Master Meter Prover Calibrations Per API MPMS 4.9.

3
Class #2510.1

Kevin Fields, COO of Coastal Flow Liquid Measurement

The Coastal Flow Measurement Companies

P. O. Box 58965
Houston, TX 77258-8965

Introduction: Master Meter:

When discussions about prover calibrations The master meter chosen for this method
occur, they normally end with a must produce good reproducibility and
disagreement about the accuracies of the repeatability throughout its operating range.
different approved methods. This paper will The API standards require run repeatability
discuss the procedures and advantages of no higher than 0.02% for five consecutive
the master meter method. This method was runs and 0.02% deviation between meter
developed over 20 years ago to minimize factor averages for the pre and post runs
difficulties in calibrating very large volume sets at the same flow rate. The
provers. In the fast pace world of today, performance of the master meter should
where down time means money, many essentially remain unchanged throughout
companies use the master meter method to the meter proving runs.
save time and money on a variety of prover
sizes. Accurate calibrations require good Master meter placement should be close
technique from a knowledgeable technician. coupled to the field prover to create a single
Having the proper knowledge and unit with the master prover. It is typically
equipment to perform the master meter referred to as the master meter prover
method will improve the accuracy and system.
minimize the time to complete the
calibration. This paper will discuss the Field Prover (prover under calibration):
Master Meter Method of prover calibration The field prover should be a displacement
as described in API MPMS Chapter 4.9.3. prover. Any and/or all inspections of the
field prover should be performed prior to
Master Prover: calibration. Inspect and verify that there is
A master prover is required in the method to no damage to the prover, 4-way valve,
determine a K-factor or meter factor for the switches, and etc. Inspections should
master meter. This meter factor and/or K- include all piping, valves, drains, and vents.
factor is used to determine the field prover’s Verify that each drain and vent valve can be
volume. Prover volume determinations checked for leaks prior to starting and
using the master meter method are only as during the calibration process. If these
accurate as the calibration performed on the valves cannot be checked, each valve
master prover. The master prover volume should have a blind installed or
shall be determined per the current API disconnected so that there is no possibility
Chapter 4.9 and 12 standards and must be of leakage. For sphere provers, verify the
traceable to NIST or appropriate NMI. condition and size of the ball if at all
Errors in the master prover calibration possible. For piston provers, the seals
directly transfer to the volume of the field should be checked for wear or damage.
prover. Switches should be inspected, cleaned, or
replaced if necessary. If the proper steps
are taken during the inspection process, the
calibration will go smoother.

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 Master Meter Prover Calibrations Per API MPMS 4.9.3

If the calibration is to be performed on the In situations where the main line flow rates
same product (fluid) as used during normal are above the master meter’s range, it is
operations, field prover cleaning may not be common to slip stream flow through the field
required or needed. Aside from the cost prover and the master meter system from
savings, the advantage of “NOT” cleaning the main line. An example would be that
the prover is that it accounts for any foreign the main line flow is higher than 2000 BPH.
pipe wall coating (typical in heavy crude To obtain flow rates in the master meter’s
application) that may have decreased or range, the main line block and bleed valve
changed the volume of the prover. is used to divert the desired flow to the field
Cleaning the prover prior to calibration can prover by partially closing it so that only
produce a volume different than the actual 1000 BPH flows to the field prover and
operating volume, and thus an error or bias master meter system.
occurs. Pre-Calibration Process:
To start the process, connect the master
Before the actual process begins, one meter prover system (MMP) to the main
should consider and review the flow rates line. An example is in Figure 1 below.
and operating conditions that the process Begin to fill the MMP with product. Once
will incur. All of these must be compatible the system is full and completely
with the master meter prover system. Prior pressurized, establish flow. Next adjust flow
to the calibration, select a flow rate range to the highest intended rate. Perform
that will result in the best performance of the temperature and pressure checks to
master meter. Typically, a master meter’s determine stabilization. While operating
performance is best in its upper flow range. conditions are stabilizing, preliminary runs
can be made on the master meter.
Our system uses a 4” PD meter. Its best Preliminary runs speed up the stabilization
performance is from 600 and 1000 BPH. process and also help remove any air in the
Therefore, when operating conditions allow, system. Open and check all high point vents
we will perform the prover calibration at to ensure all air is removed and no air
1000 BPH for the high rate and 750 BPH for remains in the entire system. Also make
the low rate. several passes on the field prover to
stabilize temperature and again remove air.
Pressure and temperature considerations While the field prover pre-runs are being
should also be made to maximize the made, verify that all valves including the 4-
master meter’s performance. Also, they way have no leaks. Special attention should
should not vary during the process. be given to valves that may bypass product
between the field prover and the MMP.
The master prover, master meter, and field Once these steps are completed, the
prover should be aligned in series and calibration process can begin.
coupled as close as possible. This ensures
that all product/fluid passing through the Calibration Sequence:
field prover passes through both the master A. Verify the target flow rate #1 has been
meter and master prover. Varying achieved and perform the operations below
temperatures and pressures have a at that rate.
tremendous effect on the calibration results.
Take all precautions possible to stabilize the  Start the pre-master meter prove.
conditions under which the calibration takes Make five consecutive runs with the
place. Stabilizing operating conditions is master prover that result in meter
the biggest factor in determining how well repeatability within 0.02% and
this method of calibration turns out. determine the average master meter
factor.

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 Master Meter Prover Calibrations Per API MPMS 4.9.3

 Begin field prover volume set, if it is the higher rate. Flow rate #3
determination #1 by making three does not have to be at the #1 rate, but it has
consecutive proving runs on the to vary from #2 by 25% of the highest flow
master meter using the field prover. rate. Therefore, you could decrease the
These three runs must be within flow rate by 25% instead of increasing it.
0.02%. Remember when calibrating The main key in making this decision is to
a bidirectional prover, a run consist consider the accuracy of the master meter
of the sum of both forward and at the third rate selected. Once that rate is
reverse directions. During these selected, change the actual flow rate of the
runs, the flow rate must be within 5% system to the third rate and begin the
of the pre and post runs of the process.
master meter. Flow rate adjustments
are common due to different flow  Begin pre-master meter prove set by
characteristics of each prover. making five consecutive runs with
 Once the field prover runs are 0.05% repeatability using the master
complete, begin the post master prover. Establish a pre-run meter
meter prove. This prove must again factor at the third flow rate.
be five consecutive runs that repeat  With pre-master meter prove
at 0.02%. The average meter factor complete, start three consecutive
from the pre and post master meter field prover runs on the master
proves must be within +/- 0.02%. meter. These runs must have a
This completes calibration set #1. repeatability of 0.02% and the flow
rate within 5% of the pre- master
B. Calibration set #2 has to be performed meter prove flow rate.
at a different flow rate. This flow rate must  Begin the post master meter prove
vary from set #1 by 25% of the highest rate by making five runs with 0.02%
used in the calibration. Typically this rate is repeatability at flow rate #3. Verify
at a lower flow rate than set #1. that the average meter factors of pre
and post run are within 0.02%. Verify
 Begin pre-master meter prove set by the flow rate between the pre and
making five consecutive runs with post runs are within 5% of the field
0.05% repeatability using the master prover runs.
prover. Establish a pre-run meter
factor at this second flow rate. Three requirements that make this method
 With pre-master meter prove difficult are:
complete, start three consecutive
field prover runs on the master 1. Each set of proving runs has its
meter. These runs must have a repeatability and reproducibility
repeatability of 0.02%. specifications that must be met. If
 Begin the post master meter prove any of the specifications are not met,
by making five runs with 0.02% then the calibration has failed and
repeatability at flow rate #2. Verify must be restarted and repeated.
that the average meter factors of pre 2. All proving runs (pre and post runs
and post runs are within 0.02%. on the master meter or field prover)
Verify the flow rate between the pre must be consecutive.
and post runs are within 5% of the 3. Consecutive proving runs
field prover runs. repeatability requirements must be
met within:
C. A third set of calibration runs are now a. 10 consecutive runs for either
required. Typically these runs are the pre or post runs by the
performed at or near the flow rate of the first master prover.

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 Master Meter Prover Calibrations Per API MPMS 4.9.3

b. 6 consecutive runs for the field years prior to being selected as master
prover run. meter. As the table demonstrates, the
meter factor variance barely changed over
Experiences: this two year period. Twice during this
The process begins and ends with the period there was a problem. During meter
quality of the master meter. Select a meter inspection, trash was found to have passed
that performs well. The better the through it. The meter was cleaned prior to
repeatability and reproducibility results a continuing. Provings during the 2007 to
meter can produce, the easier the master 2009 were on crude or condensate.
meter prover calibration is. Operating conditions varied from 70 up to
400 BPH, gravity from 25 to 55 API, and
Below is a performance history of a meter temperatures and pressures varied over a
we have used. This meter was under daily wide range.
use on a portable prover for more than two

PROVING AV. FLOW OBSERVED REPEAT- MF

DATE RATE TEMP PRES DENSITY MF ABILITY VARIATION

2/17/09 114.5 70 39.5 49.4 0.99999 0.005 -0.00048

1/20/09 195.9 72 41.3 55.8 1.00047 0.022 0.00017
11/18/08 265.5 86 42.1 58.1 1.00030 0.012 -0.00019
8/19/08 251.4 86 48.6 42.3 1.00049 0.015 5E-05
7/15/08 190.7 87 53.2 45.4 1.00044 0.016 0.00024
6/17/08 163.8 84 53.1 46.5 1.00020 0.023 -0.00045
5/21/08 127.8 80 47.7 61.1 1.00065 0.003 -0.00022
4/15/08 290 86 44.3 46.8 1.00087 0.003 0.00096
4/3/08 463.5 76.4 12.4 32.5 0.99991 0.016 -9E-05
3/18/08 86.9 78 100.3 55.7 1.00000 8.617 0.00011
2/20/08 159.7 71 57.1 51.7 0.99989 0.023 -0.0009
1/8/08 119.9 72 27.5 56.4 1.00079 0.026 0.00107
12/5/07 171.4 74 14.9 58.4 0.99972 0.008 0.00082
12/4/07 179.3 74 32.7 25.3 0.99890 0.35 -0.00234
11/13/07 129.3 100 77.6 54.4 1.00124 0.036 0.00056
11/12/07 89.1 83 32.7 57.6 1.00068 0.008 -0.00031
11/8/07 PM 79.6 78 27.8 57.8 1.00099 0.011 0.00057
11/8/07 AM 142.4 72 17.7 36.9 1.00042 0.007 0.00011
11/7/07 390.3 80 19.8 36.5 1.00031 0.021 0.00037
11/6/07 PM 152 60 13 58.9 0.99994 0.014 5E-05
11/6/07 PM 222.8 75.7 16.6 36.7 0.99989 0.008 0

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 Master Meter Prover Calibrations Per API MPMS 4.9.3

As previously discussed, one of the most early in the process leads to little or no
important attributes to have a successful wasted time.
calibration is to have good procedures and
consistency with those procedures. For Decreases in the field meter factor from the
instance, in choosing the master meter, a lot master meter factor indicate a leak or leaks
of meters have a very good repeatability but associated with the field prover. The true
not necessarily the linearity to achieve test or verification of a leak will come once a
0.02% between pre and post proves if the calibration set at a different flow rate occurs.
flow rate or conditions are not exactly the When the flow rate is lowered by 25%, the
same. So be sure to make flow rate factor will continue to decrease if there is a
adjustments as necessary to maintain flow leak. Changes are proportional to time as
deviations of 5% or less at the same related to the leak.
operating conditions.
The runs listed below are from a new field
In our procedures, we try to achieve a prover where the volume was unknown.
master meter factor as close to 1.0000 as Several passes were made to determine the
possible for the pre-runs. This helps to volume of the field prover prior to beginning
identify problems once field prover runs the calibration. Notice the first set does not
begin. For example: Any difference in pre- repeat, but the meter factor matches the
master meter factors and field prover’s meter factor from the master meter. The
meter factors indicate that the new or second data set was after the flow rate
projected field prover’s volume will be change. The field prover’s meter factor at
different by that amount for the current the new flow rate dropped considerably to
volume. There are numerous issues that 0.74493. This drop in meter factor indicates
may contribute to a difference, but a serious leak. An investigation verified that
determining there is a possible problem the prover 4-way valve was leaking.

PULSES
N Run Accepted? IMF Flow Rate
108922.252 1 No 0.99797 298.259
108889.099 2 No 0.99828 299.620
108868.083 3 No 0.99848 299.316
108943.356 4 No 0.99780 300.085
108880.246 5 No 0.99838 299.319
108912.608 6 No 0.99808 299.327
108902.607 0.99817 299.321
PULSES
N Run Accepted? IMF Flow Rate
108930.914 1 No 0.74467 191.927
108902.938 2 Yes 0.74486 191.672
108901.022 3 Yes 0.74488 191.315
108890.365 4 Yes 0.74496 190.034
108873.045 5 Yes 0.74508 191.399
108902.000 6 Yes 0.74488 191.874
108893.874 0.74493 191.259

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 Master Meter Prover Calibrations Per API MPMS 4.9.3

Results from another field prover with a slow rate were made. The meter
problem are below. As the tests begin, it repeatability was 1.3% on the slow flow
was oblivious that the prover had a serious rate, and the prover volume changed
problem. The new volume was 0.5% 0.76%. The process was stopped and a
different from the previous, and the master scope was brought in to look at the internal
meter would not repeat on the field prover. lining. The prover lining was pitted and
The calibration continued and runs at the needed replacement.

Repeatability Set I CPVavg

Fast Run 800 BPH Base Prover Volume 0.044% 43.0394 Bbl

Repeatability Set II CPVavg

Slow Run 500 BPH Base Prover Volume 1.324% 43.3671 Bbl

Conclusion: the Master Meter prover calibration might be

The Master Meter prover calibration method the most effective way to calibrate
has several advantages over the other type displacement provers.
of prover calibrations. Some of the
advantages are: References:

 Eliminates the need to clean field American Petroleum Institute Manual

prover. of Petroleum Measurement Standards,
 Eliminates the expense of cleaning, Chapter 4 “Proving Systems,” Section 9
water disposal, and down time. “Methods of Calibration for Displacement
 Good method to verify prover and Volumetric Tank Provers,” Part 3
operating condition and volume prior “Determination of the Volume of
to a volumetric or gravimetric Displacement and Tank Provers by the
calibration. Master Meter Method of Calibration”
Excellent results can be achieved when this American Petroleum Institute Manual of
method is performed by experienced Petroleum Measurement Standards,
technicians using high quality equipment. Chapter 12
Master meter calibrations may be one tier “Calculation of Petroleum Quantities,”
lower on the traceability ladder, but results Section 2 “Calculation of Petroleum
can be and are equivalent to other methods. Quantities Using Dynamic
Their accuracy is totally dependent on the Measurement Methods and Volumetric
accuracy and quality of the master prover Correction Factors,” Part 5 “Calculation
calibration. With the tight tolerances and of Base Prover Volumes by the Master
specifications of this method and good Meter Method”
historical data on the field prover calibration,

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