DEVELOPMENT OF ORIFICE METER STANDARDS (PAST, PRESENT AND FUTURE) Class # 8030 Jane Williams Consultant Savant Measurement

Corporation 3015 Idlecreek Dwg, Tx Usa Introduction Standards are developed in order to provide uniformity of action, improve efficiency, and to minimize litigation. If standards did not exist, one would have to know the dimensions (diameter, depth, thread pattern, etc.) of the socket prior to purchasing a replacement light bulb. Can you imagine the difficulties that would exist between companies if the purchaser had a set of company standards which requires that the orifice plate be installed with the sharp edge downstream and the producer had a set of company standards which requires that the orifice plate be installed with the sharp edge upstream? Measurement agreements would be very difficult to achieve in this scenario. Consequently, an orifice metering standard was necessary to avoid frequent disagreements and litigation. There are many areas of concern such as plate thickness, surface roughness, dimensional tolerances, etc that have been specified by the orifice measurement standard. If this were not the case each company would be tempted to implement whatever would benefit their company the most. Different requirements might even be employed based on whether the company was buying or selling. Thus the need for a standard was recognized many years ago. Past Standards A committee was formed by the Board of Directors of the Natural Gas Association (currently known as the Natural Gas Department of the American Gas Association, A. G. A.) in May 1924. The purpose of the Gas Measurement Committee was to: 1. 2. 3. Determine the correct methods of installing orifice meters for measuring natural gas. Determine the correction factors and operating requirements for orifice meters, using natural gas in all experimental work. Secure the cooperation and assistance of the National Bureau of Standards, NBS (now NIST), and the U. S. Bureau of Mines, and secure, if possible, the assignment of members of their staffs to the Gas Measurement Committee to assist in this work.

As a result of research performed by this committee and research performed by the NBS at the Edgewood Arsenal, a preliminary report was issued in 1927. This report was revised in 1929 and became A. G. A. Report No. 1 in April 1930. The Gas Measurement Committee realized that the Report which they developed was just the beginning as is evidenced from the following statement which is found in the introduction of Report No. 1:

This is not a final report, but is made with the understanding that the committee will continue its analytical studies of the data already developed. The committee also fully expects that it will be necessary for it to conduct further work of its own. This will make necessary one or more supplemental reports, in which the data will be summarized and the mathematical principles announced, which are the basis for the present report, and such modifications and extensions will be made as additional data and further study may require.

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A. G. A. Report No. 3 Due to the need for larger diameter meter tubes and to accommodate the higher pressures encountered, it was recognized by industry that additional work must be done. Report No. 3 thus extended the range of conditions covered, clarified some statements, and changed the pressure base to 14.73 pounds per square inch absolute (psia) from 14.4 psia. Report No. 3 was developed by a group of individuals who had dual membership on the American Society of Mechanical Engineers and the A. G. A. committees concerned with measurement. Report No. 3 was originally published in 1955. In 1969, a revision to the original Report No. 3 was published. It provided additional information which had been developed since the original publication. In 1975, the American Petroleum Institutes Committee on Petroleum Measurement adopted Report No. 3. It was published as API Standard 2530 and as Chapter 14.3 of the API Manual of Petroleum Measurement Standards. API submitted the standard for American National Standards Institute (ANSI) approval, which was granted June 1977. This provided additional credibility to the standard and it began to be utilized by governmental agencies. 1. In 1983, the standard was revised again. This was a joint effort of the API, A.G.A. and the Gas Processor Association (GPA). In this revision, several forms of the flow equations were provided. The empirical equation of state for natural gas, or compressibility was also updated to use of A.G.A. Transmission Measurement Report No. 8. The format of the standard was also changed to improve ease of application and clarity, and SI units were added and equated to the inch pound units used in the United States. The title was also changed to Orifice Metering of Natural Gas and Other Related Hydrocarbon Fluids. The revision received ANSI approval in May 1985 and was designated ANSI/API 2530-1985 and as ANSI/API 2530 Second Edition.

Current Standard Development In the early 1970s, problems with the OSU data base were suspected. Consequently, a joint committee of the A.G.A., API, and the International Standards Organization (ISO) was formed to address the problems. Wayne Fling was selected to represent the United States interests and Jean Stolz from France was chosen to represent ISO. Stolz and Fling discovered a number of physical reasons why some of the OSU data points should be questioned. The OSU data was developed prior to a standard being developed. The original objective of the tests at OSU was to determine what specifications were necessary for a standard. Several of the installations and orifice plates tested did not meet the standard requirements developed by this work. In addition, insufficient documentation existed as to which data points were utilized by Buckingham and Bean to generate the discharge coefficient equation. Stolz and Fling found 303 technically defensible data points from the OSU experiments. The defensible data points were from four meter tubes covering a Beta ratio range of 0.2 to 0.75 and a pipe Reynolds number range of 16,000 to 1,600,000 which is clearly in the turbulent flow regime. Due to the small amount of data the standard was developed from, the API and GPA initiated a project to develop a new data base for concentric, square-edged, flange-tapped, orifice meters in 1981. A similar experimental program was initiated by the Commission of European Communities (EC) in Western Europe about the same time. The goal of both research efforts was to develop a high quality data base of orifice meter discharge coefficients covering a wide range of Reynolds numbers. Experimental Pattern The experimental pattern was designed to vary the factors effecting correlation such as Beta ratio, pipe size, Reynolds number, and tapping system in a controlled manner. The concentricity, flatness, bore diameter, surface roughness, and edge sharpness were quantified for each of the orifice plates utilized. The edge sharpness was determined by lead foil, casting, beam of light and the fingernail methods. The orifice plates were replaced if any degradation was observed. Each of the meter tubes was also documented as to circularity, steps/gaps present, pipe roughness, and pipe diameter. The pipe wall roughness was determined by the profilometer and the artifact methods. The meter tubes were of a three-section design to facilitate inspection and future installation effects research. Special care was taken to assure that the experiments were randomized so that any experimental bias within a laboratory would be eliminated. This also permitted the use of statistical tests of significance, confidence levels, and time-dependent analysis. Determination of measurement precision and assessment of the uncontrolled variables which might affect the results was made possible by replication of the independent bivariate data points

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(discharge coefficient, Reynolds number). By using different laboratories, the possibility of systematic bias originating from any one laboratory could be identified, investigated, and corrected. The experiments were performed on four fluids; oil, water, natural gas, and air which allowed a wide variety of Reynolds numbers to be explored. The API/GPA experiments were performed on oil, water and natural gas using only flange tapped orifice meters. The European experiments were performed on water, dry air, and natural gas and utilized corner, radius and flange tapped orifice meters. A total of eleven laboratories participated in the experiments. The experiments covered a combination of 12 meter tubes representing five pipe diameters, and 106 orifice plates, resulting in eight Beta ratios tested. The range of Reynolds number studied was from 100 to 35,000,000. API/GPA Sponsored Research Only the experiments conducted on oil and water were included in the regression quality data base. The experiments were conducted on 2, 3, 4, 6, and 10 inch pipe diameters with pipe wall roughness of approximately 150 microinches which was representative of commercially available meter tubes. The following Beta ratio and pipe diameters were included in the experimental pattern: Beta ratio 0.050 0.100 0.200 0.375 0.500 0.575 0.660 0.750 x x x x x x x Nominal Tube Diameter, Inches 2 3 x x x x x x x x 4 x x x x x x x x x x x x x x x x x x x x x x 6 10

Sprenkle flow conditioners were utilized to assure isolation from laboratory induced piping configuration influences in addition to the 45 pipe diameters of upstream straight pipe. Velocity profile tests were performed to confirm that fully-developed, uniform, swirl-free flow profiles were present. Low Reynolds Number Experiments The Colorado Engineering Experimental Station Incorporated in Nunn, Colorado was the site for the low Reynolds number tests. The experiments were performed utilizing a white mineral oil with nominal viscosity of 8 centipoise. The density and viscosity of the mineral oil was characterized to empirically predict flowing density and viscosity. The mass flow rate was calculated using a traditional liquid turbine meter, a small volume prover and empirical density. Intermediate Reynolds Number Experiments The experiments in this area were performed at the National Institute of Science and Technology (NIST, which used to be known as the NBS) Flow Laboratory located in Gaithersburg, Maryland. Potable water with a nominal viscosity of 1 centipoise was used as the testing medium. The mass flow rate was calculated using a traditional weigh tank and empirical density. Kells water density equation was utilized to predict the water density as a function of temperature. High Reynolds Number Experiments These experiments were conducted at the Natural Gas Pipeline of Americas (NGPLA) Natural Gas Facility located at Joliet, Illinois. The nominal viscosity of the natural gas utilized was 0.01 centipoise. The mass flow rate was determined with sonic flow nozzles and an empirical PVT arrangement. An on-line gas chromatograph was utilized to characterize the density and viscosity. This data was not included in the regression data base due to inability to control all of the variables.

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European Experiments The CEC Discharge Coefficient Research experiments used 4 and 10 inch meter tubes over a Beta range of 0.2 to 0.75 at eight different laboratories. Uniform velocity profiles were achieved by the use of long (80 pipe diameters) of upstream lengths and flow conditioners were used to assure isolation from laboratory induced piping configurations. Velocity profile tests were performed to assure the presence of fully developed, uniform, swirl-free flow profiles. Regression Data Base The data was analyzed for laboratory bias. No bias was found for the low and intermediate Reynolds number tests performed in the U. S.. The CEC data was found to be randomized by graphical analysis of the data. In November of 1988, a meeting of interested international orifice metering experts met and agreed that the regression data base would be defined as follows: The Regression Data Set shall consist of those data points contained in the API/GPA and CEC discharge coefficient experiments which were performed on orifice plates whose diameter was greater than 0.45 inches, and if the pipe Reynolds number was equal to or greater than 4000 (turbulent flow regime). The number of regression data points are summarized as follows: Tapping Flange Corner Total Points Number of Points 5,734 2,298 10,192

Radius (D-D/2) 2,160 The following data details the data points taken on flange tapped orifice meters as a function of tube size: Tube Size
Beta

2 0 60 113 90 196 212 775

3 0 57 69 72 64 101

4 0 271 287 164 435 289 458

6 29 83 122 109 136 92 130 701

10 79 257 202 164 390 303 490 1885

Total 108 728 821 619 1123 944 1391 5734

0.100 0.200 0.375 0.500 0.575 0.660 0.750 Totals

104 106

469 1904

The following data details the data points taken on flange tapped orifice meters as a function of Reynolds number: Reynolds Number 4000 To Pipe 2.000 10000 112 104 to 10
5

105 to 10
6

106 to 10
7

107 to 108 Total 0 775

414

249

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3.000 4.000 6.000 10.000 Total

22 95 68 41 338

209 622 275 300 1820

238 1004 328 927 2746

0 183 30 467 680

0 0

469 701

0 1904 150 1885 150 5734

Tests were not included if they contained uncontrolled independent variables and/or operator errors. Data points were only discarded if a physical cause could be identified and both the laboratory and API/GPA or CEC experts concurred on the evidence. Points which were questionable and considered statistical outliers were not discarded. Data which was discarded was kept in a data base of comparison quality. The comparison data base includes the OSU 303 data points, the 1983 NBS Boulder experiments, the Foxboro-Columbus-Daniel 1,000 data points, the API/GPA Joliet data, and the Japanese water data base. Equation Previous forms of the discharge coefficient (Buckingham, Murdock, Dowdell, and others) were empirically derived expressions. Jean Stolz derived an empirical orifice equation based on the physics of an orifice meter in 1978. The equation has been termed the Stolz linkage form. The new coefficient of discharge equation developed by M.J. Reader-Harris and J. E. Gallagher, the RG equation, was an evolution from the work of Stolz. The RG equation was adopted at a joint meeting of the North American and EC flow measurement experts by unanimous vote in November 1988. The RG equation is made up of several terms, an infinite discharge coefficient for corner taps, a slope term consisting of a throat Reynolds number term, a velocity profile term, and the near field tap terms. A very good explanation of the various terms can be found in API Manual of Petroleum Measurement Standards Chapter 14 Section 3 Part 4. The equation is an iterative equation which is applicable on pipe sizes of 2 inches and larger, diameter ratios of 0.10 to 0.75 provided that the minimum orifice bore is greater than 0.45 inches and the pipe Reynolds number is greater than 4000. The equation was found to fit the new Regression Data better than any other equation. Due to the common use of computers it was felt that this equation was not overly complicated. The new standard implementing the RG equation was published in four parts to provide ease of future modifications. It is recognized that additional data will require slight modifications to fine tune the RG equation. The primary reason that the standard was published in parts is due to the fact that little installation specification changes were made to this edition. Insufficient data existed to make changes in as much as the data available had not been duplicated by another laboratory. Installation affects research has been performed at Southwest Research Institute funded by API and GRI. Other installation affects work was performed at NIST Gaithersburg and NIST Boulder, as well as work done in industry by NOVA and Pacific Gas and Electric. This resulted in modifications to the Part 2 originally published in February 1991. PRESENT STANDARD The latest revision of A.G.A. Report No. 3 Orifice Metering of Natural Gas and Other Related Hydrocarbon Fluids (API Manual of Petroleum Measurement Standards, Chapter 14.3; GPA 8185-90) consists of the following four parts: Part 1 General Equations and Uncertainty Part 3 Natural Gas Applications, Published August 1992 Part 4 Background, development, Implementation Procedure, and Subroutine Documentation Published November 1992 Guidelines, Published September 1990 Part 2 Specifications and Installation Requirements, Published April 2000

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FUTURE STANDARDS DEVELOPMENT As additional research is performed and verified, the standards will be modified to incorporate the new information. SUMMARY The latest standard represents substantial improvement in the knowledge and understanding of orifice measurement. The RG equation fits the available data well and far better than previous equations. However, standards development is an ongoing process to improve accuracy and efficiency. As new knowledge is confirmed expect changes in Part 2 of the new standard. REFERENCES 1. Teyssandier, R.G., Gallagher, J.E., Beaty, R.E., Review of API Chapter 14.3 MPMS (A.G.A. #3) Discharge Coefficient Equation International School of Hydrocarbon Measurement Proceedings, May 1991, Norman, Oklahoma. 2. Buxton, E.E., Development of Orifice Meter Standards Past, Present and Future and a Discussion of Orifice Meter Statistics, International School of Hydrocarbon Measurement Proceedings, May 1992, Norman, Oklahoma. 3. Teyssandier, R.G, Beaty, R. E., Gallagher, J.E., The Industrys Revised Orifice Metering Standard, International School of Hydrocarbon Measurement Proceedings, May 1992, Norman, Oklahoma. 4. API MPMS Chapter 14 Section 3 (ANSI 2530, A.G.A. Report No. 3), Concentric, Square-Edged Orifice Meters Part 4 Background, Development, Implementation Procedures and Subroutine Documentation:, American Petroleum Institute, November,1992, Washington, D. C., USA.

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