Oil and gas operators are expected to have a systematic control over their processes, facilities, equipment and other assets in order to comply with safety and environmental regulations, but also to ensure the products that reach customers are of the highest standard. Instruments that measure flow, level, pressure, temperature and other variables in hazardous locations are generally used to monitor and control oil and gas operations.
As oil and gas projects expand, so do the list of equipment that are used to measure and gather different types of information. If these measurements are incorrect, oil and gas companies could be exposed to financial and environmental risks. Therefore, ensuring meters, testers and sensors meet industry standards is crucial.
Historically, calibration has mainly been driven by financial motives since the smallest of errors can have serious consequences for both customers and governments. Today however, calibration has gained an even bigger role in the sector.
Fiscal metering
Oil and gas fiscal measurement accuracy depends on many factors including measurement technology, fluid quality, rate of production, operating conditions and process complexity.
Since oil and gas is traded on total energy delivered, errors in the measurement of product quality or flow will affect the total energy calculation. Due to the large volumes of product flowing across transfer points, even a very small error in measurement can lead to large financial discrepancies.
The performance of fiscal meters can be affected by change in physical properties (pressure, temperature, flow rate), mechanical wear, obstructions in the pipe, product build-up and encrustations. Therefore, meter performance must be regularly verified and calibrated to make sure that the results are accurate, consistent and traceable.
With regular calibration, oil and gas operators can be sure of the highest degree of measurement accuracy, reducing both measurement uncertainties and helping to maximise profits.
Recording emissions
Globally, an increasing amount of governments demand that instruments used to measure emissions are regularly calibrated and the results are documented in accordance with the jurisdiction’s regulations.
Depending on the plant type and location there may be a series of gas analysers that monitor for sulphur dioxide, nitrogen oxides, carbon monoxide, carbon dioxide, hydrogen chloride, airborne particles and organic compounds.
In addition to the continuous measurement of these emissions, the measurements must also be calibrated properly. In some jurisdictions, if a facility fails to perform these measurements or calibrations, operations could be fined for noncompliance.
Safe operations
Safety is an essential matter for oil and gas operations to reduce workplace risks but also to comply with regulatory requirements. An oil and gas site has an array of hazardous systems and high-pressure equipment which have several controls that ensure a safe operation without exceeding pressure limits.
If this critical oil and gas equipment is not assessed, calibrated and maintained employees could be put in significant danger. For example, if flare gas meters are not properly calibrated and maintained, their accuracy is also reduced. This can have a knock-on effect on the safe disposal of excess natural gas and potentially increase the likelihood of an explosion.
Advancing calibration management
While it is important that the equipment used for measuring production facilities, pipelines, tankers and other assets are of high quality, without an efficient and accurate calibration system in place, even the best systems and the most accurate manual measurements are of little value.
Given the volume of assets and equipment that need to be managed, calibration is a fairly big task. It has been estimated that the energy sector has more than 5,000 instruments that require calibrating, with the industry performing more than 2,000 calibrations each year. Furthermore, a lot of time is spent on documentation and paperwork involving calibration.
An automated calibration management software can make the task a lot easier as it enables the automated management and storage of all instrument and calibration data.
Calibration management software helps operators carry out major calibration processes including planning, scheduling, and documenting outputs. For example, calibration procedures and strategies can be planned more efficiently, device databases can be maintained and scheduled calibrations can be automated within one system. All calibration records and data can also be stored in the database which can be accessed and reported on for future audits.
An automated system also helps equipment managers to better monitor processing equipment and ensure they are working at their optimal levels. This is done by ensuring that moving parts have lubricants and that consumable products used in a process are replaced in advance.
It also provides equipment managers with automated planning options that help reduce administration and management effort. This reduces the manpower required and thus helps organisations cut down on labour costs.
The biggest benefits of calibration management software
- Streamlined workflows
Calibration management software helps streamline workflows since manual procedures are replaced with automated and validated processes. As the entire calibration process becomes more streamlined and automated, plant efficiencies also improve. As the manual procedures are replaced with automated ones, businesses can save time in a lot of labour-intensive calibration activities.
- Reduce costs
Software enables faster, easier and more accurate analysis of calibration records and identifying historical trends. Plants can therefore reduce costs and optimise calibration intervals.
- Performance management
A calibration management program can help to keep track of Key Performance Indicators (KPIs) in real-time, while also giving a detailed view of operations. Performance of the installed equipment and resources can be analysed across the entire organisation.
- Regulations and standards compliance
A calibration management software can help in meeting regulatory requirements, making sure that the guidelines and standards are met accordingly.
- Records of calibration
All calibration assets are managed automatically by the calibration management software. The program also maintains a device’s position and calibrator databases while also setting up automatic alerts for scheduled calibrations. The software also automates report generation and centralises calibration data storage.
- Equipment longevity
The software can automatically calculate an item’s due date for calibration and maintenance according to the user-defined intervals. Downtime can therefore be greatly reduced as the equipment is calibrated and maintained on schedule.
Sources: Comments to regulations relating to measurement of petroleum for fiscal purposes and for calculation of CO2 tax, Norwegian Petroleum Directorate; Reducing Errors & Uncertainties in Gas Quality Measurement, Matt Shaw, Business Development Manager, CAC Gas & Instrumentation; Fiscal Measurement – How much?, Emerson Process
