance for remote locations. The I/O modules are self-resetting after the fault clears.

The DI module provides isolation from other modules and the backplane. The DI module has its own integrated short-circuit protected isolated power supply. This power supply allows the field circuitry to be completely isolated from the backplane and the Central Processor Unit (CPU). This protection limits current during a short-circuit and is auto-recoverable after the fault clears.

Light-emitting diodes (LEDs) indicate the current status for each channel of the module.

Discrete signals are received to provide a variety of information and include:

1. Safety system status indication

2. Strainer pressure drop

3. Level limits (Pressure, flow)

4. Valve position confirmation

5. Batch Start and Stop Commands

6. Equipment status (Sampler, Prover)

7. Switch status

2.5.9 Discrete Outputs

The Discrete Output (DO) and the Discrete Output Relay (DOR) modules for the ROC800- Series Remote Operations Controller (ROC) provide the ROC800 with the ability to control various discrete output field devices.

The DO module provides five channels of discrete outputs. The DO channels are solid-state normally open switches rated at 200 mA across the complete operating temperature. Each channel can be software configured as a latched, toggled, momentary, or Timed Duration Output (TDO). The DO can be configured to either retain the last value on reset or set to a user-specified fail-safe value. The need for fuses has been eliminated on the Input/Output (I/O)

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modules through the extensive use of current-limiting short-circuit protection and surge protection techniques. This results in less maintenance for remote locations. The I/O modules are self-resetting after a fault clears. The DO module provides isolation from other modules and the backplane. The module has its own integrated short-circuit protected isolated power supply. This power supply allows the field circuitry to be completely isolated from the backplane and the Central Processor Unit (CPU). Light-emitting diodes (LEDs) indicate the current status for each channel of the module.

The Discrete Output Relay (DOR) modules module provides five channels for measuring discrete outputs. The DOR modules use dual-state latching relays to provide a set of normally open, dry contacts capable of switching 2 A at 32 Volts DC across the complete operating temperature. The module can be software configured as latched, toggled, momentary, or Timed Duration Outputs (TDO). The DOR can be configured to either retain the last value on reset or set to a user-specified fail-safe value.

Digital outputs are used primarily for control of devices like flow control valve position. The discrete outputs include functions such as

1. Digital valve control (Staged control or solenoid initiation)

2. Start and Stop Commands

3. Injector control

4. Sampler control

2.5.10 Measuring Mass

When flow is sensed in terms of units of mass (kilograms, pounds etc), no correction for temperature and pressure are required. If we know we have measured the flow on 100 kilograms of fluid we will get the same mass and any temperature and pressure. Temperature changes and pressure changes will affect the volume of measure but will not affect the mass. Working in mass simplified the entire measurement process

2.5.11 Displays

The Display and keyboard consist of two displays; each is 8-line by 21-character LCD, Display size 128 x 64 pixels. They are backlit and configurable.

1. Integrated ROC800 firmware driver2. Supports user customization 3. 25 key, multi functional alpha-numeric keypad4. NEMA 4x Flat panel mounted5. Class I Div. ll6. Serial communications

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The ROC800L has been commonly interfaced with a PC Based touch panel display where the PC is running ROCLINK and the display is used for both configuration and control. This is very useful especially when the user is using DS800 programming tool. There are three such units installed.

2.6 Understanding ROC800L Applications

2.6.1 The Leased Asset Custody Transfer Application

When an oil field does not have a nearby pipeline, it is common to see the oil stored locally in large tanks and pumped in to rail cars or trucks for removal from the site on a truck by truck basis. When a truck or rail car is loaded at this point flow measurement is needed for custody transfer and billing for the delivered product. This is different than the Preset operation in a terminal where hundreds of trucks may be loaded with a variety of products. Here the product is crude and the loading may not exceed a few truck loads a week. The well head meters are usually skid mounted on units referred to Leased Asset Custody Transfer Skids or L.A.C.T units. The basic components and functions of an L.A.C.T. unit are:

1. Charge Pump and Motor - Largely overlooked and undersized, special care should be taken into consideration during sizing to ensure correct NPSH (Net Positive Suction Head) is available to prevent cavitation and discharge pressure is enough to overcome pressure drop through the L.A.C.T. to allow the required flow and pressure to the pipeline pump inlet.

2. Strainer/Air Eliminator – After the pump there is a Strainer to strain solids. This is usually a perforated removable basket that catches the solids. The strainer should have a differential pressure indicator to show pressure drop caused by debris accumulation and be cleaned periodically, essential to prevent premature meter wear or breakage. The air eliminator is located on top of the strainer at the highest part of the system to allow air to be discharged and not metered. This should be piped with a soft-seated check valve to prevent air from being introduced into the system during shutdown.

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3. Sample System - Installed with an upstream static mixer usually flow-proportional, isokinetic, and tubed to a vapor tight storage vessel sized to allow 25 to 30 days storage. The vessel is provided with a recirculation pump; the samples are mixed and then drawn off to be checked for composite API Gravity and BS&W during the delivery period.

4.S&W Monitor and Probe – This device is sometimes installed downstream of the sampler and upstream of the three-way divert valve, this unit consists of a flanged probe that monitors the flowing stream for basic sediment and water and communicates with the "monitor" unit that is normally installed in the control panel. The "monitor" is usually wired to the solenoid valves controlling the three-way valves on the bad oil divert line. These will send oil containing high quantities of solids and water to be treated if a high S&W signal is received for a given time. When a good oil signal is received for a set time, then the valves will return to normal flow position.

5. Flow Meter - Installed downstream of the three-way valve and downstream of a properly sized thermal relief valve. The meter measures the product stream and allows totalization either through a local totalizer or electronic pulses to a flow computer. This meter can be a positive displacement, turbine meter coriolis or ultrasonic meter.

The meter will provide signals to the flow computer or PLC to allow:

Sample pacing Totalization Meter proving Meter failure detection, alarms and reports

6. Meter Instrumentation - Downstream of the meter a spool consisting of:

Temperature transmitter with platinum RTD installed in a S.S. thermowell. Pressure transmitter with a pressure gauge mounted with a three-way

gauge valve.

Test S.S. thermowell used to calibrate the temperature transmitter.

The temperature and pressure transmitters are used to send a live reading to the flow computer for compensation.

7. Check Valves - Downstream of the meter to prevent backflow to the meter in case the downstream block and bleed valve is left open and the opposite meter train is running.

8. Block and Bleed Valves - Located downstream of the check valves at the end of each run and as the main line divert valve separating the to and from lines to

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the prover four-way divert valve. This is to ensure all fluid is being diverted to the prover during proving, or a false meter factor could be obtained during proving of the meter.

9. Prover Instrumentation - On the outlet of the prover four-way divert valve a spool consisting of:

Temperature transmitter with platinum RTD installed in a S.S. thermowell. Pressure transmitter with a pressure gauge mounted with a three-way

gauge valve. Test S.S. thermowell used to calibrate the temperature transmitter. Thermal relief valve properly sized.

10. Back Pressure Valve - On the skid outlet to maintain pressure above the vapor pressure of the fluid being metered and provide a constant pressure and flow on the meter during proving.

11. L.A.C.T. Control Panel - This can be located on the skid or remotely. Equipment that can be included on the control panel is a flow computer, PLC controls and local manual proving connections. If a flow computer does not provide the functions there may be a prover counter, detector switch plug in, power for the counter, and a portable pulse generator for P.D., turbine meters or coriolis meters.

12 Flow Computer – The flow computer can be mounted remotely or on the skid and perform all flow calculations, flow totalizing, flow prover control, averaging the pressures and temperature, executing PID control loops and calculating the meter factor.

If located in the MCC room, the panel could then be equipped with a flow computer, and printer to allow for automatic proving and batch reports by pushing a button, provided the prover's four-way valve is equipped with a remote actuator, and pressure and temperature transmitters were installed.

The control panel will have the following functions:

Start and Stop Off High and Low Level Switches Hand-Off-Automatic Switch S&W Divert Controls Meter Fail Monitor Failure Internal Battery Back-Up for Power Loss

13. Calibrated Bi-Directional Meter Prover - Because of the versatility of configuring a bi-directional prover in tight offshore spaces and its' cost associated

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with normal offshore flow rates; the bi-directional prover has become the prover of choice versus the uni-directional and small volume prover.

The continuous flow technique of meter proving is accomplished by repeatable displacement of a known volume of liquid in a calibrated section of pipe between two signaling devices (detector switches).

A slightly oversize prover sphere inflated to normally 2% over the pipe inside diameter is used to displace the fluid.

The fluid is run through the meter and the prover. The metered volume is recorded by the electronic meter proving counter (built into flow computers).

The known volume displaced is checked against the meter's indicated output and a "meter factor" is obtained after correction factors (Ctl, Cpl, Cts, Cps) are applied.

2.6.2 The Digital Net Oil Computer (DNOC)

The Digital Net Oil Computer is s skid mounted stand alone application that performs oil/water/solids separation and net oil measurements and calculations and provides a variety of real-time, average, summary, and historical net oil data. This application is independent from the ROC800L and is dedicated to measuring the Net Oil volume from a separated stream.

Using the Net Oil Computer Software and the ROC809 controller, many different NOC systems can be designed. The flow measurement device can be one of many (orifice plate, turbine meter, PD meter, coriolis meter or ultrasonic meter) devices. Because the coriolis meter offers a measurement in mass, it has many advantages in the measurement of multi-phase fluids.

The solution offered by the DNOC is based on using the MicroMotion coriolis meter and a Digital Net Oil Computer Software program. The DNOC requires input from at least one MicroMotion sensor, and may optionally accept input from up to three Micro Motion sensors used for oil or water measurement,

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and other devices used for gas measurement, pressure data, or temperature data. The different configurations include:

• The DNOC system may be used with a two-phase separator, including a variety of compact separators (e.g., Gas-Liquid Cylindrical Cyclone, or GLCC™) or a three-phase separator.

• A maximum of three Micro Motion sensors can be used for oil, water, or liquid (oil/water mixture) measurement.

• On any one leg, up to three sensors can be installed in parallel.

• Gas measurement is optional. If a gas measurement device is installed, it may be a Micro Motion sensor or a conventional device from another vendor. In either case, an AGA license is required on the ROC809 platform.

• Pressure and temperature sensors are optional:

- If a pressure sensor is not installed, no pressure compensation or correction is applied to sensor data or NOC measurement.

- If a pressure sensor is installed, either pressure compensation, pressure correction, or both may be applied.

- If a temperature sensor is not installed, temperature data from the RTD on the Micro Motion sensor will be used for temperature correction.

• Water cut probes (WCP) are optional. If a WCP is installed, it can be used for all water cut measurement on the line, or used within a user-specified range.

The ROC809 platform may be used to monitor and control other devices, such as a level sensor. These functions are not managed by the Net Oil Computer Software. They must be set up and configured separately.

2.6.3 The Pipeline Application

When the flow from the well head is great enough or there are enough wells in the vicinity, pipelines are used to mover the oil. There may be a concentration of storage tanks to provide a large enough oil supply to make a pipeline worthwhile. Oil is generally propelled through pipelines by centrifugal pumps. The pumps are sited at the originating station of the line and at 20 to 100 mile intervals along the length of the pipeline, depending on pipeline design, topography and capacity requirements. Most pumps are driven by electric motors, although diesel engines or gas turbines may also be used.

Pipeline employees use computers to remotely control the pumps and other aspects of pipeline operations. Pipeline control rooms utilize Supervisory Control and Data Acquisition (SCADA) systems that return real-time information about the rate of flow, the pressure, the temperature and other characteristics of the pipeline operation. Both computers and trained operators evaluate the information continuously. Most pipelines are operated and monitored 365 days a year, 24 hours per day. In addition, instruments return real-time information about certain specifications of the product being shipped – the specific gravity, the flash

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point and the density, for example – information that are important to product quality maintenance.

Oil moves through pipelines at speeds of 3 to 12 miles per hour (5 to 15 feet per second) totaling 100,000 to over a million barrels a day depending on pipeline size.. Pipeline transport speed is dependent upon the diameter of the pipe, the pressure under which the oil is being transported, and other factors such as the topography of the terrain and the viscosity of the oil being transported. At 3-12 mph it takes 10 to 22 days to move oil from Houston, Texas to New York City.

Pipeline operators can ship different petroleum products or grades of the same product in sequence through a pipeline, with each product or “batch” distinct from the preceding or following batch. A pipeline operating in fungible (same product, multiple customers) mode also uses batch sequencing, but on larger size batches. One refined product or crude oil grade is injected and begins its journey, then another, and another. A batch is a quantity of one product or grade that will be transported before the injection of a second product or grade.

If a pipeline pumping station is near a refinery the products being transported can vary widely and include refined products such as gasoline, diesel and jet fuels.

Each pipeline publishes its batch size based on the characteristics – the logistics needs – of its shippers and on pipe size. For a pipeline operating in fungible mode, products that meet common specifications can be mixed and sent through the pipeline together as a batch. For example, a products pipeline will establish the acceptable specifications for regular grade gasoline. Shippers whose gasoline meets that pipeline's specifications can obtain transport services for smaller volumes because their gasoline will be added to gasoline of the same quality and grade from other shippers. A shipper whose product either does not meet common specifications or for other reasons must be kept separate from other products in the line, must meet a higher minimum batch size volume before transport will be economic for the pipeline.

Batching petroleum for pipeline transport has become more complex with the proliferation of product qualities. Colonial Pipeline, for instance, publishes specifications for over 100 different grades of gasoline. Crude oil pipelines, too, must meet market demands for delivering various crude types – such as high sulfur or low sulfur grades – to refineries to align with the refineries’ schedules for producing jet fuel, asphalt, diesel, and other products and to the refineries’ equipment. Lakehead Pipe Line's 1.3 million barrel per day system, for instance, can contain up to 50 batches of crude oil of distinct qualities. This is why in the pipeline world it is common for the flow computer to have the ability to queue batches. That is to predefine batches to be delivered with quantity, product type, shipper and destination information preprogrammed. In this way as a batch ends the flow computer can automatically start the next batch with meter factors and physical properties of the product already define so the switch can take place in milliseconds and starting flow calculations for the next batch immediately upon termination of the previous batch.

There is always a certain amount of intermixing between the first product and the

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second at the "interface," the point where they meet. If the products are similar, such as two grades of gasoline, the resulting mixture is added to the lower value product. If the products are dissimilar, such as diesel and gasoline, the "transmix," the hybrid product created by intermixing at the interface, must be channeled to separate storage and reprocessed. (see the drawing below.)

Pipeline operators establish the batch schedules well in advance. A shipper desiring to move product from the Gulf Coast to New York Harbor knows months ahead the dates on which Colonial will be injecting heating oil, for instance, into the line from a given location. On a trunk line, a shipper must normally “nominate” volumes – ask for space on the line – on a monthly schedule. Delivering lines, by their nature, have more changeable schedules; shippers can secure space on them with a shorter lead-time, possibly even the same day. It is not uncommon for tendered volumes to differ from nominated volumes, especially on delivering lines. These lines, by their nature, are closer to the end user and must be responsive to the changing needs of shippers and their customers. Hence, the last minute changes that are essential to the oil market balance are a routine part of pipeline operations.

As common carriers, oil pipelines cannot refuse space to any shipper that meets their published conditions of service. If shippers nominate more volumes than the line can carry, the pipeline operator allocates space in a non-discriminatory manner, usually on a pro rata basis. This is often referred to in the industry as "apportionment." (Space cannot be allocated to the highest bidder, or on a first come, first serve basis). Pipeline rate structures are discussed in more detail below.) During the peak seasons, it is common for some pipelines to be using apportionment. Such bottlenecks invite competition, of course, either from other modes of transportation or from pipeline alternatives. The need to allocate space also encourages capacity expansion. The supply of gasoline to the Midwest from the Gulf Coast provides an example.

The following diagram of a metering station involves three meters. Many stations use four or more and install one line as a spare. Upstream of the metering manifold is a sampling station that is controlled by the flow computer and takes a sample and measure product density. It is important that sampling be programmed on a flow weighted basis because most of the measurements for composition, specific gravity and density are averaged and they tend to change

Transmix areas

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over time. So to be as accurate as possible all sampling should be based on flow weighted averages so the samples taken relate to the follow of total flow that has gone through the meter.

Each meter can be switched – one at a time – into the prover mode. In this mode oil continues to flow through the meter and is diverted through the prover as well. Then on command the valves switch the flow and launch the spheres marking precisely a volume of flow through the meter for a period of time. This volume is carefully synchronized with the meter and the volume of flow measured by the meter is compared to the volume of the prover and a meter factor calculated.

A typical pipeline installation of a flow computer will involve measuring up to 6 meter runs (some will go higher), controlling a sampler and controlling a prover.

Quality / Sample Building

Static Mixer

Sump Tank

Isolation Valve

Strainer

Meter

Check Valve

Block Valve (Block & Bleed)

Prover Inlet Valve(Block & Bleed)

Backpressure PCV

HoldingPressure PCV

PpAB

TpA

TW

ZSABZSAB

FTABFTABFTAB

TpB

PpAB

TpA

TW

TpB

PG

PmAB

TmA

TW

TmB

SamplerPower Unit

M

HPM

TdA

M

ICPM

PdAB

DEAB

FSLAB

TdB

Inlet Header

Outlet Header

Prover

Prover 4-WayValve

LEFTRIGHT

DrainFCV

Isolation Valve

PDSLABPDIT PDIT PDIT

DE Densitometer

FSL Density Loop Flow Switch

FT Meter Flow Transmitter

PG Pressure Gage

Pd Densitometer Pressure

Pm Meter Pressure Transmitter

Pp Prover Pressure Transmitter

Td Densitometer Temperature RTD

Tp Prover Temperature RTD

Tm Meter Temperature RTD

TW Thermowell for a CertifiedThermometer

WT Sample Can Weigh Scale

ZS Prover Displacer Detector Switch

A Signal to Main Flow Computer

B Signal to Backup Flow Computer

AB Signal to both Main and Backup Flow Computers

Automatic Sampler

Sampler Hydraulic Actuator

Sample Can

Flow Computer System Control

Process Controller

LEGEND

M

WT

WT

PSH

There is also a sampler upstream of the meters to regularly extract a sample of the crude for density and other quality analysis of the product being piped. The flow computer can control the sampling by opening and closing valves to extract a sample and divert it into a sample can. The flow computer can control the

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sample timing or frequency, the sample size and meter the sample size if necessary. It is not uncommon for one flow computer to monitor several streams, control the proving activity and control the sampling activity.

2.6.4 Other Applications

There are other applications that could be performed by the ROC800L but are not developed they include:

1. Oil well pump off control 2. Dewatering of Coal beds for Methane3. Steam CO2 and water flood injection for enhanced recovery. 4. Leak detection and line balancing tasks5. In Process plant applications for mixing, blending and general process

control. 6. Tank Strapping – Inventory7. Offshore platforms8. These all involve specialized knowledge and many times will need a

custom program developed to accomplish the task.

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3. S600

3.1 Introduction

The FloBoss S600 Flow Manager is a panel-mount flow computer designed specifically for hydrocarbon liquid and gas measurement. The unit allows multi-stream, multi-station applications to be configured, enabling simultaneously liquids and gas metering.

Designed for use either as a stand-alone flow computer or as a system component it is capable of:

Fiscal Metering Gas & Liquids Multi-Run Flows Up to 10 gas meter runs Up to 6 Liquid Runs Batch Loading Meter Proving Full PID control

3.2 PC Boards

There are three slots for PC Boards plus the CPU. The main board contains the CPU and a generous amount of I/O.

CPU Board 2 RS-232 3 RS 422/485 1 -Ethernet Port

Intelligent I/O Board 12- AI 4 - AO 3- RTD 16 Digital In 12 Digital Out 2 Dual Pulse In 3 Densitometers In 5 Pulse Outputs HART Board

When proving is required the prover board is added. This added capability includes

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Proving Board 32 - Digital Input 12 - Digital Output 4 - Detector Switches 4 Flight Timer Level A Pulse Integrity Dual Chronometry

Hardware changes for the S600 Include:HART Support for 12 ChannelsDual Ethernet

SRAM increased form 1 to 2 Mb

3.3 The software

The software in the S600 includes

Simplification of config editors Extended API Table library

– ASTM D 1250-80:– Tables: 5A/5B/5D 6A/6B/6C/6D 23A/23B 24A/24B/24C/24D

53A/54B/54D– ASTM-IP-API Petroleum Measurement Tables for Light

Hydrocarbon Liquids 1986):– Tables 53 /54– ASTM D1250/IP200 1953 Tables (supported by algorithm)– Tables 23/24 and 53/54– ASTM D1250/IP200 1953 Tables (supported by table look up)   – Tables 5 and 6– TP-27 (Light Hydrocarbons) GPA- 2007–    Tables 23E and T4E– Compressibility calculations:–    API.11.2.1 (1984)–    API.11.2.2 (1986)–    API.11.2.1M (1984)–    API.11.2.2M (1986)–    Downer (IP2 1988)– Vapor Pressure calculations–    TP15 (1988)

Other calculations include– Volume & Mass based proving– Batch recalculation function– Wet gas calculations supported

• Murdoch• Chisolm• De Leuw

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4. FloBoss FB107

4.1 Functionality

The FloBoss 107 is the latest offering from Emerson in the flow computer area. The firmware can monitor in up to 4 meter runs. 6 point configurable I/O to provide highest level of flexibility I/O mapping similar to ROC364 for backward compatibility Auto-sense protocol support for ROC and Modbus Smart I/O cards provide specialty applications User C Program support for utmost flexibility ROCLink (RL800) Windows Configuration via fill in the blank and graphical

screens make set-up a snap

4.2 Embedded Calculation

Gas flow is calculated for both volume and energy in accordance with the AGA and ISO standards and AGA 8 compressibility calculations using Detail, Gross I, or Gross II methods.

AGA 3 ISO 5167 Gas ISO 5167 Liquids User C

Liquid Calculations are recommended for continuous flow – non-custody transfer application

4.3 I/O Options

Meter setup is made quick and easy using fill-in-the-blanks data entry. 6 to 42 I/O points 6 points of configurable I/O (18 combinations) Loop power on each module and internal 250 ohm resistor (24 Vdc) Limited liquid calculations for allocation and well testing (not custody

transfer) Operates with orifice plate (ISO-5167) or pulse input for continuous flow –

non-batching Up to 2 liquid meter runs and 4 gas meter runs Core program – easy fill-in-the-blanks configuration using ROCLINK 2 Liquid Density Inputs

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5. PRESETS

5.1 Introduction

The loading and dispensing of hydrocarbon and chemicals liquids provides a Remote Operations Controller opportunity that is ideally suited for Emerson. The Daniel Preset Meters (PetroCount and DL6000) have been operating in the field for 25 years and have an installed base that approaches 15,000.

A Preset is much like and other flow computer in that is accepts input from flow meters, temperature sensors, and pressure sensors and computes a flow then corrects that flow to standard conditions

The PetroCount is an obsolete flow computer being replaced by the DL8000. The Danload 6000 is still in production but the processor does not meet API 2004 standards of double floating point math precision. The Danload 6000 is in compliance with API 1980 standards. The most current design is the DL8000.

5.2 Preset Flow Computer

A schematic of an installed preset flow computer is shown below

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The DL8000 is based on the ROC800 placed in the DL6000 explosion proof enclosure. The DL8000 has a set of user programs very similar to the ROC80o. This includes: Preset Liquid Calculations – same as the ROC800L module used in liquid

meters Preset Batching - that provides blending control for the preset. In the preset all

batches are discontinuous and the batches are defined by a preset quantity and the loading is terminated when that quantity is reached. The Preset batch also controls features like blending and additive measurement.

Additive Control – A program to measure and control the injection of additives Reporting for printing batch tickets(reports) and Bills of Lading

The DL8000 includes: A basic ROC809 Remote Operations

Controller with:o A user program and typical I/O to meet

the needs of the preset liquid hydrocarbon and chemicals market.

o An AC_IO module to monitor and control AC powered devices

o An Advanced Pulse Module, for API integrity in dual pulse chronology

o Improved software and firmware to incorporate more robust features and calculations that comply with the latest API recommendations

The DL8000 implements flow calculations with Volume Correction Factors (VCF) for temperature and pressure to correct volume and mass flows to standard conditions.

The DL8000 Retrieves, records and manages parameters such as pressure (static and differential), temperature (RTDs).

Control of valves, pumps and injectors for additives, product flow control and batch management and control of ratio and sequential blending in terminal environments.

The DL8000 uses the same enclosure as the Danload 6000 and has the same keyboard and display, making Danload 6 operator training an easy task.

The unit also has the ability to communicate in Danload protocol so it makes it quite easy to remove a Danload 6000 and replace it with a DL8000.

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The DL8000 display is an LCD panel, 4 rows by 80 characters wide and is the primary method for operating the DL8000. The display has back-lighting features for ease of reading in low ambient light conditions. The intensity level on ambient light controls the intensity of the back lighting. There are three LEDs (Light Emitting Diodes) indicating the operational status of the unit. The three indications are:

Yellow – indicates mode, in manual mode the light is off. In auto mode it is on full. When this light is flashing it indicates a high internal temperature, the keypad /display is disconnected or power is removed

Green – Permissive power circuit is closed and permissive power is available

Red - On - A primary Alarm is activeFlashing – A secondary Alarm is activeOff – no alarms are active

The keypad is an 18 button keypad and the unit is powered up as soon a power is connected to the terminal strip and the power is applied. The initial display asks for a drive number and a PIN number. Upon entering a valid driver number and pin number and pressing enter the display will show a list of available recipes for loading

By pressing the up arrow and down arrow keys the user can navigate through the choices on the display and the user selects a recipe and presses enter.

The screen changes to allow the driver to enter a preset amount for loading and presses the start button

The display then shows the recipe being loaded and an upcounter showing the progress of the load and the percentage loaded along with a graphic bar showing the progress.

There are up to five programmable dynamic displays the user can create to configure and monitor loading.

The keypad has a weights and measures switch. When engaged the weights and measures lockout key prevents the modification of any weights and measures parameter.The DL8000 is based on the Emerson ROC800 Series of flow computers. Having a single supplier and a common platform for liquid flow, gas flow and device control and diagnostics create many system improvement possibilities and cost reduction opportunities for the customer such as:

Improved maintenance efficiency and effectiveness with a common platform

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Reduced training cost and more mobility in technicians who have a basic understanding of one product for many applications

Reduced measurement uncertainty with higher precision in math calculations

Improved regulatory compliance and reporting with the application of the latest measurement standards

Improved process systems availability Reduce maintenance costs with predictive performance and improved

diagnosis of failures. Together modularity and optical isolation lead to

shorter, less-frequent planned downtime and faster startups after shutdowns.

The DL8000 is also available in a NEMA 4 enclosure when installation areas do not require explosion proof.

5.2.1 IO Modules

All of the modules available for the ROC800 are also available for the DL8000. Of special interest is the AC-IO module. The alternating current I/O module for the DL8000 Preset Controller enables the control of various AC powered devices with AC contact closures, and Monitors AC input values for status. Each AC_IO module has 6 channels and can be selected as an Input or Output Channel and each channel can carry up to 1.5 amps AC.

The module has one bank of 6 DIP switches which controls the input/output status of each of the six channels. Placing a switch in the on position sets the corresponding channel to the “Output” mode. Placing a switch in the off position sets the corresponding channel to the “Input” mode. Dual color light emitting diodes (LEDs) indicate the current status of each channel. Red means AC is being output and Green means AC has been detected on an Input Channel.

When configured as an output, a channel uses a solid-state, normally open relay rated at 1.5 amps rms. Any AC switched out is dependent upon the safety circuits and if there is a failure in the AC permissive circuits all AC power is removed.

5.2.2 Reporting and Printing

There are standard reports that are available for batch reports and proving reports and the system has the ability for the user to develop a custom report to meet the customer's own needs. The data available for reports meets the requirements of:

NIST Handbook 44 – 2002 Edition and 2003 Update

NCWM Chapter 14;

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The DL8000 can print to a local ASCII printer or to a network printer via the Ethernet. Reports can also be saved to internal memory in the DL8000L.

The data available for reports meets the requirements of:

Batch Reports are per API MPMS Chapter 12,2,2

Proving Reports are per API MPMS Chapter 12.2.3

5.3 Definition of Blending Methods

The DL8000 is capable of several different methods of blending

Sequential Blending - Sequential blending is the loading of one product component at a time through a single flow meter and a single flow control valve. The blend ratio is correct only after all components of the blend have been loaded.

In-line blending (Ratio Blending) In-line blending is the simultaneous blending and loading of two or more product components. Each component has a dedicated flow meter and flow control valve. In-line blending can be either non-proportional or proportional as described below.

In-line non-proportional In-line non-proportional blending is accomplished by delivering the low-proportion quantity component(s) of the blend at their assigned high (normal) flow rate(s) during the first part of the delivery of the high-proportion component at its high (normal) flow rate. This method of delivery is implemented so that the flow meter for each component is operating near its maximum rated flow rate to assure maximum measurement accuracy for each component in the blend. After the low-proportion quantity component(s) have been delivered, the high-proportion quantity component continues delivery until the blend ratio is attained. The total blend ratio can be in error until the total preset quantity is delivered.

In-Line proportional In-line proportional blending is accomplished by controlling the ratio between all components at all times during the delivery by controlling the individual flow rate of each component. The ratio of the delivered blend is correct at all times during the delivery. Therefore, the delivery can be stopped at anytime and the delivered blend will be within tolerance.

Note: In-line proportional blending can only be implemented in cases where the proportion of each component in the blend is great enough to permit the component flow meters to all operate above the minimum specified flow rate of each meter during the entire batch loading cycle.

”Sidestream” Blending (SSB)”Sidestream” blending is similar to in-line blending except one product component is delivered upstream to another product component. “Sidestream” blending is typically used to inject ethanol into gasoline. Ethanol is injected into the gasoline stream and the blend is measured by the custody transfer meter.

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“Sidestream” blending can be achieved using proportional or non-proportional blending. Proportional “sidestream” blending difficulties are as follows:Product flush cannot be achieved easily at the end of a load.Trying to meet the strict requirement for meters to operate above the minimum specified flow rate is usually very difficulty with proportional blending.

5.3.1 The Ratio Blending System

The above diagram shows a typical installation for preset flow computer. This installation shows a loading involving three products, two additives all configured in a ration blending configuration.

5.3.2 The Sequential Blending System

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A sequential blending system has a different piping set up

Sequential blending is different in that each product is controlled by a block valve and there is only one control valve

5.3.3 Side Stream Blending

The diagram below shows a typical side stream blending set up where the premium and regular a sequentially blended and the Ethanol is a side stream

The side stream blending process could have a flow computer and a control valve in each leg to get a ratio blended product.

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5.4 Additive Systems

There are several different types of additive control systems they include:Smart Injectors (Not supported by the DL8000)- In this type of injector communication are established between the flow computer and the injecting system and information is provided via serial or Ethernet communications and the information for injection is provided to the injector which controls the injection process.

Another type injector is simple a pulsed unit where for each pulse received a fixed amount of additive is injected.

The third type is a metered injection where the flow computer sends a command to open a valve and start a pump then receives pulse from the injector (one pulse represents a specific quantity of additive injected) and the flow computer calculates or measure the amount of additive injected and controls the flow through a solenoid. The DL8000 can meter and control up to 6 metered injectors.

Side Stream

Wild StreamBlended Product

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6. Summary

The RAS division of Emerson Process Management offers a comprehensive line of liquid flow measurement devices. There are three platforms all capable measuring liquids. The selection of the right platform can have a dramatic effect on customer satisfaction

The diagram below shows how the products fit in the liquid flow measurement spectrum.

6.1 The FB107

The FB107 has a user program that can b added to it to measure liquid flow. This program is designed to:

Measure liquid flow and correct the volume to standard or base conditions.

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The program is based on continuous flow and cannot manager flow in batches.

The FB107 does not have the ability to manage a prover and run a prove cycle

The unit can measure 4 gas runs and 2 liquid runs. There is a serial interface card that can interface with up to four coriolis

meters and the unit can monitor well separator activity. The unit is rugged, low power consumption and designed for remote

installation

6.2 The ROC 800L The ROC800L is more capable and can measure up to six gas runs and six liquid runs and is designed to:

Control a prover and perform proves with a large volume prover, a small volume prover or a master meter.

The unit has a double precision floating point processor meeting all of the API requirements for custody transfer.

The unit is designed to control a sampler and manage custody transfer in a pipeline or at the wellhead.

The ROC800 is also the basic of the DL8000 Preset for blending up to 4 fluids and loading trucks, tank cars and ships

The ROC800 series also can be programmed to control a two or three phase separator and conduct continuous well allocation measurement or sequential monitor up to 48 individual wells for performance and allocation profile measurement.

The ROC an also interface with Delta V and serve as a part of a production or processing management system.

6.3 The S600

The S600 is the most sophisticated flow computer and can handle up to 10 gas runs and 6 liquid runs. This unit is ideally suited for applications where:

Many custom calculations are required and applications engineers can custom build a configuration to meet specific needs.

The I/O density is high and many discrete signals are need to optimize control.

Meter proving is required A more powerful processor and larger memory is needed. The installation is in a control room where an interface panel, display and

keypad are needed.

If the task is defined as a simple low power surveillance task or a complex flow measurement and control challenge, Emerson RAS has the liquid flow computer for the task.

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Usually with any measurement task there is the need for other equipment provided by Emerson. We can help you find the right turbine meter, ultrasonic meter, coriolis meter, valve or pump you may need for metering skid. If you want to purchase an entire skid let us work with you the get you the solution you need.

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Application Data Sheet

Date ___________ Completed by ___________, Telephone ______________

1. Customer Name: _______________________________

2. Project Name: ______________________________________

3. Location of project _________________________________________________(State, Country, City)

4. Fluid to be measured _________________________________ (Crude Oil, Diesel, Gasoline, Refined Hydrocarbons, Light Hydrocarbons – NGL, LPG, Bio-diesel, Ethanol - other)

5. Number of Meter Runs ____________________ on one flow computer, line size _________

6. Number of Flow Computers _______________

7. Type(s) of Meter

a. Linear - Turbine ___, Positive Disp _____, Coriolis ____, Ultrasonic _____.

b. Dual Pulse Integrity needed _______,

c. Orifice Plate, ______ Other __________

8. Flow Calculations – (API Custody Transfer) ___________ Monitoring Only ______

a. 2004 API Standards d. Colstald Equations

b. 1980 API Standards e. TP-27 for LHCL

c. 1952 Standards f. Other _______________

9. Temperature Sensing/ RTD___ Analog Transmitter _______ (Range Lo ___ hi ___)

10. Pressure Sensing (Analog) _______________ (Range lo ____ high ____)

11. Live Density Measurement______ Type of density sensing device _____________________

12. Net Oil (S&W Calcs needed), ______

13. Large Volume Prover ____, Compact Prover ______, Master Meter _____________

14. Sampler control required _______________

15. Number and Type of Valves to be controlled? ____________________

a. Analog ______ 1.Block valve _______

b. Digital _______ 2. Flow Control Valve _______

c. Two Stage _____

16. Number and types of pumps to be controlled

a. AC Power _____, Discrete DC Control _________

17. Tank Level Sensing ________, Tank Level Control ___________

18. Type of communications, (number and type of connections)

a. Serial (RS232/422/485)_______Ethernet ________

b. Wireless/Radio ____________ Other __________

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19. Notes ____________________________________________________________________________

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Preset Applications Data Sheet

Date ___________ Completed By ___________

Customer Name: _______________________________

Project Name: ______________________________________

Application Type _________________________________________

Fluid(s) to be measured ______________________________________

Number of Products ___________

Number of Additives ___________

Blending Sequential ___, Ratio ____, Side Stream ______, None _____

Number of Pumps ____________________

Number of Valves ____________________

Number of Permissives to be Monitored _______________

Flow Calculations – API Custody Transfer ___________ Monitoring Only ______1980____, 2004 _____ Other ______________

Temperature Correction, _________ Pressure Correction _________

Density Measurement ________ Density Device_____________

Type of communications, Serial _______,Ethernet ______ Wireless/Radio ____________(RS232, RS422, RS485)

ProtocolModbus____ Field Bus ______ HART _______Brooks’s _________ DanLoad ______________

TAS System ____________________ (Manufacturer, System Name, Model, Version) Other Needs _____________________________________________________________

________________________________________________________________________