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Oil & Gas Production Rosemount Best Practices
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 2 Rosemount Saab Rosemount Micro Motion Brooks Rosemount Analytical Daniel AMS Suite Services & Technologies Mechanical Equipment Electrical Systems Process Equipment Instruments & Valves Fisher Bettis El-O-Matic Shafer Delta V Ovation Industry Centers Chemical Oil & Gas (LNG) Refining Power & Water Life Sciences Metals & Mining Pulp & Paper Food & Beverage Educational Services Measurement & Analytical Systems & Solutions Asset Optimization Final Control Elements Emerson Process Management Overview Revised 02, Dec. 2003, Slide 2
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 3 AgendaAgenda Follow an O&G topsides process flow. In each unit discuss key measurement points, Temperature, Pressure, Level, Flow. Present Rosemount Best Practices, And New products.
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 4 OIL / GAS PRODUCTION FACILITY
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 5 Test Separator Production Separator Flow Treater Disposal Tank & Pump Disposal Well Stock Tank LAC unit Gas Meter OIL / GAS PRODUCTION FACILITY Well head
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 6
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 7 Wellhead Measurement 2088 3095FB w/Conditioning Orifice-plate Wet Gas Flow Measurement Tubing & Casing Pressure
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 8 Wellhead Pressure
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Rosemount 4600 The Oil & Gas Panel Transmitter
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 10 -Wellhead Control Chemical Injection –Wax Inhibitors –Corrosion Inhibitors –Odorization Hydraulic Power Units Emergency Shutdown Systems The 4600 Was Designed Specifically for Offshore Oil & Gas Panel Applications Gulf of Mexico 4600
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 11 The Rosemount 4600 Has Many Key Customer Benefits Dual Process Seal Design Increases safety and reliability by providing a secondary method of pressure containment High Pressure Measurement Provides the capability to measure pressure up to 20,000 psi All-Welded, Hermetic Enclosure Increases reliability by minimizing the effects of salt spray and humidity on the sensor and electronics Lightweight, Compact Design Provides legendary Rosemount performance in space constrained Oil & Gas panel applications 3-Year Stability Guarantee Three year stability of 0.5% of calibrated span reduces maintenance and calibration costs 40:1 Rangeability 40:1 Rangeability increases flexibility and lowers inventory costs
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 12 Separation System
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 13 Separator Measurement 3302 Radar Oil/Water Interface 8800 Vortex Water Flow Coriolis - Oil Flow 3051 / 2088 Pressure 3301 Radar Oil Level 3301 Radar Oil/ Water Level 3095MFCC Gas Flow Water Oil / Condensate Inlet Gas Relief Valve
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 14 Test Separator (gas flow)
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 15 ‘Flow Best Practices’ Dramatically Improve Flow Measurement To reduce capital and operating costs, users are: 1.Measuring mass flow (base volumetric) in Gas and Steam to reduce process variability. 2.Eliminating impulse lines where possible to improve reliability, lower installed cost, and minimize maintenance. 3.Selecting in-line flowmeters for smaller lines and insertion flowmeters for larger lines to minimize installed cost.. 4.Selecting maintenance-free flowmeters over mechanical meters to reduce maintenance costs 5.Utilize diagnostics to enable predictive maintenance to lower operating costs. 6.Minimizing pressure loss to lower operating costs, improve capacity. 7.Minimize upstream/downstream piping requirements to lower installed cost and reduce process variability
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 16 Gas Flow from Separator, 4 -in-1 Model 3095 Reduces Installed Cost & Process Variability Mass Flow Computer GP or AP Transmitter DP Transmitter Temperature Transmitter Q=N C d E Y 1 d 2 DP( ) Mass Flowmeter
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 17 3095MV Reduces Installed Cost by 42% Fewer components to procure, assemble & install –Single transmitter –Singe run of twisted pair –Single I/O use –Single controller –Reduced hardware One loop delivers 4 variables Reduced DCS memory No DCS programming 3095MV Electrical Savings = 58% I/O Savings = 67% Instrument Savings = 36% Mechanical Savings = 34%
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 18 P&T (Density) Variation Problem: Density Variability in Gas & Steam Flow Solved with 3095MV: “Real-Time” Density Correction 1.1% error reduced to 0.1% 3095MV Reduces Variability by Correcting All Three Sources of Flow Error Primary Element DP Transmitter Problem: Reference accuracy is not Installed accuracy Solved with 3095MV: Best-in-Class” Pressure Measurement 2.6% error reduced to 0.34% Problem: Coefficients Vary with Flow Solved with 3095MV: “Real-Time” Coefficient Correction 1.5% error reduced to 0.6%
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Rosemount Conditioning Orifice Plate Technology
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 20 Conditioning Orifice Plate 4 Diameters Flow Accuracy: ±0.7% Traditional Orifice Plate Up to 61 Diameters Flow Accuracy: ±1.0% 2D 7D 22D
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 21 Better Accuracy Than A Standard Orifice Plate Unique Design Measures Accurately in Short Straight-Run Each orifice hole is positioned to help condition flow profile irregularities Geometry reshapes the flow profile across the entire pipe
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 22 Flexible Installations Save Time and Money Two Platforms for Installation 2 to 8” (50mm to 200mm) C d Uncertainty: ±0.5% for 0.4 and ±0.75% for 0.65 3-valve, direct-mount head Fits between standard flanges Packaged as an integrated Flowmeter –3051SFC and 3095MFC 2 to 24” (50mm to 600mm) C d Uncertainty: ±0.5% for 0.4 and ±0.75% for 0.65 Fits between standard orifice flanges Retrofits existing installations Packaged as an integrated flowmeter –Engineered Assemblies
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 23 Application Information – Encana (Pinedale, WY) Product: 1595 Line Size: 4” sch 120 Installation: single 90deg elbow Fluid Type: Wet Gas (ntl gas) Flow Rate: 1MSCFD to 10MSCFD Press / Temp: 125 psig / 350 F New Conditioning Orifice Applications Installation Success Stories Application Information – MPEC (Casper, WY) Product: 3095MFC Line Size: 3” sch 120 Installation: single 90deg elbow Fluid Type: Wet Gas (ntl gas) Flow Rate: 1MSCFD to 10MSCFD Press / Temp: 125 psig / 350 F
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 24 Gas Compressor (temperature)
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 25 Flexibility Performance 244EH & 244ER Head & Rail Mount 1 Input PC Programmable Control and Safety Applications MonitoringApplications 848T Rail Mount 8 Inputs 144H Head Mount 1 Input (RTD only) PC Programmable 3144 Field Mount 1 Input 3244MV Field Mount 2 Inputs 644H & 644R Head & Rail Mount 1 Input Temperature Transmitter Breadth & Depth
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 26 3244MV for Control & Safety Temperature Applications 3244MV1K5B4M5T1U2C2X3 Dual-Element RTD Transmitter-Sensor Matching Constants Pre-programmed into Transmitter Rosemount Reliability Proven Rosemount Reliability Pre-Configured for Sensor Drift Alert, Hot Backup, and Average Temperature “U” Configuration option codes reduce start-up time Integral transient protection Integral LCD Meter Transmitter-Sensor Matching Factory-configured Transmitter-Sensor Matching for superior accuracy Dual-Compartment Housing provides superior reliability in harsh environments Installation Ready: Transmitter is shipped assembled to sensor assembly
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 27 644 For Control and Safety LCD Meter Transmitter-Sensor Matching Custom Alarm and Saturation Levels Improved Head Mount Design Complete Temperature Solution
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 28 Gas Sales Meter (flow)
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 29 “ % of reading” accuracy is much better than “ % span” accuracy at low flow conditions % Flow Rate Flow Turndown 0 1 2 3 4 5 6 7 8 9 10 203050100 ±0.075% span ±0.1% span ±0.04% span % Reading 10:15:13:12:11:1 ±0.5% reading
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 30 Ultra for Flow – vastly improved transmitter accuracy at low flow conditions % Flow Rate Flow Turndown 0 1 2 3 4 5 6 7 8 9 10 203050100 ±0.075% span ±0.1% span ±0.04% span % Reading 10:15:13:12:11:1 ±0.5% reading
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 31 Applications for Ultra for Flow More accurate measurement and better control during start-up and shut down of processes Flows that vary widely Air or gas flows with normally low DP –Ducts or stacks Custody transfer gas measurement where stacked DP’s are traditionally used
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 32 Glycol Regeneration
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 33 Condensate & Water Storage
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 34 Level ‘Best Practices’ To reduce capital and/or operating costs, users are: 1.Matching technologies to available tank openings to minimize installation costs. 2.Selecting devices that are easy for technicians to commission and maintain. 3.Matching the best level technology to the application conditions 4.Selecting systems designed for vacuum service when needed. 5.Eliminating mechanical devices where possible to reduce maintenance costs. 6.Considering the affects of temperature on level measurement performance
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 35 Radar Technology Has No Moving Parts Eliminate mechanical devices where possible - To reduce maintenance costs. No Moving Parts!
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 36 Displacer/Mechanical Float vs. Series 3300 Displacer/Float Technology Limitation: –Moving parts of displacers and floats require frequent cleaning and replacement; affected by mechanical vibration and turbulence –Maintenance costs can be very high –Level measurement unavailable during maintenance Model 3300 Advantage: –Guided Wave Radar technology has no moving parts –Maintenance cost dramatically reduced –Measurement availability improved Economic Payoff: –Reduced OPEX –Increased Safety & Environmental Monitoring
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 37 GWR can offer significant stability over technologies affected by density, turbulence or other factors Output Signal Plots For a 20 inch span, a density change of 20% can yield a 4” error. A O.2 change in SG is common in many oil separators
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 38 Bridle Measurement Replace!
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 39 Different probes to suit most applications
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 40 Interface Level Measurements Common Technologies Used for Interface Measurements: –Capacitance only capable of single measurement –Displacers affected by changes in density –Pressure affected by changes in density Model 3300 Advantage: –Multivariable TM device capable of BOTH level and interface measurement –Single tank penetration –Single pair of wires Economic Payoff: –Reduced CAPEX from reduced tank penetrations and wiring –Reduced OPEX from reduced calibration/maintenance requirements
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 41 Water Treating System (flow)
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Series 8700 Magnetic Flowmeters Magmeter Introduction
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 43 8705 Flanged Flowtube used with 8712D, 8732C, and 8742 All steel construction Welded coil compartment –IP68 (submersible to 30 ft continuous) Variety of liners and electrode materials 1/2”-36” (15mm-900mm) line sizes 0.5% of Rate Accuracy –0.25% Optional Accuracy Standard ISO lay length up through 8” –1/2” - 8” ANSI 150# flange –more sizes coming soon
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 44 8712D Universal Transmitter Universal Transmitter drives ANY flowtube: –AC tubes –Pulsed-DC tubes –ALL other manufacturers’ flowtubes Provides SMART capability for existing flowtubes –Simple, automatic calibration –Empty pipe detection –Digital Signal Processing, Multiple Coil Drive Frequency Reduced inventory,training and maintenance
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Rosemount 8800CR Reducer Vortex
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 46 8800C Vortex Reliable in Tough Applications Rosemount 8800C Vortex Reliable, Cost-effective flow measurement Designed for Reliability Eliminates impulse lines Only Vortex on the market with no ports or gaskets All-cast, Non-clog design Vibration Immunity with ADSP filters & mass-balanced sensor Fast Filter Optimization with ‘Auto Filter Adjust’ Replaceable Sensor without breaking process seals Simple, ‘In the Field” Troubleshooting through device diagnostics Designed to Reduce Cost and Risk Doubles low flow range compared to standard vortex Avoid costly field welding by using Reducer Vortex where downsized Vortex meters were historically used. Reducer Vortex and Standard Vortex have the same Face-To-Face dimension eliminating pipe change costs and risk Simplified Installation with no field welding of reducers & expanders 8800CR Reducer Vortex Extends Low Flow Coverage at a Reduced Cost
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 47 8800C Vortex - ‘Set for Life’ Reliability Simplified Troubleshooting Device Diagnostics enable field verification of Meter Electronics and Sensor with no process shutdown. Easy Filter Optimization ADSP ‘Auto-filter adjust’ optimizes filters to process conditions with single command. In HART & Foundation Fieldbus protocols. Vibration Immunity Mass Balancing of the Sensor system, and Patented Adaptive Digital Signal Processing (ADSP) provide Vibration immunity. Replaceable Sensor Sensor is isolated from the process and can be replaced without breaking the process seals. Single spare sensor for all line sizes. Non-clog Design Unique All-cast, All-welded Construction. No ports, crevices or gaskets to clog. All Cast/All Welded * No Crevices * No Gaskets Isolated Sensor Designed for Reliability 8800 Vortex eliminates impulse lines, and is the only Vortex available with no ports or gaskets.
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 48 Why “Reducer Vortex”? Approximately 75% of ALL vortex meters installed are smaller than the process piping! “60% of the Vortex meters supplied on this refinery project were oversized” Senior Project Engineer Shell Pernis - referring to Yok “On Start up 30% of the Vortex meters failed to register flow” BP Ethylene Plant - Line Size meter selection by Engineering Contractor talking about Rosemount and Yokogawa “We often run into issues with low flow cut off, impacting the rangeability, it is causing us to re-think our standards” Dow Chemicals Tarragona -talking about Rosemount and Yokogawa “If I see a Vortex meter the same size as the piping, I know something is wrong - either the plant is running at too high capacity, or the Vortex meter is not reading low flows well” Shell Chemical - Instrument Specialist
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 49 8800CR Reducer Vortex Extends the measurable flow range at a reduced cost Simplified Installation With Reducer Vortex, meter size can typically match the process piping size and still measure the low flows.* * - All Rosemount Vortex meters are sized prior to installation. Reduced Cost Eliminates field assembly and welding of separate reducer, piping and expander, reducing installed cost by as much as 50% Rosemount Reliability 8800CR uses the same non-clog meter body design Extended Measurable Flow Range Low-end flow range is typically doubled for Reducer Vortex compared with same size standard Vortex. Reduced Project Risk Reducer Vortex and Standard Vortex have the same Face-To-Face dimension. Avoid costly piping changes by using Reducer Vortex where downsized Vortex meters were historically used. Same Lay Length Reducer Vortex Standard Vortex * No Crevices * No Gasket Isolated Sensor
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 50 Fuel Gas & Instrument
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Rosemount Pressure Product Improvements
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 52 Customer Value Capability Niche Process Core Pressure 1151/2088 3051C/T 3051S 3095 Rosemount’s Comprehensive Pressure Offering Covers All Process Applications Complete Point Solutions TM
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 53 The 3051S Series of Instrumentation -- The Next Generation Pressure Transmitter 2X the Performance 2X the Reliability Enabling Platform –Integrated Solutions –Best Measurement Practices
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 54 “SuperModule TM ” Design Platform 0.025% Accuracy 10-Year Stability 200:1 Turndown Scalable Measurement Systems 12-Year Warranty Model 3051S Series is Based on a “SuperModule TM ” Design Platform
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 55 3051S Series SuperModule Sets New Standard in Pressure Measurement Hermetic, All-welded, 316L SST Housing Withstands the Harshest of Environments Optimizes Performance and Diagnostic Capabilities Saturn TM Capacitance Sensing Technology Single Circuit Board Design Improves Performance and Reliability Multi-bus Output Scalable Functionality, Output Protocol Flexibility Coplanar Process Isolators Integral Manifolds, Diaphragm Seals, and Primaries Improves Reliability, Enables Scalable Design Patented ASIC Technology
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 56 3051S Series -- The World’s First Truly Scalable Measurement Architecture Scalable Performance 0.025% Accuracy 10 Year Stability 12 Year Warranty 0.055% Accuracy 5 Year Stability Scalable Process Connections Scalable PlantWeb Functionality Scalable Electrical Connections New! “Ultra for Flow” 0.04% of READING 200:1 turndown
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 57 3051S Quick Connect Customer Benefits Improved Productivity with 3051S Best-in-Class Performance Reduced Installation Costs Compact size allows installation where space is a premium Cordset eliminates need for boundary seal between hazardous and nonhazardous locations Increased Reliability All 316L SST design with hermetically sealed sensor withstands the harshest environments Easy Start-Up Quick, error-free wiring Available on all 3051S Models
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 58 4-20mA with HART output All 316L SST Construction A size Mini, 4-Pin Male Connection (7/8"-16UN threads) CE Approved to IEC/EN 61326 and NAMUR NE-21 Integral EMI/RFI protection Rated to IP66 with suitable cordset Intrinsically Safe Nonincendive - Class 1, Division 2 10.5 – 42.4 V dc Power Supply Refer to 3051S PDS for complete performance & functional specifications 3051S Quick Connect Product Details 8.375 in (213 mm) Quick Connect Weight: 0.35 lbs (Compare to typical SST housing weight of 3.4 lbs) Customer Supplied Cordset or Field Wireable Connector (Right Angle Cordset Shown)
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Web Based Monitoring With Rosemount 753R & iTraX™ Rosemount 753R (Remote Mount) iTraX™3051S with Option Code (Assemble-To 753R)
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 60 GSM/GPRS iTraX™ can also be linked to customer database (FTP) Rosemount 753R & iTraX Web Based Monitoring Solution Is A Flexible & Scalable Platform Inventory monitoring Chart Recorder Metering (future) View data history Configure alerts Account mgmt 753R
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 61 Rosemount’s Web Based Solution Provides Reliability, Performance, and Ease of Use Reliability & Quality –Reputation for world leading products & service Performance –Up to 100 transmissions / day –Data logging capability –Premier measurement durability, reliability, and stability Ease of Use –Simple to install & operate Preconfigured & commissioned Remote configuration capabilities –iTraX™ web interface Via Rosemount.com No special software; any browser Security to ensure confidentiality
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 62 Rosemount 753R: Can Be Fully Integrated With A 3051S Transmitter Or Remote Mounted 753R Can Be Attached to Any 2-Wire 4-20/HART Sensor Can have integrated DP sensor Or connect to any 4-20/HART sensor Accessories Solar panel Battery PW Housing w/ “cell phone”
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3420 Wireless For Advanced Monitoring & Control-in-Field + 0_+ 0_ CIF, AMS
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 64 Ethernet or Wireless (2.4GHz) Rosemount 3420 Expanded To Provide Wireless Functionality Model 3420 –Designed to bring FF to legacy control systems via Modbus –Use Ethernet as a way to get at the advanced features of FF –Extended to wireless –Typically used for higher density applications –Encrypted data optional –Class 1, Div 2 FOUNDATION Fieldbus Modbus
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 65 Configure >60 FF devices from PC browser (and/or AMS) Integrate into legacy plants via Modbus RTU/TCP, Ethernet, OPC Balance of plant monitoring with rich FF information Field mount / locate hardware (Class 1, Div 2) 3420 linking capabilities (ie: CIF and AMS in Q2 FY05) 3420 With Wireless Functionality Enables Control-in-Field & Advanced Monitoring Ethernet Full Configuration & Monitoring via PC Up To Miles With Good Line of Sight Modbus And / Or DCS ….. + 0_+ 0_ LPVTFDI/O8 Analog Inputs 4-20mA, RTD, T/C Control-in-Field
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