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VALIDATION ON GAS AND ORIFICE PLATE INSPECTION

PROCEDURE

1. SCOPE OF WORK

2. PREPARATION

3. VALIDATION

4. ORIFICE PLATE TEST MEASUREMENT

1.0 SCOPE OF WORK

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This procedure covers on validation of secondary & orifice plate
inspection & measurement for gas metering system;

2.0 PREPARATION

2.1 Prior to perform Validation test, identify:

1. Type of instruments to be validated.
2. Instrument particulars & specifications.
3. Testing range to enable proper test scale.
4. Fittings and equipment needed.
5. Equipment required during dismantling and installing from the metering
skid (if required).
6. Spares to be on site.
7. All the relevant party involved in the exercise are notified.
8. JSA has been prepared and reviewed.
9. Work permit has been applied and approved.

2.2 Prior to perform orifice plate inspection, identify:

10.Type of instruments to be validated.
11.Instrument particulars & specifications
12.Scaffolding to be erected (if require).
13.Disable gas detector (if any).
14.System to be depressurised (if require).
15.All tools required on site.
16.Spares to be on site.
17.Equipment required during dismantling and installing from the metering
skid (if required).
18.All the relevant party involved in the exercise are notified.
19.JSA has been prepared and reviewed.
20.Work permit has been applied and approved.

3.0 VALIDATION TEST ON GAS

3.1 Validation Procedure for Temperature Transmitter

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i. Disconnect the temperature element wiring from the terminal block
in the temperature head, and connect the resistance test
equipment in place of the temperature element.

ii. Set resistance values equivalent to 0%, 25%, 50%, 75%, and 100
% of the signal converter span on the decade resistance box.

iii. Complete an Instrument Calibration Sheet. If the temperature

readings were within the required acceptance limit for all applied
resistance values, then identify the Instrument Calibration Sheet as
As Found .

iv. Disconnect the test equipment and return all wiring to operational
status.

v. If the temperature readings were outside acceptance limits at any

calibration point, then identify the Instrument Calibration Sheet as
As Found.

vi. When the temperature reading are within acceptance limits at all
calibration points then complete a second Instrument Calibration
Sheet, identifying as As Left.

vii. Disconnect the test equipment and return all wiring to operational
status.

viii. Compare the actual results with the required result; all the
temperature readings should be within + 0.1 % span.

3.2 Test Procedure Three Point Check for Temperature Element

i. Remove the temperature element from its thermo well.

ii. Place the Temperature Transmitter with the element in an ice

container together with certified mercury in glass thermometer.

iii. Allow temperature to stabilize. Read the temperature reading from

the thermometer and compare with the temperature reading of the
flow computer display. The difference between them should be
within + 0.3oC.

iv. Repeat the above test with water at ambient and hot water.

3.3 Validation Procedure for Pressure Transmitter

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i. Isolate the transmitter from the meter tube at the main and
manifold isolation valves. Open the transmitter equalising valve.
Depressurised the transmitter via the vent valve, then closed the
equalising valve.

ii. Connect the validation test equipment for pressure transmitter

testing.

iii. Increase the pressure from zero to maximum span, in step of 25%
(Raising). Over-pressurize by 10 % of its the calibrated span.

iv. Decrease the pressure from maximum span to zero, in step of 25%
(Falling)

v. Record the As Found results of each rising and falling on the

instrument calibration sheet.

vi. Calculate the error, and check if the calculated span error is within
the required accuracy. If not, recalibration is required according to
the manufacturers instruction manual.

vii. After recalibration, perform the calibration test again and record
the results on the same instrument calibration sheet, under the As
Left.

ix. Compare the actual results with the required result; all the pressure
readings should be within + 0.2 % span.

4 Procedure of Measurement

Inspect and measure the orifice plate for compliance with the
characteristics detailed below. Measurement points are shown in
Figure 1.
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THICKNESS E OF PLATE
d1

UPST REAM FACE A DOWNSTREAM FACEB

d2

ANGLE
OF BEVELF

THICKNESSe

DIAMETERSD& d d3
DOWNSTREAM
EDGES H& I

UPST REAM
EDGE G

d4

Figure 1

ORIFICE BORE DIAMETER (d)

Measure orifice bore diameters at d1, d2, d3 and d4. The
Beta Ratio ( = d/D) must be greater than or equal to 0.20
and less than or equal to 0.60. No individual diameter may
differ by more than 0.05 % from the value of the mean
diameter.

THICKNESSES (E and e)
1 Thickness e to be between 0.005D and 0.02D
.
2 The difference between values of e at any point on the
. orifice bore to be not greater than 0.001D
3 Thickness E to be between e and 0.05D
.
4 The difference between values of E at any point on the
. orifice plate to be not greater than 0.001D
5 If 50 mm D 64 mm a thickness E of up to 32 mm
. is acceptable.

UPSTREAM FACE (A) : FLATNESS

The slope of a straight line connecting any two points on
the upstream face in a plane perpendicular to the centre
line of the orifice bore must be < 0.5 %. This is tested using
a straight edge and feeler gauges. See Figure 2.
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UPSTREAM FACE (A) : CONDITION

Upstream face roughness within a diameter of at least D
must be 10-4 d. Visually inspect the surface for
indentations, scratches or any other marks which may cause
the acceptance criteria to be exceeded.

DOWNSTREAM FACE (B)

Visually inspect the face. If the surface appears flat and
smooth then the surface finish is acceptable.

UPSTREAM EDGE (G)

Visually inspect the edge for wire edges, burrs or any
peculiarities visible to the naked eye. If any such
peculiarities
Straight Edge can be seen, then the orifice plate must be
rejected. Edge radius to be 0.0004d. If d 25mm then the
edge sharpness is considered acceptable if it does not seem
reflect a beam of light when viewed with the naked eye.
Portable Light

DOWNSTREAM EDGES (H and I)

Visually
Touching inspect the edges. Small defects are acceptable.
Point
Feeler gauge at
Max. gap
ANGLE OF BEVEL (F)
The angle must be between 45 and 60
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Measure the perpendicular distance from the straight

edge to the plate at the worst point. The slope of
straight line connecting any two points on its surface
in relation to a plane perpendicular to the centre line
of the orifice bore should be less than 0.5 %.

Figure 2 : Method of Checking upstream face flatness

Method
Inspection is to verify compliance with International Standard:
i) ISO 5167: Measurement of fluid flow - Orifice plates, nozzles
andVenturi tubes inserted in circular cross-section conduits
running full.
ii) Petronas Gas Measurement Guideline (Rev.1, August.2000)

Acceptance Limits

Acceptance limits are those required for compliance with ISO

5167..