WITNESSING ORIFICE METER CALIBRATIONS AND FIELD TESTING Class # 4160 Allen Chandler Training and Development Coordinator

Atmos Energy 14032 Distribution Way Farmers Branch, Texas, USA, 75234 Introduction The need for witnessing gas measurement equipment testing has probably been around since the dawn of the gas custody transfer age. That is, where the gas is physically changing ownership from one entity to another. In the modern age, the old handshake is no longer the equivalent of a valid contract as it once was and rightfully so, each producer, transmission pipeline operator, distribution system owner or transportation broker is concerned that their product is bought and/or sold in as accurate an environment as is humanly possible. Modern day gas prices are volatile to say the least. The market bounces around on an almost daily basis and the price per thousand standard cubic foot of gas seems to steadily increase. Coupled with generally milder temperatures in many regions of the United States and the huge gas volumes that change hands daily, it becomes ever more critical that natural gas is measured with greater accuracy and a witness to the testing procedure is one more positive step toward that end. The Witnesss Role The witnesss role is more important than ever to ensure that contractual obligations are met. All parties to the contract must be satisfied that the best effort is being exercised in achieving quality measurement standards. Electronic flow computers and other highly technical devices are now being utilized to achieve greater accuracies and yet the human factor is and always will be a contributing input to the process. The witness of a field calibration test is exactly what the word implies; He or she bears witness to the test. They may be considered an auditor or onlooker to ensure that the testing equipment used and procedures performed are of the highest standards satisfying the demands of all parties involved including assurance that accepted gas measurement standards are met. The Mark of a Good Witness The person chosen to function as a witness to a testing procedure should have an extensive knowledge and background in the gas measurement field and possess personal experience at performing testing procedures. They should be familiar with their individual company standards for gas measurement, following their companys respective Operation and Safety Practices Manuals. They should be familiar with and understand the guidelines set forth by the American Gas Association, Report 3 and API 2530, which are the industry accepted standards for quality gas measurement practices. Further, a witness should understand that they are on site to witness the testing procedure as an agent representing their company, keeping their companys best interests in mind. They should exhibit a professional and businesslike attitude while being friendly and cordial. They should be prepared to be diplomatic and sometimes assertive when disagreements arise during a test. A good witness should know that gas measurement is essentially the cash register of the company and errors can have a huge impact on the bottom line profits of the company, thus impacting virtually every aspect of the company, even to their own paycheck.

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Testing Equipment There are numerous choices in todays market for testing equipment and about as many opinions associated with which ones to purchase. There are various opinions throughout the industry about which test equipment is the best to use. One guideline that may be helpful is the A.G.A. reference that states that any test equipment should have twice the stated accuracy as the instrument it is being utilized to test. Example: If a transducer has a stated accuracy of .1%, the test device used to test it should have at least a stated accuracy of .05%. A typical rule is the higher the accuracy, the higher the cost. For that reason, testing equipment can be very costly considering the higher stated accuracies in the modern market. The type of equipment is not specified by the A.G.A. Therefore a decision may be made between pneumatic/hydraulics and an electronic equivalent as long as the accuracy is adequate and meet N.A.S.T. Standards. Generally, some testing equipment types are considered to be primary standards. That means that a certain type is utilized as a reference for other equipment to relate to. An example of a primary standard could be a dead weight tester in which the laws of physics are in effect and cannot be violated if maintained and used properly. Therefore, other types of equipment such as electronic pressure testers may be acceptable as long as they have the ability to mimic or represent the physical quality of the dead weight tester and have a proven acceptable accuracy. Since electronic devices are subject to deviate from physical laws due to internal circuitry problems, internal voltages, or in some cases, external radio frequency distortion, many companies opt for the primary standard devices for testing purposes. However, new generation electronic testers have addressed most of these anomalies and are very reliable. A typical set of test equipment for electronic measurement should include the following: Adequate hand tools to set up and install the testing equipment A liquid soap or other substance to check for leakage A certified volt/amp meter A dead weight tester, approved deadweight gauge, or digital electronic equivalent for the static pressure test A dead weight or comparable electronic device for differential pressure testing in inches of water column A pressure supply source when applicable (typically nitrogen) A caliper and/or micrometer (digital micrometers are acceptable) A straight edge for checking orifice plate flatness A mercury or electronic digital thermometer A water content testing device Gas sampling cylinder Laptop computer with required software(s)

Digital Caliper

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The Testing Schedule Most contractual agreements provide for how the test schedule is to be performed; monthly, quarterly or some other frequency. The frequency of testing is usually dependent on the company representative who owns the custody meter. They are responsible for setting the testing schedule and notifying the other parties to the contract when a test is scheduled to be performed. The test schedule should be flexible enough to allow for last minute alterations if one or more parties cannot attend as witnesses. In the event that a witness cannot be present but tells the tester to proceed with the test, the tester should send the comprehensive test results in a report to the absent party after the fact. The report should state any and all results including any changes that were incurred during the testing procedure. If a measuring device or recorder is found to have problems, a follow up telephone call to the absentee witness may be necessary to discuss the how the corrections are to be applied. The contractual agreement will usually state very specifically how adjustments are to be handled for auditing purposes. If a problem is found it is not unusual to make a volume adjustment to one half of the elapsed time period since the last test was performed. The report should clearly state: The name, location, and station number The steps taken to perform the verification or calibration As found and as left conditions If a gas sample was collected, and if a gas chromatograph is present for live inputs to the flow computer, how it was verified to be correct. Many companies use a gas sample to verify the chromatograph. That data has to be followed up since the sample is taken to a laboratory to be run. A chromatograph analysis must be run at the time the sample is gathered. The results of a comprehensive inspection of the primary element (meter tube and orifice plate) and the recording device (secondary element). Note: The gas volume is only as accurate as the primary element regardless of the accuracy of the secondary element. The gas volume before and after the test was performed Any additional remarks pertinent to the condition of the station Recorder Verification/Calibration Although it may sound rhetorical, there is a distinct difference between a verification procedure and a calibration procedure, particularly for a flow computer. The tester should check the static pressure up and down the full range of the device as well as the differential verification of the zero value while both under operating pressure and at atmospheric pressure. Depending on the contract, the static pressure zero may be either set on psia or psig and the witness should be aware of the difference and the implications. The witness should be alert to any as found conditions which may reveal problems with the device and be knowledgeable of the acceptable parameters for which the device can be in error. These problems must be recorded before any attempt is made to correct them; else a meaningful quantitative adjustment is lost. If the flow computer passes the verification procedure, a calibration should not be arbitrarily performed. Field calibrating a flow computer re-characterizes the transducers and should only be done when an error is found. The test procedure may be considered completed if the verification proves the instrument to be correct in the as found condition.

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Meter Tube and Orifice Plate Inspection The meter tube and orifice plate are the heart of quality orifice measurement and any errors that exist are transmitted and usually multiplied to the secondary element. The meter tube should remain clean and free of liquids and other debris that can alter the flow pattern. Although it is not feasible to internally inspect the meter tube at each testing interval, periodic inspections should be performed. When the meter tube is inspected the witness should be on site to verify micrometer readings and any other conditions which need to be noted. Some companies schedule routine meter tube inspections and cleaning on an ongoing basis. Internal observations may be done by disassembling the meter tube or by the use of a bore scope which allows internal inspection without the disassembly of the meter tube. In either case, the witness should be on site when the procedure is performed and know what to look for. Included in the meter tube inspection is a full inspection of the orifice fitting, its operational condition and verification as to what type of fitting is installed. Dual chambered orifice fittings should be inspected to be sure that all shafts are in good working order and the isolation device is in good working order. The witness should be familiar with the internal parts and their function.

At each testing interval, the orifice plate should be removed and inspected for: Dirt, grease, any other build up Orifice bore direction if beveled Bore diameter using a round-tipped micrometer Verification of the bore diameter with the stated record, the stamped size on the plate, and the bore diameter entered in the flow computer program Bore condition, looking for nicks, gouges, dullness, or sharpness Flatness Thickness Eccentricity Seal ring condition

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Typical Orifice Plates Inspection Report

Seal Ring

The inspection test report should be considered a mini contract in and of itself. Once the witness signs the report, it finalizes all of the data on the report to be correct and acceptable and any follow up disputes could be very difficult to argue once the signature is in place. Following the completion of the inspection, the witness should verify that all information is correct and properly recorded on the test document before signing. The witness and all other parties present should receive a copy of the report before leaving the site. Conclusion As natural gas changes hands in a volatile and high priced market, errors in gas measurement translate to possible huge revenue losses for either the buyer or seller. These losses impact the bottom line success or failure of any gas company. The witness serves a very important role and is a key component in the process to ensure that the gas measurement devices are in the best possible working order and meet industry standards and contractual agreements by all parties.

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