Calibration Methods - Gas

Author Mike Seabrook

Date 20/2/2018
Revision 2

EuroLoop B.V. T +31 (0)10 216 03 11 Bank 41.16.53.210

Petroleumweg 36 E [email protected] IBAN NL66ABNA0411653210
3196 KD Rotterdam I www.euroloop.nl SWIFT/BIC ABNANL2A
Havennummer 3125 KvK 54.624.401 BTW NL851376745B01
 Title Calibration Method - Gas
Revision 2
Page 2 of 9

Contents
1 Introduction............................................................................................................... 3
1.1 Overview ................................................................................................................... 3
1.2 Accreditation and CMC ............................................................................................. 3
1.3 Traceability ............................................................................................................... 3
1.4 Other Capability Details ............................................................................................ 4

2 System Description .................................................................................................... 5

2.1 Instruments and Piping ............................................................................................. 5
2.2 Differential Pressure Measurements........................................................................ 6
2.3 Calibration Management System (CMS) .................................................................. 6
2.4 Calibration Principle.................................................................................................. 6

3 Calibration Sequence ................................................................................................. 8

3.1 Calibration Definition................................................................................................ 8
3.2 Initial Meter Checks .................................................................................................. 8
3.3 Installation ................................................................................................................ 8
3.4 Start-up ..................................................................................................................... 8
3.5 Calibration ................................................................................................................ 9
3.6 Reporting .................................................................................................................. 9

4 Witnessing ................................................................................................................. 9
4.1 Local Witnessing ....................................................................................................... 9
4.2 Remote Witnessing................................................................................................... 9
 Title Calibration Method - Gas
Revision 2
Page 3 of 9

1 Introduction

1.1 Overview
This document describes the capabilities and operating method of the gas calibration facility at
Euroloop, mainly for the reference of clients and potential clients.

1.2 Accreditation and CMC

Euroloop in Rotterdam is accredited to perform gas flow calibrations in accordance with ISO
17025 by RvA, the Dutch Council for Accreditation. RvA certificate K161 defines the accredited
Calibration and Measurement Capability range (CMC) of the laboratory, and may be accessed
on the RvA web site at https://www.rva.nl/en/scopes/details/K161. The accreditation covers
both volumetric and mass calibration, including DP generating devices such as Venturis.
The accredited calibration ranges, extracted from the certificate, are as follows.
Volumetric Flow 500 – 30 000 m³/h
Mass Flow 430 – 26 000 kg/h Depending on pressure
Pressure 9 – 63 bar abs
The uncertainty at each calibration point is determined dynamically, depending on the rate of
flow and the pressure. At high pressure and high flow, the normal operating area of the
system, the accredited uncertainty is around ±0.17% of volume delivered.
Euroloop participates in various round-robin intercomparisons with other flow calibration
laboratories in Europe and beyond.

1.3 Traceability
The gas system at Euroloop has a very short traceability chain, resulting in low uncertainty
figures. Traceability is established through VSL, the Dutch metrology institute.
The first step in the chain is the Gas-Oil Piston Prover (GOPP), which is able to calibrate meters
at full operating pressure with a volume directly linked to the Dutch primary length standard.
Calibration is transferred to Euroloop from the GOPP using the Traceability System (TraSys).
TraSys uses a bank of rotary meters to “bootstrap” from the low flow rate available from the
GOPP to higher flow rates within the range of Euroloop’s master meters. A second bootstrap
procedure enables the large master meters to be calibrated over their full range.
A major advantage of TraSys is that it is portable. The master meters can therefore be
calibrated in place, eliminating any installation effects.
 Title Calibration Method - Gas
Revision 2
Page 4 of 9

1.4 Other Capability Details

The following limitations normally apply. Please contact Euroloop to discuss special
requirements.
Loading / unloading capacity 5 tonnes
Travelling crane capacity 7 tonnes
Large test section length 40 m
Small test section length 17 m
Temperature stability ± 0.05°C
Pressure stability ± 20 mBar
Flow control accuracy ± 2% of reading
 Title Calibration Method - Gas
Revision 2
Page 5 of 9

2 System Description

2.1 Instruments and Piping

The gas calibration system is a closed loop, which includes five parallel 16” master meter runs
and three sized 10”, 6” and 2”. Each master meter run except for the smallest includes a
turbine meter as a reference, an ultrasonic meter as a check, and multiple pressure and
temperature measurements.

Flow from the selected master meter(s) passes through two sets of test lines. The large test
lines are 24” and 16”; the small test lines are 3 x 10”. Each is long enough to fit more than one
meter in series if required, depending on conditioning requirements.
The system operates on stored natural gas originally sourced from the Dutch grid, classified in
the Netherlands as “high calorific”. Gas is stored in two large holders, and is pumped into the
system at the start of each calibration to achieve the required pressure. The filling
arrangement in the diagram is simplified, and the emptying arrangement is not shown.
A blower with a variable speed drive circulates the gas in the loop. Three control valves sized
12”, 6” and 2” fine-tune the rate of flow. A heat exchanger driven by an ammonia cooling
plant controls the temperature.
The gas composition in the loop is stable within any one calibration, but the amount of
nitrogen varies because the test sections are purged before filling. A gas chromatograph is
therefore fitted. A dewpoint analyser is provided as a gas quality check.
 Title Calibration Method - Gas
Revision 2
Page 6 of 9

2.2 Differential Pressure Measurements

The following differential pressure transmitters, calibrated annually, are available for use with
DP generating devices such as Venturis:
40 mBar
120 mBar
1200 mBar
5000 mBar
Two transmitters of each range are available. Where two sets of tapping are available it is
standard procedure at Eurooop to check both simultaneously, as there can be a noticeable
difference between them.

2.3 Calibration Management System (CMS)

A highly flexible, automated Calibration Management System (CMS) controls the system and
provides all required signal interfaces. The system is capable of handling multiple pulse signals
or 4-20mA signals from meters under test without reconfiguration.
Dedicated flow computers gather all signals relevant to calibration. The flow computers
monitor pulses with a 100 ns time base, enabling them to apply a form of pulse interpolation.
Excellent repeatability it therefore possible using a standard run time of 100 seconds, even for
meters with (stable) low frequency outputs.
Server-class PCs collect and process information from the flow computers. They also provide
the operators with a convenient interface to control and monitor the system.
A redundant PLC system takes care of safety and process control.

2.4 Calibration Principle

In steady state conditions, conservation of mass applies. The volume (vm) delivered by each
master meter during a run can therefore be adjusted to a volume through the meter under
test (vt) by applying the density ratio between the two locations. This, in turn, is determined
from the ratios of absolute pressure (p), absolute temperature (T), and compressibility (Z) by
applying the following equation in any consistent units:
𝑝𝑚 𝑇𝑡 𝑍𝑡
𝑣𝑡 = 𝑣𝑚
𝑝𝑡 𝑇𝑚 𝑍𝑚
In practice, conditions are never totally stable. The CMS therefore makes allowance for the
pipework inventory.
Pressure and temperature are directly measured at all relevant points. Compressibility is
calculated based on measured composition, temperature and pressure using GERG2004 or,
optionally, AGA 8.
The meter error (e) for volumetric devices is calculated using mass ratio (m), or equivalently
ratio of density (ρ) multiplied by volume (v) according to:
𝑚𝑀𝑈𝑇 𝜌𝑀𝑈𝑇 𝑣𝑀𝑈𝑇
𝑒= −1= ∙ −1
𝑚𝑅𝐸𝐹 𝜌𝑅𝐸𝐹 𝑣𝑅𝐸𝐹
 Title Calibration Method - Gas
Revision 2
Page 7 of 9

Where a DP generating device is calibrated, the reported quantity is the discharge coefficient C
calculated according to the definition from ISO 5167-1 (3.3.5), with the expansibility ε inserted
as defined in ISO 5167-1 (3.3.6):
𝑚𝑅𝐸𝐹 √1 − 𝛽 4
𝐶=𝜋
2
4 𝑑 𝜀√2𝛥𝑝 ∙ 𝜌𝑀𝑈𝑇
Expanding mass to take account of volumetric reference devices:
√1 − 𝛽 4 𝜌𝑅𝐸𝐹
𝐶=𝜋 ∙ 𝑣𝑅𝐸𝐹
𝑑 2 𝜀√2Δ𝑝 √𝜌
𝑀𝑈𝑇
4
As long as the same values of the geometrical terms diameter (d) and diameter ratio (β) are
used during calibration and when installed, calibration adjusts out any error that may be
associated with them so they do not add to the uncertainty in flow.
The value of expansibility (ε) depends on the type of DP device used. The equation of ISO
5167-2 (5.3.2.2) is used for orifice plates, where τ is downstream pressure divided by upstream
pressure:
1
𝜀 = 1 − (0.351 + 0.256𝛽4 + 0.93𝛽8 ) (1 − 𝜏 𝜅 )

The equation of ISO 5167-3 (5.1.6.3) and ISO 5167-4 (5.6) is used for all other DP devices:

2 𝜅−1
𝜅𝜏 𝜅 (1 − 𝛽 4 ) (1 − 𝜏 𝜅 )
𝜀=√ 2
(𝜅 − 1) (1 − 𝛽 4 𝜏 𝜅 ) (1 − 𝜏)

Both of these expansibility equations are implemented in Euroloop’s software and used as
appropriate. The uncertainty of the expansibility is significant. The orifice version was
determined using real-world data during the development of ISO 5167, and the version for
other device types was based only on theory. It makes a noticeable contribution to CMC when
Euroloop (or any other laboratory) calibrates a DP generating device.
 Title Calibration Method - Gas
Revision 2
Page 8 of 9

3 Calibration Sequence

3.1 Calibration Definition

Proper definition of calibration requirements is a critical step in the process. All calibration
parameters are agreed in advance, and checked with the client before the meter is received.
Unless otherwise required, calibration is performed at ambient temperature. It is possible to
calibrate at other temperatures, but please contact Euroloop to discuss implications such as
increased uncertainty and potential stratification effects at low flow.
Any requirement for meter adjustment is also determined at this stage. Depending on the
meter type, options include Weighted Mean Error adjustment, a piecewise linearization curve,
or a polynomial fit.
Calibration points for differential pressure generating devices are chosen according to client-
specified Reynolds numbers (Re). A calibration pressure is then chosen within the safe
pressure range of the device and the working range of the facility to give a measurable
differential pressure at all specified points (see 2.2). For a given value of Re, lower pressure
gives higher DP. The proposed calibration pressure is confirmed with the client.

3.2 Initial Meter Checks

Incoming meters are checked to ensure that they are clean and in good working order. As-
found calibration of dirty meters is possible but requires additional procedures and
precautions, and therefore additional cost. Please contact us to discuss requirements.
Euroloop is able to arrange for cleaning of meters, and for some types of repair.
Received meters are photographed to record their condition. The images are stored for a
minimum of one year.

3.3 Installation
Euroloop owns over 500 pipe spools for the gas system, with access to more by arrangement.
Zanker flow conditioners are available in a variety of sizes, although we advise clients to supply
meters complete with any associated conditioners.
The piping build up is defined and implemented by Production and then inspected by
Metrology before pressurisation. Horizontal alignment of installed pipework is ensured by
track-mounted pipe supports. The height of the supports is adjustable to align the piping
vertically.
All flanged joints are individually monitored for leaks under nitrogen pressure before the
pipework is filled with natural gas.

3.4 Start-up
The system is pressurised as required. Pressure transmitters are then cross-checked at
operating conditions and zero flow to ensure that correction from meter conditions to test
meter conditions will be correct.
Initial stabilisation requires typically 20 – 30 minutes. An interlock in the CMS prevents
calibration from starting until stability is achieved.
 Title Calibration Method - Gas
Revision 2
Page 9 of 9

3.5 Calibration
Calibration of clean meters starts at maximum flow. Contamination is likely to be dislodged
from dirty meters at maximum flow, so in this case the first point will generally be taken at a
lower flow as agreed with the client.
At least three repeats are performed at each flow rate (five for DP devices), with a check if the
results are shifting significantly. Once an acceptable set of repeats in line with expectations
has been collected at the first rate of flow, the next rate of flow is selected. Stabilisation after
a change in flow typically takes 10 – 15 minutes.
Combining automation with operator supervision reduces the risk of human error while
allowing corrective action when needed.
If adjustment is required, the as-found calibration is processed and the required correction
calculated and implemented. As a minimum, a spot check is made after adjustment. A full as-
left calibration may also be performed if required.

3.6 Reporting
As a minimum, a signed calibration report is provided using the RvA approved format in SI /
derived SI units. Detailed information for each calibration run and an installation sketch are
appended to the report.
Where a meter has configurable parameters, a meter configuration report is appended to the
calibration report. This is subject to availability of software and of any password needed to log
in to the meter.
A report in non-metric units may optionally be appended to the certificate for information. It
is a condition of Euroloop’s certification that the main report is in SI units.

4 Witnessing

4.1 Local Witnessing

Euroloop has three witnessing rooms, each equipped with three monitors that provide a live
view of activity on the CMS and of the meter diagnostics (where applicable). Witnesses are
welcome to inspect the installation under the supervision of Euroloop staff, with due regard to
the confidentiality of activities relating to other clients.

4.2 Remote Witnessing

Remote witnessing via the web is also available. As Euroloop operates two shifts, it is normally
possible to arrange calibration times to suit various time zones.