DGS-IE-001-Rev-0

Abu Dhabi Oil Refining Company

FLOW INSTRUMENTS DGS-IE-001 Rev-0 March 2006

Takreer DGS-IE-001-Rev-0 March-2006 Printed 22-Jul-09 13:23:41 Initials Page 1 of 14

FLOW INSTRUMENTS

Amendment History

No Date Amendment Description Proposed Approved Incorporated

DGS History

0 March 2006 DGS-IE-001-Rev-0 Previous Project / Lessons Learnt Incorporated

HM/DDC ETSDM / EPDM

No Date Description Source Reviewed Approved

DGS-IE-001 Rev-0




TABLE OF CONTENTS

1.0 GENERAL ................................................................................................................................3 1.1 INTRODUCTION.............................................................................................................3 1.2 PURPOSE.......................................................................................................................3 1.3 DEFINITIONS .................................................................................................................3

2.0 CODES AND STANDARDS .....................................................................................................3 3.0 REFERENCE DOCUMENTS ...................................................................................................4 4.0 DOCUMENT PRECEDENCE...................................................................................................4 5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ......................................................5 6.0 QUALITY ASSURANCE/QUALITY CONTROL ........................................................................5 7.0 DOCUMENTATION - GENERAL..............................................................................................6 8.0 SUBCONTRACTORS/SUBVENDORS ....................................................................................6 9.0 HANDLING...............................................................................................................................7 10.0 DESIGN ...............................................................................................................................7

10.1 GENERAL .......................................................................................................................7 10.2 DIFFERENTIAL PRESSURE TRANSMITTERS .............................................................8 10.3 POSITIVE DISPLACEMENT METERS...........................................................................8 10.4 TURBINE METERS ........................................................................................................9 10.5 MAGNETIC METERS ...................................................................................................10 10.6 VARIABLE AREA FLOW METERS ...............................................................................10 10.7 VORTEX METERS........................................................................................................ 11 10.8 ULTRASONIC FLOW METERS.................................................................................... 11 10.9 FEED AND PRODUCT STREAM FLOW METERING ..................................................12 10.10 CORIOLIS METERS .....................................................................................................12

11.0 INSTALLATION ......................................................................................................................13 11.1 DIFFERENTIAL PRESSURE TRANSMITTERS ...........................................................13 11.2 VARIABLE AREA FLOW METERS ...............................................................................13 11.3 TURBINE METERS ......................................................................................................13 11.4 POSITIVE DISPLACEMENT METERS.........................................................................13 11.5 CORIOLIS METERS .....................................................................................................14 11.6 OTHER FLOW METERS ..............................................................................................14

List of Authorized Signatures/ Initials

DGS Discipline Committee Member, ADRD ------------------------------

DGS Discipline Committee Member, RRD ------------------------------

DGS Discipline Committee Member Leader, E&PD Hazem Marzouk (HM)

Engineering & Technical Services Manager, E&PD Quazi Abdul Matin (QAM)

Engineering & Projects Division Manager, E&PD Mohamed Al Yabhouni (MAY)




1.0 GENERAL

1.1 INTRODUCTION

This specification, and the practices and standards referenced herein provides the basis for engineering and design of the flow instruments to be provided for the ABU DHABI OIL REFINING COMPANY (TAKREER) in the United Arab Emirates.

1.2 PURPOSE

The purpose of this specification is to establish the minimum technical requirements and standards for the flow instruments for the Project.

1.3 DEFINITIONS

CONCESSION REQUEST - A deviation requested by the CONTRACTOR or VENDOR, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.

SHALL - Indicates a mandatory requirement.

SHOULD - Indicates compliance is strongly recommended.

2.0 CODES AND STANDARDS

It shall be the VENDOR’S responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The following codes and standards shall, to the extent specified herein, form a part of this specification. The latest edition in force shall apply.

American Petroleum Institute (API)

Manual of Petroleum Measurement Standards (MPMS):

Chapter 4 Proving systems

Chapter 5 Metering

Chapter 5.1 Foreword, General Considerations and Scope of Metering

Chapter 5.2 Measurement of Liquid Hydrocarbons by Displacement Meter Systems

Chapter 5.3 Turbine Meters

Chapter 5.4 Instrumentation or Accessory Equipment for Liquid Hydrocarbon Metering Systems




Chapter 6 Metering Assemblies

Chapter 6.6 Pipeline Metering Systems

Chapter 6.7 Metering Viscous Hydrocarbons

Chapter 12 Calculation of Petroleum Quantities

Chapter 12.2 Calculation of Liquid Petroleum Quantities Measured by Turbine or Positive Displacement Meters

Chapter 12.2 Field Manual

Instruction for Calculating Liquid Petroleum Quantities Measured by Turbine or Displacement Meters

International Organization for Standardization (ISO)

ISO 9001-2000 Quality Management System Requirements

ISO 9004-2000 Quality Management Guidelines for Performance Improvement System

ISO 9011 Quality Management Guidelines for Performance Improvement System

3.0 REFERENCE DOCUMENTS

Project Specifications

DGS-IE-002 dP Type Flow Elements and Meter runs

DGS-IU-001 Instrumentation and Control

DGS-IU-002 Instrument Installation Design

DGS-IU-004 Instrument Storage and Calibration

DGS-MU-002 Preservation and Export Packing

DGS-MU-014 Minimum Shop Inspection and Certification Requirements

Project Drawings

STD-PU-00004 Piping Standard Drawing Flange Tap Orientation, Clearances and Meter Runs

4.0 DOCUMENT PRECEDENCE

It shall be the VENDOR’S responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The VENDOR shall notify the CONTRACTOR of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and/or interpretation precedence shall be




obtained from the CONTRACTOR in writing before proceeding with the design/manufacture.

In case of conflict, the order of precedence shall be stated in the AGREEMENT or other PROJECT documents as applicable.

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the VENDOR only through CONCESSION REQUEST format. CONCESSION REQUESTS require CONTRACTOR’S and COMPANY’S review/approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

6.0 QUALITY ASSURANCE/QUALITY CONTROL

The VENDOR shall have in effect at all times, a QA/QC program which clearly establishes the authority and responsibility of those responsible for the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action.

VENDOR’S proposed quality system shall fully satisfy all the elements of ISO 9001 - 2000 and ISO 9004 - 2000. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design.

A copy of the VENDOR’S QA/QC program shall be submitted to the CONTRACTOR with its quotation for CONTRACTOR’S review and concurrence prior to award. If VENDOR’S QA/QC program and facility, where the work is to be performed, is ISO 9001 certified, then only a copy of the VENDOR’S ISO 9001 certificate is required. In addition, if VENDOR’S facility is ISO certified, CONTRACTOR’S QA audit requirements will be waived in favor of ISO 9001 registrar audits, unless the CONTRACTOR’S trend analysis program indicates areas of concern.

The VENDOR shall identify in purchase documents to its SUBVENDORS all applicable QA/QC requirements imposed by the CONTRACTOR, and shall ensure compliance thereto. On request, VENDOR shall provide objective evidence of its QA/QC surveillance of its SUBVENDOR’S activities.

The VENDOR shall submit certified reports of production tests as soon as the tests are completed satisfactorily.

The COMPANY/CONTRACTOR reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests. The VENDOR, 30 days after award but prior to the pre-inspection meeting, shall provide the CONTRACTOR with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory COMPANY/CONTRACTOR witness points.




A Criticality Rating (CR) for each flow meter is listed on the data sheet or line list. The CR shall be used for various design and inspection functions by the CONTRACTOR.

7.0 DOCUMENTATION - GENERAL

The MANUFACTURER/VENDOR shall submit the type and quantity of drawings and documentation for CONTRACTOR’S authorization or information as listed in the individual Material Requisitions and Purchase Orders. For each type of document to be produced, a basic format shall be submitted for review and approval.

Mutual agreement on scheduled submittal of drawings and engineering data shall be an integral part of any formal Purchase Order. Where drawing presentation is not defined, CONTRACTOR shall send an example of type to be used for COMPANY approval before the start of actual drafting.

Comments made by CONTRACTOR on drawing submittal shall not relieve VENDOR or SUBVENDORS of any responsibility in meeting the requirements of the specifications. Such comments shall not be construed as permission to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing. Any request for approval shall be obtained prior to large scale application.

Each drawing shall be provided with a title block in the bottom right-hand corner incorporating the following information:

• Official trade name of the VENDOR.

• VENDOR’S drawing number.

• Drawing title giving the description of contents whereby the drawing can be identified.

• A symbol or letter indicating the latest issue or revision.

• PO Number and item tag numbers.

• TAKREER Logo.

Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given, and if applicable, the authority and date of the revision shall be listed. The term “Latest Revision” shall not be used.

8.0 SUBCONTRACTORS/SUBVENDORS

The VENDOR shall assume unit responsibility and overall guarantee for the flow instruments, and associated equipment.

The VENDOR shall transmit all relevant purchase order documents including specifications to his SUBVENDORS and SUBCONTRACTORS.




It is the VENDOR’S responsibility to enforce all Purchase Order and Specification requirements on his SUBVENDORS and SUBCONTRACTORS.

The VENDOR shall submit all relevant SUBVENDOR and SUBCONTRACTOR drawings and engineering data to the CONTRACTOR.

The VENDOR shall obtain and transmit all SUBVENDOR and SUBCONTRACTORS warranties to the CONTRACTOR/COMPANY, in addition to the system warranty.

9.0 HANDLING

Preparation for shipment shall be in accordance with the VENDOR’S standards and as noted herein. VENDOR shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers.

Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the jobsite.

Preparation for shipment and packing will be subject to inspection and rejection by COMPANY’S/CONTRACTOR’S inspectors. All costs occasioned by such rejection shall be to the account of the VENDOR.

After inspection and test, equipment shall be completely free of water and dry before start of preparation for shipment.

All equipment and material shall be preserved and export packed in accordance with Project Preservation Specification, DGS-MU-002.

10.0 DESIGN

10.1 GENERAL

For all flow applications that do not require other types, use differential pressure instruments and concentric orifice plates. For this type, flow measurement accuracy is reliable over a 3-1 rangeability. For 10-1 rangeability, use rotameters, turbine meters, vortex shedding meters, and positive displacement meters.

For lines under 2 inches and other special applications, use integral orifice meters, target meters, corner tap calibrated runs, rotameters, turbine meters, positive displacement meters.

For viscous flows, use quadrant edge orifices, target meters and positive displacement meters. For corrosive fluids, use magnetic meters and rotameters. For low differential pressure loss, use venturi, pitots, proprietary averaging pitot tubes, and vortex shedding meters.

For material balance and sales meters, flow shall be compensated. Custody transfer meters shall have their own meter prover.




All flow instruments shall conform to the electrical, environmental and general requirements in DGS-IU-001, Instrumentation and Control.

For information regarding dP type flow elements and meter runs, refer to Project Specification DGS-IE-002.

10.2 DIFFERENTIAL PRESSURE TRANSMITTERS

Electronic differential pressure Transmitters shall be blind solid state strain gauge, or capacitance, diffused silicon or semi-conductor type.

The DP transmitters shall be “smart” type used in analog mode and output signal be 4-20 mA DC (2 wire system).

All instruments shall have over-range protection up to the maximum permissible static pressure of the instrument.

Use of Liquid Filled seal type instruments require COMPANY approval.

The body and all wetted parts in contact with process fluids shall be a minimum of 316 stainless steel unless service conditions require higher metallurgy. In any event, the metallurgy selected shall be fit for the intended use and subject to COMPANY approval.

Based on a square root scale or chart reading of 1-10, the flow meter shall be ranged for a reading at:

• Maximum flow between 9.0 and 9.8 of the scale

• Normal flow between 7.0 and 7.5 of the scale

• Minimum flow not below 4.5 of the scale for flow meters used in accounting, material balancing and alarm or tripping services.

• Minimum flow not less than 3.0 of the scale for other services.

Where conflicting flow ranges are encountered, multiple dP transmitters (up to a maximum of three) shall be used with different but overlapping ranges.

10.3 POSITIVE DISPLACEMENT METERS

Positive displacement meters may be used for batch operations, or high accuracy totalizing when rate of flow is not required. A removable strainer shall be installed ahead of each meter.

Positive displacement meters shall have flanged connections. The body shall be rated for the design pressure and temperature per the line class. The body material shall be carbon steel, unless the line class specifies otherwise. The body design shall minimize the effects of piping stress and vibration. The construction shall facilitate cleaning, inspection and service.




The material for the internal moving parts shall be selected based on process conditions and type of meter applied. For gear type meters 316 SS or Alloy 20 gears and shafts shall be considered. For rotor type meters, heat treated aluminum or nickel plated cast iron rotors, nitrided alloy steel shafts and stainless steel bearings shall be considered. For rotary blade type meters, heat treated aluminum, nickel plated cast iron, or 316 SS blades with stainless steel sealed bearings shall be considered.

Positive displacement meters shall normally have a direct coupled pulse generator and be provided with signal amplifiers mounted close to the meters. For fluids that are toxic or highly dangerous, magnetically coupled pulse counters shall be used.

Positive displacement meters are not recommended for use with nonlubricating liquids such as propane, butane, etc., and when applied for such liquids they shall be provided with automatic pressure lubrication of bearings, gears, etc.

• Flow limiting devices shall be considered to prevent over-ranging of positive displacement meters.

• Certain types of positive displacement meters have their maximum capacity limited not only by flow, but also by the maximum allowable pressure drop across the meter. Consideration shall be given to limiting the maximum pressure drop especially when the meter is used with liquids having a high viscosity.

• Meters shall be protected against damage due to hydraulic shock, caused for example by quick opening or closing of a valve.

• Positive displacement meter systems shall be in accordance with API MPMS 5.2.

The selections between turbine meters and positive displacement meters should take into account the following considerations:

• The application of turbine meters is normally limited to products with relatively low viscosities, typically 10 mm2/s (10 cSt); positive displacement meters are recommended for higher viscosities only.

• Turbine meters are preferred for use with nonlubricating liquids such as LPG, gasoline, water, etc.

• Turbine meters require a straight length in the upstream piping.

10.4 TURBINE METERS

Turbine meters shall have flanged connections. The body shall be rated for the design pressure and temperature per the line class. The body material shall be carbon steel, unless the line class specifies otherwise.

The material for the internal moving parts shall be selected based on process conditions. For rotors, aluminum and 316 SS shall be considered. For inlet diffusers, stainless steel shall be considered. Bearings shall be tungsten carbide. Rotor




shrouds shall be used when measuring higher viscosity fluids or fluids having varying viscosity.

Turbine meters shall be selected based on the meter’s area of operation. Adequate meter backpressure must be verified to avoid cavitation.

Due consideration shall be given to prevent turbine meters from over-ranging and from suffering hydraulic shock.

All turbine meters shall have signal amplifiers mounted close to the meter. Turbine meter systems shall be in accordance with Chapter 5.3 of the API Manual of Petroleum Measurement Standards.

Flow straighteners may be used with turbine meters.

Turbine meter may be used on clean liquid streams where high accuracy or greater flow rangeability is required.

Applications include accounting streams and in-line blending.

10.5 MAGNETIC METERS

Magnetic meters may be used for severe liquid services such as slurries, some corrosive fluids and gravity flow. Liquid must be at least slightly conductive.

Magnetic flow meters shall have flanged connections. The metering tube shall be rated for the design pressure and temperature per the line class. The metering tube material shall be 304 SS, unless the line class specifies otherwise. The meter tube shall be lined with a material suitable for the application. For tube liners, Teflon, Kynar, polyurethane, and in some applications, ceramics shall be among the materials considered. The liner shall be attached to the tube such that the partial or full vacuum will not cause the liner to collapse. The field coils and cores shall be field replaceable without removing the tube from the line and without affecting calibrated accuracy.

The material for the electrodes shall be selected based on process conditions. For electrodes, 316 SS, tantalum, Monel, Hastelloy C, titanium, platinum, or Alloy 20 shall be considered. Ultrasonic cleaning shall be considered where the process fluid may coat the electrodes. Grounding rings shall be furnished to assure that the fluid is at the same potential as the flow meter.

The transmitters for magnetic flow meters shall be integrally mounted where the metering tube is accessible or remotely where the metering tube is inaccessible. The transmitters shall be of a “smart” type microprocessor based design. The calibration parameters shall be stored in nonvolatile memory, and be capable of being reconfigured in the field. The transmitter shall display both the flow rate and totalized flow.

10.6 VARIABLE AREA FLOW METERS

Variable Area Flow Meters (Rotameters) may be used;




• where a suitable orifice installation cannot be used

• for highly viscous or highly corrosive materials

• for fluids containing solids in suspension

• when rangeability greater than 3:1 is required

Glass tube meters with light metal protective cases are used for air and water unless the temperature or pressure exceeds the meter rating. Meters on other services will be armored type, either metal tube, or glass tube within a pressure sealed enclosure. Indicating scales are graduated 0 to 100 and a scale factor is used.

Rotameter transmitters shall be magnetically coupled type. Local indication is by a deflection pointer and scale.

10.7 VORTEX METERS

Vortex meters may be used for the following application:

• Reynolds number higher than 20,000 (best performance for RE > 100,000).

• Flow rates which will not go beyond 115 to 120% of the design value (to prevent damage to shedding bar).

Vortex shedding type flow meters shall have flanged connections. The metering tube shall be rated for the design pressure and temperature per the line class. The metering tube and shedding bar material shall be 316L SS, unless the line class specifies otherwise.

The meter shall be sized giving due consideration to the operating limits and turndown capabilities stated by the MANUFACTURER/ VENDOR.

The transmitters for vortex flow meters shall be integrally mounted where the metering tube is accessible or remotely where the metering tube is inaccessible. The transmitters shall be of a “smart” type microprocessor based design. The calibration parameters shall be stored in nonvolatile memory, and be capable of being reconfigured in the field. The transmitter shall display the flow rate.

10.8 ULTRASONIC FLOW METERS

Ultrasonic flow meters of the leading-edge (time of flight or transit time) type may be considered where no restrictions in the flow stream are allowed or a rangeability of more than 3 : 1 is required and:

• An electromagnetic meter would be unsuitable

• The fluid is a liquid without any second phase, at a temperature suitable for the meter which will be used.




10.9 FEED AND PRODUCT STREAM FLOW METERING

Feed and product streams of offsite area and process units shall be measured to enable accurate mass balances be made.

All custody transfer meters should be of reliable and proven design such as Turbine meters and Positive Displacement meters (PDMs). New mass measurement techniques such as coriolis meters may be used if proven. Necessary calibration and proving facilities shall be provided such as meter provers or high accuracy calibration meters. Pressure, temperature, density corrections, as required, shall be provided.

The necessary meter accuracy shall comply with the requirements of Advanced Process Control (APC) and RIS applications which require high accuracy flow metering within a unit; flow totalizing and balance shall be performed continuously within the process control/optimization system, enabling losses/ upsets/ off-spec performance to be identified quickly and operational corrections to be made. Application examples would include but not limited to:

• Utilities balance

• Energy balance

• Heat balance

• Component balance

• Mass balance

10.10 CORIOLIS METERS

Coriolis type flowmeters shall in general be preferred for critical flow metering applications requiring highly accurate and reliable measurements of mass flow and density. The mass flow measurement shall be unaffected by changes in temperature, pressure, flow profile, viscosity and small volumes of air or gas in the flowing stream.

The flow meter shall have flanged connections. The flow meter shall be rated for the design pressure and temperature per the line class. The flow meter shall normally be 316L SS inside a 304L SS housing unless the line class specifies otherwise. The sensor shall be comprised of flow tubes which are vibrated at their natural frequency by an electromagnetic drive system and shall incorporate electromagnetic sensors located on each side of the flow tube assembly to measure the phase shift resulting from a “twist” in the flow sensor tubes, which is directly proportional to the mass flow. The natural frequency is a function of density and shall also be measured.

The transmitters for Coriolis flow meters shall be integrally mounted where the metering tube is accessible or remotely where the metering tube is inaccessible. The transmitters shall be of a “smart” type modular microprocessor based design. The calibration parameters shall be stored in nonvolatile memory, and be capable of being reconfigured in the field. The transmitter shall provide two independently configure 4-20 mA analog outputs, proportional to flow rate, density or temperature; one frequency output proportional to flow rate and independent of the analog outputs; one digital




output indicating flow direction, fault alarm, or zero in progress. The transmitter shall display the flow rate.

11.0 INSTALLATION

11.1 DIFFERENTIAL PRESSURE TRANSMITTERS

For installation requirements of differential pressure transmitters see Project Specification DGS-IU-002.

11.2 VARIABLE AREA FLOW METERS

Variable area flow meters shall be mounted with the center of the indicating scale at approximately 1.3 m above grade or platform and in such a way that maintenance can easily be carried out. Sufficient clearance shall be provided over and under the meters for dismantling, cleaning or repair.

The meters shall always be mounted in a true vertical position and in such a way that strain or stress caused by the weight of unsupported lines or by thermal expansion is prevented.

The meters shall be offset from the main line and be located between block valves. A bypass valve shall be provided in the main line. Block valves shall of the same size as the meter connections. The bypass valve shall be of the same size as the main line.

Variable area meters with a top extension shall have a vent line with a 1/4 inch NPT needle valve. Where feasible, the vent line shall have a permanent connection to a point down-stream of the meter. This point shall have a sufficiently lower pressure to ensure a continuous escape of possible vapors from the meter extension, if required.

11.3 TURBINE METERS

For accurate measurement with turbine meters the velocity profile of the fluid needs to be uniform. Therefore flow straightening should be accomplished by providing sufficient straight length immediately upstream and downstream of the turbine meter. Where the available space is limited, a combination of straight pipe and flow straighteners may be employed.

For each application, certified dimensional drawings shall be consulted for sizes and flange ratings of meter and ancillary equipment.

11.4 POSITIVE DISPLACEMENT METERS

In view of their considerable mass, especially for large sizes, positive displacement meters and their ancillary equipment, such as filters and vapor eliminators shall be installed such that they are well supported, and can easily be reached by hoisting equipment.

Adjacent piping shall not exert any stress on the meter body.




For each application the (certified) dimensional drawings shall be consulted for sizes and flange ratings of the meter and ancillary equipment.

11.5 CORIOLIS METERS

The selected location for Coriolis type flow meters must be free of sources of electromagnetic interference and vibration. The inlet and outlet piping must be anchored securely to avoid transmitting stresses and vibration to the flow meter.

For liquid flow meters, the sensing tubes must be mounted such that slug flow is minimized and entrained gases can exit the meter. In addition, the piping must remain full during operation. Adequate backpressure must be maintained to avoid flashing and cavitation.

For gas flow meters, the sensing tubes must be mounted such that any liquids can freely drain from the meter.

11.6 OTHER FLOW METERS

Meter runs for vortex, ultrasonic, thermal and magnetic flow meters shall be in accordance with drawing STD-PU-00004.

For flow meters not covered in this section, the MANUFACTURER’S documentation shall be consulted for installation requirements.

Documents

DGS-IE-001-Rev-0