Ben Leach Managing Director, Swinton Technology

Ben Leach Managing Director, Swinton Technology As Managing Director of Swinton Technology Ltd, whose core business is the supply of oil and gas metering computer system solutions and associated services, Ben s role involves general management of the company with a particular emphasis on Commercial Matters and Business Development

Flow Computers & Control Systems Interface or Integrate?

This Presentation. What is a traditional metering computer system? Historical computer system changes 25 years DCS embedded metering computer systems Conclusion

What Is A Traditional Metering Computer System? Supervisory Computer Stream 1 Stream 2 Stream 3

What Is A Traditional Metering Computer System? Key Components Single or Multi-stream flow computers Redundancy at stream level Single serial communication link to supervisory computer Sometimes separate prover flow computer Bespoke supervisory computer Data handoff to higher level systems Serial modbus

What Is A Traditional Metering Computer System?

What Is A Traditional Metering Computer System?

What Is A Traditional Metering Computer System? Flow Computers - Legacy ROM based Very limited configurability Very secure / lead seal

What Is A Traditional Metering Computer System? Flow Computers - Current

What Is A Traditional Metering Computer System? Flow Computers - Current Configurable products No software coding HART connectivity (data subset) Multi-stream capability Obsolescence Far shorter support period

What Is A Traditional Metering Computer System? Supervisory Computers - Enhanced Features Communications Hardware - Ethernet Redundant Networks Protocols OPC / ODBC / Modbus Data Historians Remote Connectivity

What Is A Traditional Metering Computer System? Supervisory Computers - Enhanced Features Constants Management FC data entry via supervisory HMI System comparison highlights errors Automated update following validation checks and fc replacement avoids finger trouble etc. Requires a 64 bit system Storage of flow computer reports Back up purposes

What Is A Traditional Metering Computer System? Supervisory Computers - Enhanced Features Integrated Diagnostics DP Meter Diagnostics USM Diagnostics Totalisation Not New But Now Considered Advanced Stream and Station Increments Retains totals when flow computer is reset or replaced

What Is A Traditional Metering Computer System? Supervisory Computers - Hardware Off The Shelf Bespoke

What Is A Traditional Metering Computer System? Supervisory Computers - Software Bespoke Software Off The Shelf SCADA Packages Still Bespoke Software (But With Constraints)

What Is A Traditional Metering Computer System? Supervisory Computers - Software

What Is A Traditional Metering Computer System? Most Common Architecture Supervisory Computer Still The Same Stream 1 Stream 2 Stream 3

What Is A Traditional Metering Computer System? Despite Rapid Technology Change

What Is A Traditional Metering Computer System? Despite Rapid Technology Change

What Is A Traditional Metering Computer System? Despite Rapid Technology Change

What Is A Traditional Metering Computer System? Despite Rapid Technology Change

What Is A Traditional Metering Computer System? No Standard Design

What Is A Traditional Metering Computer System? Contrasting Condition Of Systems We see prestine metering systems But also the opposite! Poor State No Spares Low Metering Integrity

DCS Embedded Metering Computer Systems ERP Systems Distributed Control System (DCS) Metering Supervisory Computer (MSC) ERP Systems Distributed Control System (DCS) Flow Computers FIELD FIELD

DCS Embedded Metering Computer Systems

DCS Embedded Metering Computer Systems Why Look For An Alternative @ 2004? Drive Within The Industry For Change Scalable solutions Move away from bespoke systems Reduced cost Enhanced future support Discussions With Two Major Operators

DCS Embedded Metering Computer Systems Common Functions 1. Processor 2. I/O Capability 3. User Interface 4. Data Hand-off

HAS Historian Email Spreasheets Period Reporting 4 Hourly Report Metering STREAM 1 STREAM 2 GVOL xxxxxxx xxxxxxxx SVOL xxxxxxx xxxxxxxx Mass xxxxxxx xxxxxxxx GVOL FR xxxxxxx xxxxxxxx SVOL FR xxxxxxx xxxxxxxx Mass FR xxxxxxx xxxxxxxx DCS Temp xxxxxxx xxxxxxxx Pressure xxxxxxx xxxxxxxx Line Dens xxxxxxx xxxxxxxx Std Dens xxxxxxx xxxxxxxx Pipeline Integrity Systems

How Does Control System Technology Compare? DCS Embedded Metering Computer Systems Common Functions 1. Processor 2. I/O Capability 3. User Interface 4. Data Hand-off

DCS Embedded Metering Computer Systems Perceived Benefits Of DCS Incorporating Metering Single technology for both metering and control system Reduced Cost especially for large systems Enhanced support Infrastructure

DCS Embedded Metering Computer Systems Why Honeywell? Major oil and gas player Technology appeared appropriate Scalable, IEEE 64 bit Management desire to perform the trials

DCS Embedded Metering Computer Systems Gas System Evaluation Objective @ 2004 Assess the suitability of Control Systems for Custody Transfer & Allocation Metering Applications

DCS Embedded Metering Computer Systems Gas System Evaluation Why Gas? Ref: ISO 5167-1:2003(E) Equation 1 The standard uses d in meters and p in Pascals. Where d is in mm and p in mbar. ISO 5167 states: q q q m Therefore for mm and mbar C 3 2 2 m 1 d x 10 2 p x 10 p 1 where: C D 1 C 4 1-4 1- C 1 d 4 4 4 2 2 p 2 5 m 1 d 2 p 1 x 10 4 1 1 1 Discharge coefficient Orifice diameter at operating conditions (mm) Fluid density at upstream tapping (kg/m3) Diameter ratio at line conditions Qm qm x t x 0.001 where: qm is the mass flow rate (kg/s) t is the increment in time since the last totalisation.

DCS Embedded Metering Computer Systems Gas System Evaluation Architecture Single Server & HMI Redundant Controller C200 Controller Field I/O Foundation Fieldbus, HART or Traditional (4-20mA) Devices

DCS Embedded Metering Computer Systems Gas System Evaluation Challenges Functionality Reliability Security Accuracy / Uncertainty Customer / Regulator Acceptance

DCS Embedded Metering Computer Systems Gas System Evaluation Functionality Temperature, Pressure, Differential Pressure and Density Measurement - Yes Totalisation - Yes Reporting Yes Communications Yes Alarms / events - Yes Flow weighted averages - Yes Control - Yes Calculations AGA Yes / ISO 5167 and 6976 - No Restart from power fail - No

DCS Embedded Metering Computer Systems Gas System Evaluation Functionality Temperature, Pressure, Differential Pressure and Density Measurement - Yes Totalisation - Yes Reporting Yes Communications Yes Alarms / events - Yes Flow weighted averages - Yes Control - Yes Calculations AGA Yes / ISO 5167 and 6976 - Yes Restart from power fail - Yes

DCS Embedded Metering Computer Systems Gas System Evaluation Reliability Designed for critical applications High availability and MTBF Redundancy Server Controller I/O Rack PSU Networks

DCS Embedded Metering Computer Systems Gas System Evaluation Security Builder tools password security Operator workstation passwords security Login set-up so only HMI can be accessed Qualification Version Control System (QVCS) used in pharmaceutical industry Secure totals on power failure Secure process control networks and firewalls

DCS Embedded Metering Computer Systems Gas System Evaluation Accuracy / Uncertainty Accuracy Clock I/O Calculation

DCS Embedded Metering Computer Systems Gas System Evaluation Accuracy / Uncertainty Description Error % Mass Flow Rate -0.023 Mass Total -0.025 Standard Volume Flow Rate -0.023 Standard Volume Total -0.025 Energy Flow Rate -0.023 Energy Total -0.025

DCS Embedded Metering Computer Systems Gas System Evaluation Accuracy / Uncertainty Approach Typical Uncertainty in Mass Flow Rate Measurement (%) Liquid Gas Custody Transfer 0.25 1.00 Allocation 0.50 5.00 2.00 5.00

DCS Embedded Metering Computer Systems Gas System Evaluation Accuracy / Uncertainty Uncertainty Margin, 0.46% Discharge Coefficient Uncertainty, 0.50% Other Uncertainty Contributors, 0.04% Sources Of System Uncertainty Typical Gas Orifice Application (Maximum Flow Rate Measured Density)

DCS Embedded Metering Computer Systems Gas System Evaluation Accuracy / Uncertainty Uncertainty Margin, 0.11% Other Uncertainty Contributors, 0.39% Discharge Coefficient Uncertainty, 0.50% Sources Of System Uncertainty Typical Gas Orifice Application (Minimum Flow Rate Measured Density)

DCS Embedded Metering Computer Systems Gas System Evaluation Customer Acceptance @ 2004

DCS Embedded Metering Computer Systems Gas System Evaluation Regulator Acceptance @ 2004

DCS Embedded Metering Computer Systems Liquid System Evaluation Challenges @ 2006 To Verify That The System Can: Accurately perform the liquid calculations Appropriately handle the turbine meter dual pulse train Prove the meter including pulse gating, four way valve handling, prove sequence and error checking

DCS Embedded Metering Computer Systems Liquid System Evaluation Challenges @ 2006

DCS Embedded Metering Computer Systems Approvals @ 2014 MID approved OIML R117 Approved ERCB Directive 017 compliant DECC / Operator Acceptance Standards

DCS Embedded Metering Computer Systems Widely Adopted and Global Support @ 2014 National Cooperative Refinery Association

DCS Embedded Metering Computer Systems Scaleable@ 2014 Benchmark Tests 20 Gas Streams in 1 Controller (running full AGA8, ISO6976, ISO5167) 20 Liquid Streams in 1 Controller (running full API Calcs )

DCS Embedded Metering Computer Systems High Density I/O / Reduced Panel Footprint @ 2014

DCS Embedded Metering Computer Systems Highly Configurable @ 2014

Connectivity (Everything Is Standard In Control System) DCS Embedded Metering Computer Systems Connectivity Everything Available @ 2014 Wireless Profibus HART

DCS Embedded Metering Computer Systems Integrated Diagnostics @ 2014 Traditional analog diagnostics with oscilloscope and multi-meter. Digital diagnostics with meter dashboards like RMG-view, and many other meter diagnostic packages. Integrated system diagnostics. The Total Energy Measurement concept is Extended Data Mining

SELECT ATTRIBUTE 06 JUN 94 09:07:49 3 AREA POINT ATTR SUMMARY : UNIT GE - GENERIC DEMOS ** ** PARAMETER VALUE1 VALUE2 VALUE3 VALUE4 CLEAR PARAMETERS 1) ALENBST INHIBIT DISABLE 2) 3) 4) 1 2 3 4 ALL ALARM ENABLE STATE PROCESS MODE ALARM ENABLE STATE POINT EXEC STATE MODE ATTRIBUTE POINT VALUE SOURCE RED TAGGED EQUAL TO NOT EQL TO POINT VALUE STATUS OVRRIDE ALRM W/CF ENABLE DISABLE POINT MODE COMPUTER SHED INHIBIT CASCADE REQUEST MODE INITIALIZED SEQ EXEC STATE BYPASS INPUT WINDUP STATE PV CLAMPING OUTPUT WINDUP STATE POINT IN ALARM PRINT DISPLAY DCS Embedded Metering Computer Systems Plant Wide Common Platform @ 2014 Firewall Advanced Enterprise Applications Servers (i.e. MES) POMSnet OptiVision Business.FLEX WorkCenter PKS Business Network Plant Wide Data Warehouse Uniformance/ PHD Process Display Process Data access Web Server Secure Read Only User Access e - Server Operations & Production management Business Agility Web Browser Access for advanced applications Automation Level 4 e - Server, WorkcenterPKS & Uniformance / PHD Automation Level 3 Video as a Process Sensor Digital Video Manager Assets & Production units avalability management Remote Operations and Maintenance Multivariable Control & Optimization Plant Simulation Fault Tolerant Ethernet Experion Station Asset Manager Advanced Control Network Experion Station Alert Manager Profit Suite UniSim TM Video Ethernet Automation Level 2 Fault Tolerant Ethernet User Application Platform i.e: Batch recipies, optimisers, etc Advanced Control Execution (ACE) node Supervisory Control Network Redundant Global Database & Historian Experion Server Web - based Human Interface Experion Station Console Ergonomic Operator Furniture ICON Series Investment Protection Experion for legacy Total Plant Solutions TPS Process & Control Engineering Experion Station Automation Level 1 Wireless Access Field Operator Mobility Mobile PKS Field Rounds Automation IntelaTrac SIL 3 Safety Instrumented System Safety Manager Regulatory, Logic Sequential & Model Based Control Redundant and / or Remote I/O Fieldbus Foundation and / or Hart Foundation C200, C300 Control Firewall Process Manager I/O (PMIO) Foundation Fieldbus Wireless Transmitters Local Control Network High Performance Process Manager (HPM) Basic Controller Experion PKS architecture NL_CBG_Oct_2005

Long Term Support DCS Embedded Metering Computer Systems Long Term Support @ 2014 869M (1982 to 2001) Example: Flow Computer Family S500 (1992 to 2006) Support Time-line S600 (1998 to?? - already revised to S600+ Future? Fisher Products ROC RTU Technology???? Example: Honeywell DCS 1974 To Scale 1998 2002 2005 Support Time-line

DCS Embedded Metering Computer Systems Reduced Lifecycle Costs @ 2014 Integrated Single Technology Solution Single point of contact for project implementation Single database rather than bespoke systems with discrete databases Scalable solution High data accessibility / availability Reduced training costs Reduced spares holding costs Reduced panel footprint Opportunity to reduce operating costs Single support contract / local support Flexible configuration language reduced cost of changes Multiple standard redundancy options Improved connectivity HART, Fieldbus, Profibus etc. Availability of Experion toolset DCS, advanced control, batch control, loop tuning, movements automation, CCTV, safety systems etc. etc. Improved Lifecycle Support Supported a lot longer than flow computers

Conclusion Traditional metering computer systems have changed very little over the last 25 years The most appropriate approach depends on the specific application There are many advantages of using a control system for the metering computing system when it is available in the same technology as the DCS The integrator / implementer must have metering computer system experience

Conclusion Split Of Systems Implemented By Swinton Technology Traditional DCS Embedded

Thank You Ben Leach