Presentation on

Gas Metering
By SNGPL-Metering Department

OVERVIEW
Metering Department is responsible for accurate
measurement of gas, operation and maintenance of
all metering and regulating stations having following
major scope of work.

Operation and maintenance of instruments like

Valves, Regulators, Relief Valves, Electronic Volume
Corrector, Meters etc.
Calibration of Instruments such as Pressure /
Temperature Recorders, Calorimeters, Gauges etc.
Design of metering and Regulating Stations
Schedule meter replacement
Operation and Augmentation of Distribution
network
Repair of all types of meters at Central and
Regional meter shops and generation of impartial
and accurate Meter Inspection Report

What is natural Gas?

Natural gas is a gaseous mixture of
hydrocarbons, comprising primarily of
methane (CH4) with other hydrocarbons,
inert and impurities as minor constituents.
Composition of natural gas depends on the
Production field from which it is extracted

Processes of Natural Gas

Extraction & Utilization
Exploration
Extraction
Production
Well Completion
Processing

Transportation
Distribution

 Exploration
In the early days of the industry, the only way of
locating underground petroleum and natural gas
deposits was to search for surface evidence of these
underground formations. Those searching for natural
gas deposits were forced to scour the earth, looking for
seepages of oil or gas
By surveying and mapping the surface and sub-surface
characteristics of a certain area, the geologist can
extrapolate which areas are most likely to contain a
petroleum or natural gas reservoir.
Once the geologist has determined an area where it is
geologically possible for a natural gas or petroleum
formation to exist, further tests can be performed to
gain more detailed data about the potential reservoir
area.
Arguably the biggest breakthrough in petroleum and
natural gas exploration came through the use of basic
seismology.
The basic concept of seismology is quite simple. As the
Earth's crust is composed of different layers, each with
its own properties, energy (in the form of seismic
waves) traveling underground interacts differently with
each of these layers. These seismic waves, emitted
from a source, will travel through the earth, but also be
reflected back towards the source by the different
underground layers. It is this reflection that allows for
the use of seismology in discovering the properties of
underground geology.

Seismology in Practice

Offshore Seismic Exploration

 Extraction

Once a potential natural gas deposit

has been located by a team of
exploration geologists and
geophysicists, it is up to a team of
drilling experts to actually dig down to
where the natural gas is thought to
exist.
The exact placement of the drill site
depends on a variety of factors,
including the nature of the potential
formation to be drilled, the
characteristics of the subsurface
geology, and the depth and size of the
target deposit.
If the new well, once drilled, does in
fact come in contact with natural gas
deposits, it is developed to allow for
the extraction of this natural gas, and
is termed a 'development' or
'productive' well. At this point, with the
well drilled and hydrocarbons present,
the well may be completed to facilitate
its production of natural gas. However,
if the exploration team was incorrect in
its estimation of the existence of

A Small Drill

Gas Well Schematic

Installing Well Casing

 Production
Well Completion
Once a natural gas or oil well is
drilled, and it has been verified that
commercially viable quantities of
natural gas are present for
extraction, the well must be
'completed' to allow for the flow of
petroleum or natural gas out of the
formation and up to the surface. This
process includes strengthening the
well hole with casing, evaluating the
pressure and temperature of the
formation, and then installing the
proper equipment to ensure an
efficient flow of natural gas out of the
well.

Well Heads

Production Continue ..

- Processing Natural Gas

Natural gas, as it is used
by consumers, is much
different from the natural gas
that is brought from
underground up to the
wellhead. Natural gas
processing consists of
separating all of the various
hydrocarbons and fluids from
the pure natural gas, to
produce what is known as
'pipeline quality' dry natural
gas. Major transportation
pipelines usually impose
restrictions on the make-up of
the natural gas that is allowed
into the pipeline. That means
that before the natural gas
can be transported it must be
purified. While the ethane,
propane, butane, and pentanes
must be removed from natural
gas, this does not mean that
they are all 'waste products'.

. Production

 Transportation
The efficient and effective movement of natural gas
from producing regions to consumption regions
requires an extensive and elaborate transportation
system. In many instances, natural gas produced from
a particular well will have to travel a great distance to
reach its point of use. The transportation system for
natural gas consists of a complex network of pipelines,
designed to quickly and efficiently transport natural
gas from its origin, to areas of high natural gas
demand.
There are essentially three major types of pipelines
along the transportation route: the gathering system,
the transmission/interstate pipeline, and the
distribution system. The gathering system consists of
low pressure, low diameter pipelines that transport
raw natural gas from the wellhead to the processing
plant. Should natural gas from a particular well have
high sulfur and carbon dioxide contents (sour gas), a
specialized sour gas gathering pipe must be installed.
Sour gas is extremely corrosive and dangerous, thus
its transportation from the wellhead to the sweetening
plant must be done carefully.
To ensure that the natural gas flowing through any one
pipeline remains pressurized, compression of this
natural gas is required periodically along the pipe. This
is accomplished by compressor stations, usually
placed at 40 to 100 mile intervals along the pipeline.
The natural gas enters the compressor station, where
it is compressed by either a turbine, motor, or engine.

Gas Transmission Line

 Distribution
Local distribution companies typically transport natural gas from
delivery points along transmission pipelines through thousands of
miles of small-diameter distribution pipe. Delivery points to (Local
Distribution Company) LDCs (i.e. Distribution Regions), especially for
large municipal areas, are often termed 'city-gates', and are
important market centers for the pricing of natural gas. Typically,
LDCs (i.e. Distribution Regions) take ownership of the natural gas at
the citygate, and deliver it to each individual customer's location of
use. This requires an extensive network of small-diameter distribution
pipe.

Why should the gas be measured?

To know the volume of gas being consumed

by each consumer for the purpose of billing
(revenue collection)
Standardize the measurement for each
customer, everybody should be treated
equally
For the reconciliation of the system
To minimize the measurement losses

Volume Measurement

Measurement can be done by filling a known

container and passing it to the consumer
The above method is not continuous, it can
only provide volume of a known quantity in
batches
For the continuous measurement, rate of flow
is determined by time period in which the
volume has passed

Volume / Flow Units

The volume is measured in the following units

Gas cubic feet (ft3), cubic meters (m3), MCF, MMCF

The flow is measured in the following units

Gas cubic feet/hr (ft3/hr), cubic meters/hr (m3/hr),
MMCFD

REVIEW OF SOME BASIC CONCEPTS

Pressure of Gas

Pressure is the force exerted by the gas

molecules on the container in which the gas is
present

Container

Gas Molecules

Temperature of Gas
When the temperature of the gas present in the container rises the gas
molecules absorb the heat energy which results in increase in the motion
of the molecules (kinetic energy), hence more molecules will strike the
walls of the contained meaning that the pressure on the walls will
increase

Flow of Gas

Gas flows when a there is a difference of pressure between

two points, the gas flows from a point of higher pressure to
the point of low pressure
The rate of flow will depend upon the difference of pressures
between the points

REVIEW OF SOME BASIC CONCEPTS

PRESSURE: Force per unit Area, P = F / A (Units: lbforce/inch2 )

ATMOSPHERIC PRESSURE: (PSIA) Ponds per square

inch absolute. It is measured by a barometer and
considered to be 14.73 psia at sea level. As we go
higher the value of atmospheric pressure decreases.
For instance atmospheric pressure at Karachi
14.73 psia , Lahore 14.4

GAUGE PRESSURE: Gauges are used to measure

pressure in the gas system. They measure pressure
above atmospheric pressure. So that absolute
pressure = Atmospheric pressure + Gauge pressure.

QUESTION: Will absolute pressure be independent of

It may be remembered that absolute pressure is independent of

height effect.
The pressure gauge in Karachi measuring zero psig which is
equal to 14.73 psia will measure gauge pressure of -0.33 psig at
Lahore. This error will be adjusted by adding 0.33 psi to bring
gauge reading to zero.
So that Absolute pressure = 14.4 + 0.33 = 14.73
100 psig

114.7 psia

75 psig

89.7 psia

50 psig

64.7 psia

25 psig

39.7 psia
Zero Absolute Pressure

Vacuum

14.7 psia

MEASUREMENT OF GAS

Gas is a compressible fluid

Volume of gas keeps changing with changing Pressure &

Temperature

Define Standard cu-ft of gas.

SNGPL defines one cu-ft as a volume of gas which occupies 1 cuft 3

space at a pressure of 14.65 psia and 60F called base
condition.

1 cuft

cuft

L/2

After application of Pressure

on the plunger

GAS LAWS

Ideal Gas Laws

Boyles Law:

At constant temperature, the volume of a given mass of gas is inversely

proportional to the applied pressure. Mathematically,

This means that at constant temperature, the product of Pressure

and Temperature of a given mass of gas is always constant. Thus

Volume

(at constant temperature)

1/Pressure

Pressure

P1 V 1 = P 2 V 2

Volume

..Ideal Gas Laws

Charles Law:

At constant pressure, the volume of a given mass of gas is directly

proportional to its absolute temperature:-

P= 1 atm.
P= 2 atm.

Volume

P= 3 atm.

Temperature

Volume of a definite mass of

gas (say 1 mole) is plotted
against absolute temperature

..Ideal Gas Laws

Pressure Temperature Law:

At Constant volume, the pressure of the given mass of the gas is

directly proportional to the absolute temperature. Mathematically

Avogadros Law & Standard Molar Volumes:

Equal Volumes of all gasses under the same conditions of pressure and
temperature contain the same number of molecules i.e.
Standard Molar Volume 1 Mole of and ideal gas at STP = 22.414 dm 3
(1 dm3 = 1 litrs)
One mole of a gas i.e. 22.414 dm3 at STP contain 6.022 1023 , this number is called Avogadros number, NA

The General Gas Equation

Boyles Law:
Charles Law:
Avogadros Law:
Combining these laws we get:

In General we can say:

Ideal or Universal Gas Constant

The Gas Constant R:

The value of R is independent of nature of gas
but dependent on the number of moles of the
gas and units of P, V & T used:

Kinetic Molecular Theory

The pressure of a gas is the result of the collisions of the
molecules with the walls of the container. The theory is
based on following assumptions:

Gases consist of discrete molecules that are similar as regard to the mass and
size

Molecules are far apart and they exert no attraction on each other except
liquefaction

The volume occupied by the gas molecules is negligible as compared to the

total volume

Gas molecules are in continuous random motion, straight line motion with
different V

Collision of the gas molecules and wall of the contained are perfectly elastic

Pressure exerted by the gas is due to the elastic collision of the gas with
container walls

The average Kinetic energy is equal to the absolute temperature

The motion imparted to the molecules by the gravity is negligible

Laws of mechanics are applicable to the motion of the molecules

Concept of Compressibility: Real gas in general, closely follow the General

Gas Law, however, they do deviate, and for
accurate measurement this deviation must be
considered. This definition is termed as
Compressibility
so another multiplying factor called
compressibility (z) is used as another correction
factor. In case of orifice meter calculation
Fpv (Super Compressibility Factor) = (1 / Z)
However for other meters the super compressibility
factor is equal to S = 1 / Z = (Fpv)2

Experiments by Charles and Gay

Lussac:
At constant pressure, the volume of a given mass of gas increases or
decreases by 1/273 of its volume at 0C for every 1C rise or fall in
temperature

Temperature

This temperature, -273C (or -273.15 to be exact) is the temperature

at which the volume of the gas becomes zero is known as absolute
zero and is taken as zero of Kelvin scale.

Volume

Gas Measurement Through Gas Equations:

Pb = Base Pressure = 14.65 psia
Vb = Needs to be calculated
Tb = Base Temperature = 60 F = 459.67+ 60 = 519.67R
Pf = Flowing gas Pressure on the meter, fixed pressure or measured by a recorder/
volume corrector
(measured value)
Vf = Flowing gas volume at the flowing pressure and temperature (volume recorded by
the meter)
Tf = Flowing gas temperature (measured value)
Pressur
e
Factor

Temp
.
Facto
r

Uncorrect
ed Vol.

For correction due to compressibility multiply the

equation by appropriate Compressibility Factor.

..Gas Measurement Through Gas Equations:

The equation of gas measurement becomes

Compressibility natural gas at base conditions is assumed to be 1

Where S is Compressibility factor

For meters other than the orifice meters, we need to

measure following flowing gas parameters.

Flowing volume at line pressure and temperature

conditions. This is accomplished by installing a
meter (P.D. meters/ Turbine meters)
Flowing gas Pressure
Flowing gas Temperature

Bernoullis Equation :
V2 / 2g + P / + Z = constant
V = velocity g = Acc. Due to gravity
P = Static Pressure

= Sp. Wt. of fluid = 62.416 for H2O

Z = Feet of Height above

Terms: V2 / 2g = velocity Head in feet (Kinetic Energy)

P / =Pressure Head in feet (energy stored as pressure)
Z = Head in feet (Height, Potential Energy)
Given Q = 1000 Gallons/min
Dia. = 6

(nominal 6 = 6.065 inside dia.),

conversion 1 cu-ft = 7.48 Gallons

= 62.4 lb/ft3

P= 100 psi = 100144 psft

Pressure P2 = ?

Q = 1000 Gal/min 1/60 = 16.67 Gallons/sec

Q = 16.67 / 7.48 Gall/sec cu-ft / gallons = 2.23 cu-ft / sec,
A=

=3.14(6.065)2/4=28.89in2

=28.89/144 = 0.2005 ft2

V = Q / A = 2.23 / 0.2005 = 11.15 ft/sec

V12 / 2g + P1 / + Z1 = V22 / 2g + P2 / + Z2
(11.15)2 /232.2 + 100144/62.4 +100 = (11.15)2/232.2 + P2 / 62.4 +150

Solving Equations we get P2=11300 lbs/ft2

P2= 11300 / 144 = 78.5 psi
NOTE: (i) each 2.31ft of head of water is equal to one
pound
per square inch pressure
(ii) The Bernoullis equation is considered the
foundation for study of fluid motion (liquids as well
as gas) and it may be used to solve majority of
problems in fluid flow.
(iii) The equation we have discussed is for idealfrictionless system. If friction is to be considered
this equation will look like
V12 / 2g + P1 / + Z1 f1 = V22 / 2g + P2 / + Z2

For gas flow Bernoullis equation reduces to

V12 / 2g + P1 / = V22 / 2g + P2 /
Or

P2 P1 / = V12 V22 / 2g

the above equation can only be used if the pressure difference

is less than 3% otherwise the expression for relationship
between pressure and density would be incorporated.

Volume Measurement by Gas Meters

Gas meters are used for the accurate and continuous measurement of gas
Gas Volume Meters

Positive Displacement Meters

The meters which measure gas by
filling in the chambers of known
volume and then displacing the gas,
hence direct measurement

Inferential Meters
The meters which uses some
property of fluid flow usually
velocity to inference volume,
hence in-direct measurement

Diaphragm Meters

Turbine Meters

Rotary Meters

Orifice Meters
Sonic Meters

Meters

Meter Capacity:

Maximum Allowable Operating Pressure

(MAOP): The maximum pressure at which meter can be

The maximum flow of gas that a meter can

provide is known as meter capacity. As the flow of gas through the
meter increases, the differential pressure (between meter inlet and
outlet) also increases

operated is called MAOP

Rangebility:

Cyclic Volume:

Pressure absorption or Differential Pressure:

The band of lowest and highest flow which a

meter can accurately measure
The Volume of gas that has passed in one
complete cycle of the gas meter i.e. movement of all the moving
components has completed
The difference of pressure measured at inlet and outlet of
connections of the meter during meter operation

Types of Gas Meters and

their Principles of Operation
1.

Positive Displacement Meters:

These meters measures the known volume of
gas in the fixed chamber and displaces this
volume. The no of fixed volumes displaced are
calibrated to provide volume of gas passed
through the meter on its index. These meters
have deformable chamber walls in which
volume of gas fills and displaces out. These
meters are further subdivide into :(i)
(ii)

Diaphragm Meters
Rotary Meters

A is emptying
B is filling
C is empty
D is full

A is empty
B is full
C is emptying
D is filling

A is filling
B is emptying
C is full
D is empty

A is full
B is empty
C is emptying
D is filling

Operation Schematic of Diaphragm Meters

Range ability 100 : 1

DIAPHGRAM METERS
REMUS G4
MKM250
RW275 AC250
SP250
RW310 MKM400
RW415
AL425
RW750
AL800
SP1000
AL1400
RW1600
RW3000
AL2300
RW5000
RW10000

DIAPHGRAM METERS

RW-750

SP-1000
1400

RW-1600

RW-5000

RW-5000

Al-2300

RW-3000

Al-

Rotary Meters

Fundamentals of Rotary
Measurement
Clearance b/w impeller tips cylindrical walls & head plates:
0.001 0.015

0.05 w.c. Differential pressure causes

the impellers to move and flow of gas starts

Rotary Meter Operation

Range ability 25 : 1

Rotary Measurement
Advantages

Disadvantages

Compact, smaller
sizes

Heavy, larger sizes

Low-flow limitations

Various sizes
available

Maximum pressure
limitation

Potential service
interruption

Susceptible to
contamination

Requires lubrication

Wide variety of
readouts

ROTARY METERS
RC3M175
RC5M175
RC7M175
RC11M175
RC16M175
RC23M175
RC38M175
RC56M175
RC102M175
D5
D6
D7
D8.8
D14
D23
DELTA G400
UGI 56M
RVG100
RVG160
RVG250
ROMET3000
ROMET11000 ROMET23000

ROTARY METERS
CVM-5.3
38M175

D-9
Delta D-23

RVG-250

Rc 7M175

Delta G-100

Rm-38000

Rc6M175

Delta D-23

UGI-56000

G-1000

Rc

Inferential Meters :
These meters do not directly measure the volume
of gas but uses some property of fluid flow to
inference the gas volume. Usually velocity of fluid
stream is measured through the fixed Area and
volume is computed by using formula
Q = VA
These meters are further sub divided into: (i) Turbine Meters
(ii) Orifice Meters
(iii) Sonic Meters
(iv) Vortex Meters

Turbine Meters
Gas turbine meters are velocity
sensing devices as are orifice
meters. The direction of flow
through the meter is parallel to a
turbine rotor axis and the speed of
rotation of the turbine rotor is
nominally proportional to the rate
of flow. Gas volumes are derived
or inferred from the rotations of
the turbine rotor.

A turbine meter introduces a restriction (called a nose cone) of known cross-sectional

area into the gas stream as does an orifice meter. However, the turbine meter
determines flow velocity through this restriction by counting rotations of a turbine rotor
mounted in the open or throat area of the restriction. The turbine blade rotations are
transferred through a gear train to a wide variety of readout devices where totalized
volume at line conditions is displayed.

FLOW PROFILES
LAMINAR

56

TURBULENT FLOW PROFILE

57

SWIRL FLOW PROFILE

58

Assuming a Perfect Turbo-Meter

A single gas molecule

impinging on the rotor
blade would cause the
blade to move with:
No retarding forces to
resist movement
(mechanical friction)
No loss of energy from
the flowing gas (fluid
friction)
Constant velocity
and the
Direction & angle of
flow would remain
constant

Actual Turbo-Meter

Under actual operating

conditions, the speed of
the rotor is affected by:

Mechanical Friction

Fluid Friction

Bearing and gearing wear

Readout devices
Windage drag of rotor
Surface roughness
Interaction of flow layer

Installation Effects

Negative swirl
Positive swirl
Jetting
Pulsation

The Worst-case Single Rotor

Turbo-Meter Condition

Gas flow deflects off the

locked rotor at the angle

of the rotor blades

Turbo-Meter Fundamentals
Inferential

Measurement Device

Infers volume of gas by

measuring the velocity of
gas through a known area.

Basic Components
of a Turbo-Meter
Readout

Gear Train

Q= V A
Flow
Rate

Velocity

Area
Nose Cone
Rotor

Installation Consideration ?

Body

Auto Adjust Turbo Meters

Operating Conditions
Adjusted Volume
Pulse Output

Main Rotor

Mechanical Volume

Sensing Rotor

(MR Volume SR Volume)

Main
Rotor

Sensing
Rotor

Auto-Adjust Turbo-Meter Technology

Self-Adjusting Feature

Detects and adjusts for changes in

upstream flow conditions, meter
component wear, and contamination
Avoids over and under-billing
Self-adjusted output

Provides constant accuracy

Provides continuous measurement certainty

Auto-Adjust Turbo-Meter Technology

Self-Checking Feature

Up-to-the-minute remote monitoring

Advises accuracy changes

Advises required meter adjustments

Verifies the accuracy of the entire

installation
Reduces spin-testing and site visits

Auto-Adjust Turbo-Meter Technology

Performance

Superior flow rangeability (10:1 min to over

200:1) as pressure increases
Wide operating pressures (vacuum to 1440 psig)
Good repeatability (0.05%) and reproducibility
(0.1%)
Linearity 0.5% or better available at high
pressure calibration
Module interchangeability of +/- 0.1%

Self-Checking vs. Self-Adjusting

Self-Checking Feature

Detects changes in
retarding torque
Detects changes in
upstream flow
conditions
Detects installation
effects
Indicates deviation
from factory
calibration

Self-Adjusting Feature

Adjusts to original
calibration for changes in
retarding torque
Adjusts to original
calibration for changes in
upstream flow conditions
Records deviation from
factory calibration for
long-term analysis

Note: Compatible electronics required

AAT Operating Principles

Adjusted Volume
at Initial
Calibration
Basic Adjustment
Principle
Operating
Changes in
Retarding Torque
Self-Checking
Feature

110% of
Flow Rate

10% of
Flow Rate

Self-Adjusting Principle
Assume

main rotor slows

by 2% due to increase in Field condition w/ Factory
Calibration
drag
mechanical drag
Results in an increase in
exit angle, slowing
sensing rotor 2% in
proportion to main rotor
MR

Vol. - SR Vol. = Adj.

Vol.
108% - 8% = 100%

Ideal

Self-Checking Principle
Amount
Field
Factory
of Change = Adjustment Adjustmen
t

A =

100
- A
Vm
-1

Vs

A = Change in mechanical output accuracy from original calibration

(Delta A)
A = Average amount of adjustment at factory calibration (A-Bar)
Vs = Ps/Ks
Vm = Pm/Km

Pm = Pulses from main

rotor
Km = MR factor
(pulse/ft3)

Ps = Pulse from sensing

rotor
Ks = SR factor (pulse/ft3)

Self-Checking Example 2% Main Rotor Slowdown

Amount of Change =
Field AdjustmentFactory
Adjustment

A =

A =

A =

100
- A
Vm
-1

Vs

100
Vm
-1

Vs
100
108
-1

100
Vm

Vs -1

100
110

10 -1

A = 8%-10% = -2%

Self-Checking Feature

Compatible
Electronics

Measures inaccuracies in the

entire piping set
Documents changes in
accuracy vs. suspected wear
and provides early detection
of line or meter problems
Tests your meter in-line
without interruption of service,
or easily monitor accuracy &
performance remotely
Reduces spin testing and
maintenance costs with fewer
site visits
Provides ability for in-line spin
testing

The Sonic Meters

The Sonic meters are based
on ultrasonic and electronic
platform

The Added Value of Electronics

Logs operating and

consumption data

Programmable
measurement
factors

60 days of hourly
data

Fixed factor

Recordable
evidence of
tampering and
fraud

Reverse flow
Air in meter

Ultimate in Flexibility

Sonix 12,16, & 25

Standardized and
compact installations
In an inferential
meter, the capacity
expands in direct
proportion to the
pressure multiplier
factor

Measurement Principle

Transducer A

Piezoelectric
transducers generate
and detect waves

Waves travel at the

speed of sound relative
to the moving fluid
Sound will travel faster
with the flow of gas
than against the flow of
gas
Enabling the meter to
determine gas velocity

Volume = velocity x
cross sectional area of
flow tube

Transducer B

Fundamentals of Ultrasonic
Measurement
Single Path Low Flow

Ultrasonic pulses are

produced with - and
against - the gas
stream. Pulses
flowing with the gas
velocity speed up;
pulses flowing against
the gas velocity slow
down. The difference
is used to calculate
the gas speed or
velocity within the
known area.

Front and Bottom View of Measuring Element

Cross section of
flow tube. Inlet
section is sealed
from outlet
section ensuring
that all the gas
passes through
the flow tube
Inlet of Meter

Inlet of Flow tube

Outlet of Flow
tube

Outlet of
Meter

Positive O-ring
seal prevents
leakage from
inlet to outlet
and to
atmosphere

 Disadvantages
Ultrasonic Measurement
No

Advantages
Low

pressure loss
across meter
No mechanical
components
Bi-directional flow

mechanical
backup
Reliability on
electronics
Velocity profile effects
Complex calibration
requirements
On site power
requirements
System complexity

Vortex Meters
The vortex meter like turbine meters measure
the angular velocity with the Rotar. Rotron USA
used to manufacture these meters but due to
financial loss its manufacture has been
stopped now. Only a few of these types of
meters were used on our system.

METER READING

Meter Type: SP - 1000

0195100

6590383

7618700

0776919

Classification of Diaphragm Meters ANSI B109.1 & B109.2

Class
Capacity Range
Approx:
Designation
Min. Max OIMLMODEL
Ft3 /h
Ft3 /h
Equivalents

1.Class-50

2.Class-175
175 249 G4 RW-175, RW- 200, Gallus 6/20-C, UGI-200,
UGI-DO7, Sprauge-175, AL-175

3.Class-250
250 399 G6
Sprauge-400, AL-250.

4.Class-400
400 499 G10 RW-415 , RW-415, 1-1/2, AL-425 ,
AL-425 1-1/2

5.Class-500

500 899 G16 RW-750, RW-1600, AL-800

6.Class-900

900 1399

7.Class-1400

1400

2299

G40 RW-3000, AL-1400.

8.Class-2300

2300

3499

G65 RW-5000, AL-2300.

9.Class-3500

3500

2259

G100

RW- Rockwell
Sp- Sprague
AL- Singer American Meter

50

METER

174 G2.5 Yazaki, Remus, Ricoh, RW-150, Wilson.

RW-310, RW-315, RW-275, Sprauge-250,

G25 RW-1000, Sprauge-1000, AL-1000.

RW-10000, AL-3500.

Determination of Flow Rate at Site

Determine, in how much time the meter counter

completes circle of 10 Cuft or passes 10 Cuft gas
FLOWRATE
10 FT3 / 6 SEC
10/6 X3600
6000 FT3 / Hr

Alternatively we can determine flow rate by noting that

how much volume of gas has passed in one minute.
Suppose that it comes = 100 Cuft in 1 minute then
flowrate will be 100 X 60 = 6000 Cuft/Hr
Determination of flow rate of the meter in video?

Calculation of Bill
Domestic Consumer:
Meter Reading (Previous Month) = 0.450 M3
Meter Reading (Current Month) = 68.000 M3
Difference (Gas Consumed) = 67.550 M3
Apply P and T factors to arrive at Standard Volume. In case of Domestic Consumers such
factors are not applied
Conversion to Hm3 = 67.550/100 = 0.67 Hm3

If the Readings are in Cuft then conversion to Hm3 as follows: (Cuft 0.02817385) / 100
Conversion of Hm3 to MMBTU = (0.67 100)/0.02817385 CV

(Btus/SCF)

Complete Bill also includes GST and Meter Rent

Slab = (no of days/30) (Hm3 GCV ) 100 35.31467 / 1000,000

1/1000,000

Domestic Slab Rates

Slab

Usage of gas in
Hm3

Rs. Per MMBtu

Upto 1 Hm3

95.0

1 to 3

190.0

3 to 5

800.0

Over 5 and Above

1006.4

1.57 95.01 = 149.16

0.62 99.48 = 61.68

Conversion Factors
1 m3 (Cum) = 35.31467 ft3 (Cuft)
1 MCF = 1000 CF

(MCF means thousand Cubic feet)

1 MMCF = 1000 MCF

Btu = Cuft GCV

(MMCF means Million Cubic feet)

(Gross Calorific Value in Btus per SCF)

MMBtu = MMCF GCV

F = 1.8 C + 32
1 bar = 14.50377 psi

Metering Stations in
Distribution
CMS (Consumer Meter Station) supplies
consumers at the desired pressure.
Regulators

ON/OFF VALVE

Meters
ON/OFF VALVE

Pressure
Gauge

Regulators

gas to

Different Methods used for Gas Measurement:

Fixed Factor Measurement: A very precise regulator is installed
upstream of the meter which ensures fixed pressure to the meter all
times. The temperature of gas is normally measured by the P/T
recorder in the close vicinity of the CMS
Important Guidelines:
Regulator should have minimum droop (pilot operated)
Regulator should be properly sealed
Regulator should be adjusted at low flows i.e. within the
capacity of the regulator at operating conditions.
Restricting orifice should be used at the downstream of the
meter to avoid overloading of the meter/sudden jerk to the
meter.

Measurement Techniques in Gas

Industry
Fixed Factor Billing:
Precise
Regulator

Gas Flow

High Pressure Measurement: By the use of volume correctors / P/T recorders

The inlet pressure (metering pressure) is usually not fixed

Fluctuating line pressure enters into the meter (metering pess.)
The volume corrector or P/T recorder on the meter senses
/records instantaneous line pressure and flowing temperature
(EVCs only) and applies corresponding conversion factor
automatically / manually in case of P/T recorders to compute
standard volume at the base conditions.
The capacity of the meter enhances with increase in metering
pressure.
If the line pressure is more than the MAOP of the meter / volume
corrector, a suitable regulator should be installed upstream of the
meter to set the pressure within the MAOP.
Important Guidelines:
Monthly volume correction ratio report must be prepared to check
the performance of volume corrector.

Monthly downloads of EVCs should be taken to check /

analyze the data and any alarm conditions.
During site inspections, it is a good practice to note corrected
and uncorrected readings at an interval of to 1 hour and
compute the metering pressure applied by the volume
correctors which should be cross checked with physical
metering pressure.
The pressure gauges to note inlet/delivering pressure should
be installed downstream of the meter
In case of P/T recorders the monthly calibration of P/T
recorders must be performed and consumer/his
representatives endorsement must be taken. This will help in
resolving any billing disputes at the later stages.

Measurement Techniques in Gas

Industry
Billing with Pressure/Temperature Recorder:

The Meter is supplied at higher pressure than the usual

delivery pressure. The pressure at the meter is
continuously recorded by the Pressure/Temperature
Recorder & corresponding Pressure/Temperature factors
are applied manually on the gas volume registered on the
meter to arrive at the corrected billed volume of gas at
Base Conditions.
Pressure / Temperature
Recorder
Regulator

Regulators

Valv
e
Meter
Gas
Flow

Gas
Flow

RECORDER CHARTS

LINEAR CHARTS (DAILY / WEEKLY)

SQUARE ROOT CHARTS (DAILY / WEEKLY)

COMBINATION OF LINEAR &

SQUARE-ROOT CHARTS (DAILY / WEEKLY)

READING THE
CHARTS
FOR READING THE CHART ONE MUST

KNOW THE FOLLOWINGS

BOURDEN TUBE RANGE (BTR)

TEMP. ELEMENT RANGE

DIFF. PRESSURE ELEMENT RANGE

TOTAL NO OF DIVISIONS ON CHARTS

READING OF LINEAR
CHARTS

BTR = 1500 PSIG

TEMP RANGE = 150 OF
TOTAL NO. OF DIVISIONS = 30

ONE DIVISION OF CHART = BTR / T.D

PSIG
= 1500/30 = 50 PSIG
PRESSURE = 9.4 X 50 = 940 PSIG
O
ONE DIVISION OF CHART = T.R / 30
F
= 150/30 = 5 OF
TEMPERATURE = 13 X 5 = 65 OF

Measurement Techniques in Gas

Industry

Upstream Measurement with Volume Correctors:

A Volume Corrector is mounted on

the meter, which automatically
applies
Pressure/Temperature
factors on the volume of gas
registered by the meter to
calculate corrected volume at
Base Conditions.
Volume corrector
Regulators
Regulator

Meter

General Checking of CMS by an Officer:

The relevant forms for general checking should be used

The complete information such as cons. no., name & address,
meter/volume corrector sr. no., meter type, regulator type, types of
measurement, metering pressure, valve sizes, piping sizes, filter stainer
size etc. should be noted.
Any discrepancy needs to be reported
Sealing: Meter/Regulator seals or seals at any other vulnerable points
must be inspected and any discrepancy should be noted.
Check general condition of meters
Check oil levels in case of rotary meters
Check volume corrector ratio by taking two corrected/uncorrected
readings after some time.
Check record of last P/T recorder calibration and compare the existing
pressure with the instantaneous pressure recorded by recorder.
Take flow rate and metering pressure and perform analyses against the
metering pressure and under sizing of meters.
The load limiting devices should be checked.

Filter strainers must be installed at the CMS, arrange its cleaning

Check lubrication of plug valves, arrange lubrication if required
Check leakages and arrange rectification if required
Check regulator shutdown if required
Check meter replacement record and include in the list of schedule
meter replacement if required
Consumer /his representatives signature should be taken to
endorse the checking records
Checking of paint condition, enclosure condition, locking
arrangement and do whatever required
Few P/T recorders should be calibrated in the presence of an
engineer on monthly basis
Any other remarks should be noted and remedial action if required
should be taken
In case CMS needs to be modified. Complete proposal with
necessary drawings and list of material should be prepared for
approval from the competent authority

1.

2.

3.

Estimation of Human Resource Requirements Based on the

Work Load
Work Load Estimation: it is the work load per year in each
identifiable activity
Identify all activities in the region, such as schedule
maintenance, CMSs/TBSs etc, General Checking of CMSs /
TBSs, P/T Calibration, High Gas Bill complaints,
Emergencies, Condensate Drainage, Schedule and Defective
meter replacement
Identify schedule maintenance requirements (as mentioned in
the metering manual) and estimate frequency of such
occurrences which are not prescribed but needs to be
estimated from the statistical field data.
Have data about the no of consumers in each category, no of
TBSs / DRSs, no of pressure/temperature recorders, large
capacity CMSs (cement, fertilizers, power etc)

Example of Work Load Calculations:

Maintenance of General Industrial CMSs:
Total no of General Industry CMSs = 100
Schedule maintenance period / frequency of schedule
maintenance per year = 1 (once a year)
Work Load per Year = 100
General Checking of General Industry CMSs:
Total no of consumers = 100
Frequency of checking per year =02 (twice a year)
work load per year = 200
Emergencies and Complaints:
Estimated no complaints per year needs to estimated from the
statistical data, which will be the work load in this activity

Estimation of Teams to accomplish Metering Activities

Need to define work norm in each activity
Example1: work norm for schedule maintenance of
general industry = 3 CMS/day
No of working days in a year is taken as = 250 days
work norm per year = 750
Example2: work norm for attending emergencies (based on
experience and averaging time for various emergencies) =2 per
day
no of working days = 250
Work norm per year = 500

now we know the yearly work load and work norms in each
category, it is simply to work out the no of teams required
= work load / work norm

Consolidated worksheet in excel for these activities

Activity

No of cons.

Frequency
of
Operation

Work load

Work norm

No of
teams
required

Gen. Ind.

100

100

750

0.13

General
Checking
Ind

100

200

1500

0.13

Emergenci
es

1000

500

2.00

.
.
.
Total

2.26

Word about Record Keeping:

Maintain separate file for each high pressure commercial and

industrial consumer
Region should be suitably segregated into geographical areas
(best way to do it is by using meter reading books) about 12
groups of commercial and domestic consumers may be formed.
A group of commercial consumer should be =500-1000
A group of domestic consumers should be = 30000 50000
list of all commercial consumers in each group should be
properly filed having master data. This data should also be
available on the computer.
Data base of all industrial and commercial consumers should be
maintained, allowing entry of activities performed in the fields
such as schedule maintenance, meter replacement (schedule
and defective), consumer category w.r.t. pilferage (vulnerable or
otherwise)

A list of meters against schedule replacement should be able to

be generated from this software
The data base should be capable of segregating meters /
regulators wise lists e.g. lists of CMSs with EVC meters, meters
with mechanical volume correctors, meters with IDs but without
volume correctors etc.

REGULATORS
Fundamentals of
Pressure Control

GAS REGULATOR
A DEVICE USED TO CONTROL OR
DECREASE THE PRESSURE IN GAS FLOW
DEFINITION: -

A regulator is defined as a mechanism for controlling or

governing the moment of machines, the flow of liquids and
gases. It is often referred to as control valve, governor,
pressure reducer.

WORKING PRINCIPLE
IT CONTROLS THE PRESSURE BY
DECREASING OR INCREASING
THE GAS FLOW RATE

APPLICATIONS
GAS REGULATORS ARE USED TO
CONTROL / DECREASE THE GAS
PRESSURE AT:

SALES METER STATIONS (SMSs)

TOWN BORDER STATIONS (TBSs)
DISTRICT REGULATING STATIONS (DRSs)
CONSUMER METER STATIONS (CMSs)

BASIC ELEMENTS OF
REGULATORS

REGULATING ELEMENT
(VALVE OR EXPANSIBLE SLEEVE)

SENSING ELEMENT
(DIAPHRAGM OR BOURDEN TUBE)

LOADING ELEMENT
(SPRING OR DIAPHGRAM)

BASIC REGULATOR: There are three essential elements for a regulator.

1.
2.

3.

To measure / sense the desired level of control pressure

If the desired pressure deviates due to changing conditions,
there must be a device to change the flow of material in the
system to suit the system conditions, usually this element is
a variable restriction or a valve.
There must be some means of positioning the valve in
response to the deviation detected by the sensing element.

Three basic regulator control

actions normally encountered
are: on-off, proportional action,
proportional reset.
In this figure at 50% level,
the valve is half open and the
pressure in the gauge is 50,
pressure is 100 psig at
open and 0 at close. This system operates between 0 and 100 for full
open and close position. This is unacceptable regulation having 100%
proportional band. If the operator is told to open / close the valve by one
no. for each 1/10 line change on the gauge. In this case gauge would
vary between 45 & 55 for full open to close. The final action to
considered is proportional plus reset. The operator is instructed to open
the valve one mark for a decrease of one mark on the gauge and then
open slightly more until the gauge reads its original OK, regardless of
the valve position. The initial valve changes are proportional, therefore,
the valve is repositioned to bring the sensing element back to the
desired level. Thus valve is reset to maintain the desired pressure level.

The previous is for manual operated regulator.

The Automatic Self Operated Regulator.
Three elements in this case are: 1. Sensing Measuring element: diaphragm bourden
tube etc.
2. Restricting Element: Variable restriction in valve, it
could be single port, double port etc.
3. Loading Element: Weight spring etc.

Basic Principle of Operation:

Downward Force = 100 lbs
Diaphragm Area = Area of Diaphragm = 10 in2
Downstream Pressure = Set Pressure = 10 psig
Upward Force = P2 A = 10 10 = 100
System is in Equilibrium
Weight

Valve

Diaphragm

Out Let Pressure

Regulator Performance Characteristics

Regulation Curve

Rate of Flow

The above curve shows the ideal performance of a regulator.

Actual performance of the regulator differs from this curve.
The curve deviates from its ideal behavior due to following
reasons
(i) Diaphragm Effects
(ii) Spring Effects
(iii) Body Effects
(iv)Inlet Pressure Effect

B- Actual Performance : Diaphragm Effects : The diaphragm effects arises

due to change in the effective
diaphragm area as the valve
travels

The Upward Force = Fu = Diaphragm Area D/S Pressure

The Downward Force = Weight
Dr = Effective Diaphragm Area
Let Initial Diaphragm Area = 10 in2 in initial position when
the valve is almost in a closed position
Fu = Fd
=> 10 = Ad P(D/S)
10 = 10 P so P(D/S) = 1.0 psi

Later when regulator valve is in open position the effective

diaphragm area increases. Let it be now
Ad = 12
Fu = Ad P
10 = 12 P
So P = 10 / 12 = 0.833 psi
The Curve will look like

Out let Pressure

Ideal
Diaphragm Effect

Rate of Flow

 How to Reduce Diaphragm Effects:

1.
2.

Use Larger Diaphragms

Use Roll-Out Diaphragm to keep the effective
Diaphragm Area Constant.

Spring Effects : In a self operated regulator spring is used as a loading

force. Let us see the behavior of a spring having spring
constant (K) = 5 lbs

Initial Diaphragm Area = 10 in2

The Spring is Compressed to = 2 in2
Force Produced = 10 lbs if the diaphragm did not move downwards
Let us assume the diaphragm moves 0.2 in (Valve travel) for full open condition
In this condition the spring has not compressed to 2 inches, but in fact it has
compressed 0.2 inches lesser

The less force exerted by the spring = 0.2 5 lbs/inch = 1 lbs

Fu = Fd
Fd = K Compression = 5 (2 0.2) = 9 lbs
Fu = Ad P
9 = 12 P
or P = 0.75 which is less than the pressure due to diaphragm
effect alone
Body Effect: Effect of turbulence between diaphragm and
point of measurement on D/S pressure.
Out let Pressure

} Diaphragm Effects
} Spring Effects
} Body Effects

Rate of Flow

Inlet Pressure Effects: The inlet pressure acts on the front side
of the regulator seat, whereas outlet pressure acts on its back.
The force due to differential pressure acts in the direction of the
force exerted by the diaphragm i.e. this force should be added to
the upward force., which means that as the inlet pressure will
increase from the initial conditions.

Example: Area of Seat = As = 1 in2

Inlet Pressure = 10 psig
Outlet Pressure = 1 psig
Fu = Fd
(Upward Force) = (Downward Force)
Force on Seat + Force on Diaphragm = Force of Weight /
Spring
As (Pi Po) + Ad Po = Force of Weight / Spring
1 (10 1) + 10 1 = 19 = Force of Spring or Weight
Now if the inlet pressure is increased to 11 psig what happens
to the outlet pressure
Fu = Fd
1 (11 Po) + 10 (Po) = 19
Po = 8 / 9 = 0.89

This means that outlet pressure decreases with an increase of

inlet pressure by 1 psig. This is the reason that :
Appliances regulator have narrow inlet pressure limits and
have relatively larger diaphragm areas in comparison to the
seat area.
High pressure regulators such as our domestic regulators
have smaller orifice sizes
High pressure large capacity regulators imposes limits on
inlet pressure with respect to the orifice size to be used.

Body Effects: It is normally the impinging effect of flow of

gas on the diaphragm giving an additional upward force.

The downstream pressure immediately after the valve is

imposed on the diaphragm. The impact pressure due to flow
impinges on the diaphragm is produced which tend to close
the regulator valve.

Zero Flow: The hard seat does not provide complete lockup at
zero / low flows. The soft seats provide complete lockup at
zero flow.
Boosting Outlet Pressure: All effects such as diaphragm effect,
spring effect and body effect tend to reduce the outlet pressure
from the set point.
Out let Pressure

} Diaphragm Effects
} Spring Effects
} Body Effects

Rate of Flow

In order to overcome this short coming a technique called

Boosting outlet pressure is used. The pressure at the bottom of
the diaphragm is reduced by causing an aspiration effect.

In this design a restriction

has been constructed in
the flow of gas stream
after the valve. The
increased velocity tend to
cause low pressure
resulting in loss of
pressure under the
diaphragm, which helps
to enhance outlet
pressure.

Valve Body: Main fluid boundary and

pressure containing
component
Secures internal parts (Trim
Components) and end
connections

Bonnet: It is also a major pressure

containing component and
fluid boundary
Bolted or threaded onto the
main valve body
Guides valve stem
Provide means to mount an
actuator

Trim: All internal process wetted components e.g. valve plug,

valve plug stem, cage, seat ring, plug sealing rings

Gaskets: Bonnet Gasket (Provide sealing between body and bonnet)

Cage Gasket (Provide sealing between bonnet and cage )
Seat Ring Gasket (Provide Sealing between seat ring and body )
)

Packing: Prevents leakage between valve plug stem and bonnet

ANSI Class Body and Bonnet

PRESSURE &TEMPERATURE Ratings

Valve Plug Guiding Methods

Cage Guiding
Post Guiding
Stem Guiding

 Plug Balancing
Unbalanced Valve Plug
Tight Shot off because
only one leak path when
closed
Suitable for high
temperature application
when metal to metal
seating is specified
Because of unbalanced
design very large stem
force is required so
these are available in
smaller sizes

Balanced Valve Plug

Stem force required is greatly reduced hence a much smaller
actuator is required
Disadvantage of balanced plug is that is gives a second leak
path between the plug and cage wall when valve is closed,
seal rings or piston rings used to prevent this type of leakage.

Flow Direction
Flow-up

Flow-Down

Pressure-tends-to-open PTTO
Pressure-tends-to-close PTTC

PTTO is recommended as it prevents valve plug

from slamming into the seat
In an unbalanced plug PTTO is achieved when
valve is installed in flow-up configuration
In an balanced plug PTTO is achieved when the
valve is installed in a flow-down configuration

Unbalanced Plug
Flow Direction is Flow up
Pressure Tends To Open

Balanced Plug

Flow Coefficient (CV)

The flow coefficient refers to the number of U.S. gallons water at 60
degrees F that will pass through the valve with a 1 psi pressure drop across
the valve.

The following factors influence the flow coefficient of a

control valve:
Port size
Percentage of valve travel opening. To prevent excessive
fluid velocity at low flow, control valves are sized to pass
to pass the minimum flow at 10-20% travel and max. flow
at 80-90% travel.
The flow geometry. The flow geometry has little impact on
gas flow capacity, for gases flow is a function of the port
area alone.
Q = CVP1x

X = dP/P1

Flow
Characteristics
Relationship
between the flow
coefficient and
valve travel as the
valve travels from
0 100% open.
The three most
common flow
characteristics are
illustrated below.

ANSI Class Shutoff Ratings

The ability of a Control
valve to stop
Flow is SHUTOFF.
Depends on plug and
seat construction and
material

Design Variations Fisher E Series

ES:unbalanced plug (Metal Seated), cage guided
Typically used for wide variety of liquid and gas application that
require better shutoff (normally Class-IV) and/or High
temperature application. Typically flow up design. (Limitations:
Large Actuator force)

ED:

Balanced plug (metal seated), cage guided,

Used for clean fluids over a range of temperature (1100F).
Reduces stem force. Piston ring material affects shut off class
normally-II but class-III,IV,V are optional.
(Limitations: Shut off class-very moderate)

ET: Balanced, Cage Guide, Soft seated

Reduced Actuator force. Shutoff class achieved is IV,V and TSO
over a temperature range of up to 600F

EZ:Unbalanced, Post guided, Metal or soft seat

Used for Hydrocarbon and Dirty or viscous fluids. Limitations:
Actuator force

Various Types of Regulator Loading

and Principles of Operations
1.Self Operated Regulator
2.Pilot Operated Regulator

1.

Self Operated Regulator: Spring / Weight Loading

Pilot Operated Regulators:

Constant Pressure Loading:

This loading system enables to reduce spring and diaphragm

effects because: (i) Use of spring has been eliminated by a gas pressure
(ii) Gas pressure on both sides of the diaphragm allow use of
larger sized diaphragm to reduce diaphragm effect.

Relay Gas Loading:

Inlet pilot regulator is set at higher pressure than the required

downstream pressure
Outlet pilot regulator is set at the desired downstream pressure
Diaphragm is loaded with a pressure between these two pilots
Increase in the downstream pressure will tend to close final pilot
resulting in increase of pressure under the diaphragm to close /
restrict gas flow by closing main regulator valve.
In this regulator a small change in the outlet pressure will cause
relatively a larger change in the diaphragm chamber.

Pilot Control Variable Pressure Loading:

It is combination of gas loading and pilot control

It senses the outlet pressure and correspondingly varies the
loading pressure
If the pipeline pressure decreases, the pilot opens, increasing
the pressure on top of the main diaphragm
Downstream pressure simultaneously acts beneath the
diaphragms of the main regulator and the pilot to give quick
speed of response.

 Main diaphragm is thin because of gas pressure on its both

sides.
This system has a drawback for high pressure operation. As
the pipeline pressure increases, the pilot tends to close. If the
pilot closes completely, the gas over the diaphragm bleeds off
and pipeline pressure under the diaphragm can cause
rupture in the diaphragm.
Variable Pressure Loading Bleed to Line:
It has bleed in line
Pilot uses two diaphragms
A valve closing spring has been provided
This loading system allows high pressure operation
Loading pressure is inside both diaphragm so the effect of
changing loading pressure is cancelled out due to two
diaphragms

 As downstream
pressure decreases,
the pilot opens and
provides additional
loading pressure to
overcome the spring.
Bleed gas is
discharged to the
pipeline, thus no gas
is lost to atmosphere.
As the downstream pressure increases, loading pressure is
decreased and spring forces the valve to closing position. When
pilot shuts off, the spring force closes the valves, since no
pressure differential exists across the main diaphragm due to the
bleed.
This system provides excellent regulation at any operating
pressure
It requires minimum differential pressure to operate the regulator

Pilot Unloading Type Regulator:

Inlet of the pilot has a restriction
Inlet pressure acts on the elastomeric
element/diaphragm
Pilot regulator controls it outlet pressure to the pipeline

If

the outlet pressure decreases, the pilot

regulator opens and permits flow into the
pipeline, since the restriction exists in its inlet or
supply line, the pressure on the elastomeric
element is decreased permitting the differential
pressure to open the main regulator to restore
the pressure
Proportional band setting should be made
carefully
A very small restriction will make the regulator
sensitive, while a large opening of the restriction
valve will make the unit sluggish. Care must be
taken in case of dealing with the dirty gas as
clogging of restriction can cause the main valve
to go wide open.

Instrument Loading:
These are another class of regulators with wide
application
Normally used for larger pressure cuts such as SMSs
Have inherent advantage of pressure sensing from
downstream of the regulator, eliminating chances of
freezing within small orifice of the pilot.
Principle of Operation:
Main valve is operated
with pressure applied to
one side by the
instrument controller with
the other side exposed to
atmosphere and a spring
Spring pulls the valve open
Valve is air to close type

Main valve is operated with pressure applied to one

side by the instrument controller with the other side
exposed to atmosphere and a spring
Spring pulls the valve open
Valve is air to close type
Supply pressure of 20 psig is supplied through a supply
regulator
Spring on the diaphragm operator are designed to
provide full stroke over 3 15 psig output pressure
from the controller
Bellow moves the flapper according to the outlet
pressure, as outlet pressure increases the distance
between flapper/nozzle increases, creating low
pressure in the bellows of the Relay Valve, which
moves the Relay pilot spindle upwards (open) to allow
increased flow to diaphragm to increase pressure
causing the valve to move in the closure position.

 When flapper closes the relay valve closes, resultant loading

pressure is zero, when flapper/nozzle is wide open loading
pressure is 20 psig thus closing the control valve
By proper selection of the spring and proper setting of the preload, the closure of the control valve at 15 psig and full
opening at 3 psig could be accomplished
In this example if the bellow required 100 psig to open the
flapper to a position that 15 psig would result from the relay
valve and at zero, 3 psig would result, the valve would be wide
open at 0 psig D/S pressure and fully closed at 100 psig. That
means it has 100% proportional band i.e. it require 0 100
psig range to move the valve from one extreme to the other.

In the above figure another device, small set point spring is added
If set point spring is compressed to produce 50 psig pressure. It
will restrict the movement of the bellows up to 50 psig. The
movement of the flapper will occur after the downstream
pressure exceeds 50 psig. This means that control valve
remains full open up to 50 psig downstream pressure.
This set point spring permits the lower limit of control point
In this case the valve will half open at 100 psig
This picture shows further
refinement in
arrangement/pressure regulation.
The nozzle has been shifted
close to open point of the
flapper.

 The full opening of the flapper that have occurred at the

downstream pressure of 100 psig in the old arrangement will
take place at a pressure of say 60 psig in the new
arrangement.
Now the control valve move from full close to full open position
within the downstream pressure change of 10 psig i.e. at 50
psig - full open and at 60 psig full closed hence the
proportional band is reduced to 10%

441-57S Roll-Out Diaphragm Regulator

As the downstream pressure
decreases below the set point.
The force on the lower side of
the diaphragm decreases than
the force of the spring
As a result the spring force
pushes the plug downwards
(double seated, balanced plug),
which allows flow of gas from
inlet to outlet
The flow of gas from inlet
increases pressure in the
downstream piping which
eventually increases pressure on
the bottom of the diaphragm
As this pressure has increases to
the level of set point the
pressure on the diaphragm
becomes greater than spring

Fisher 299H Series Regulator,

Operation Schematic
When outlet pressure is less
than the set point . The top
side of the pilot diaphragm
assembly F will have a lower
pressure than the setting of
the control spring A.
The control spring A forces
the diaphragm assembly upward, opening the pilot orifice C.
Additional loading pressure is supplied from the pilot orifice to the
top side of the main diaphragm E
This creates a higher pressure on the top side of the main
diaphragm E than on the bottom side, forcing the diaphragm
downward. This motion is transmitted through a lever, which pulls
the valve disk open, allowing inlet pressure to flow through the valve.
When demand in the downstream has been satisfied, outlet pressure
increases. This increased pressure is transmitted through the
downstream control line and acts on pilot diaphragm F. Closing it.

Installation of 441-57S
Regulator as Monitor
Both the sketches show the monitor
in the downstream position when
installed in this way, the 441-57S is
usually set for an outlet pressure 2
4 psi higher than the operating
regulator and thus is wide open
during normal operation.
The monitor can be located
upstream, with this arrangement,
the regulator is usually set for an
outlet somewhat higher than the
above.
These regulators have a fast
response and therefore will take
control quickly in case of
emergency.

Fisher 399 Pilot Operated

Regulators

As long as the outlet pressure

is above the set point, the pilot
valve plug or disk remains
closed.
Inlet pressure bleeding
through the type112 restrictor
provides loading pressure to
keep the main diaphragm TSO.
When outlet pressure
decreases below set point, the
pilot plug opens.
Loading pressure bleeds
downstream through the pilot
faster than it is replaced
through 112 restrictor.
This reduces pressure on the
main diaphragm and
399diaphragm is opened
slightly to allow flow, increases
downstream pressure.

Fisher 399 Pilot Operated

Regulators

Downstream Wide-Open
(Standby) Monitoring System
The upstream regulator is in
working condition and the
downstream monitoring
regulator opens only far
enough to pass the required
flow and changes position with
each flow rate change. The
upstream working regulator
automatically supplies the
correct intermediate pressure
required to keep the
downstream monitoring
regulator open to the correct
position

Operation of Two Sets of Regulators at TBSs

Regulator orifices must be carefully selected. Larger

orifice in a regulator can handle lower pressures but
can provide larger flows, whereas smaller orifices
can handle larger inlet pressures but lower flows.
Normally maximum inlet pressures are marked with
thick lines on the capacity tables.

If

larger orifices are used at high pressure, regulator will not

give a tight lock-up.
Calculation of Regulator Capacity of Rockwell Regulators:
Q = K (Pi (Pi Po)) when Pi/Po >1
Q = K Pi / Z

when Pi/Po <1

K = valve constant given in the regulator

brochures.

CLASSIFICATION
BASED ON
WORKING
PRINCIPLE

BASED ON
APPLICATION
1.

SERVICE REGULATORS

1.

2.

FIELD REGULATORS

3.

MEDIUM SIZE INDUSTRIAL

REGULATORS

4.

LARGE SIZE INDUSTRIAL

REGULATORS

2.

3.

SPRING LOADING
REGULATORS
PILOT LOADING
REGULATORS
INSTRUMENT GAS
LOADING REGULATORS

SPRING LOADING
REGULATORS
PAK

B-36R

RW-043

B-32R

RW-042

S-402

RW-141

RW-441

RW-461

BIGJOE-630

SPRING LOADED REGULATORS

SPRING LOADED REGULATORS

PILOT LOADING
REGULATORS
FISHER-EZR

FISHER-299H

CL-31R

FISHER-399

1813

MOONEY

CL-34

RW-243-8

PILOT LOADING REGULATORS

INSTRUMENT GAS
LOADING REGULATORS
FISHER-657
USED AT LARGE CAPACITY
TBSS
CMSS
SMSS

INSTRUMENT GAS LOADING

REGULATORS
PICS

SERVICE REGULATORS
PAK
RW-043
1813
S-402
CL-31R
B-32R
B-36R
RW-042

6 WC
14 WC
2 PSIG
2 PSIG
8 PSIG
5 PSIG
8 PSIG
12 PSIG

FIELD REGULATORS
RW-042-M

50-100 PSIG

RW-141

50-100 PSIG

BIGJOE-630

50-100 PSIG

MEDIUM SIZE INDUSTRIAL

REGULATORS
CL-34
RW-243-8
FISHER-299H

8-12 PSIG
8-15 PSIG
8-15 PSIG

LARGE SIZE INDUSTRIAL

REGULATORS
FISHER-EZR

20-100 PSIG

FISHER-399

20-100 PSIG

RW-461

20-100 PSIG

RW-441

20-100 PSIG

MOONEY

20-100 PSIG

Design Of Meter and

Regulating Stations

Introduction
Proper Design of meter and regulating station is required for :

Sustained Safety
Accuracy
Pressure / flow control

FACTORS TO BE CONSIDERED FOR PROPER DESIGNING

Many particulars are to be considered and assembled into
specifications and drawings to accomplish for proper
design objectives.

Flow Range Considerations

As

a first step establish the gas load

Maximum Flow Rate
Minimum Flow Rate
Whether loads are constant, have little or wide variations
Utmost care should be taken while assessing the load
In our conditions consumer try to provide low loads to save
in security deposit, which eventually result in meter under
sizing / bad design of metering station
Normally metering stations are designed for maximum flow
rate. However minimum hourly loads should be considered
to ensure that regulators and meters have satisfactory
rangibility / regulator to have tight shutoff
Future Projections should also be included. It is appropriate
to have it agreed at the time of contract.

Pressure Conditions
Inlet pressure
Does it have wide variation
Whether it is more than normal MAOP of the instruments,
good to deliver outlet pressure e.g. normally MAOP of
meters in distribution system is 175psig and that of
Emcorrector is 100psig. If inlet pressure is more than
90psig than a regulator at the inlet of the meter would be
installed.
The maximum pressure will determine the MAOP of the
instruments, particularly of regulator
The minimum value of the pressure will be used for sizing
the regulator and metering equipment.

Pressure Conditions
Outlet Pressure
This pressure is set by the contract / operational
requirements
The regulator should be designed according to the
minimum and maximum outlet pressure acceptable to
the customer.
The amount of pressure reduction is a major indication
of whether a single stage pressure regulator will be
satisfactory or if multiple stage reduction is required.

Pressure Conditions
Type of Load
Cyclic loads needs critical analysis, to ascertain the exact
peak load (design load)
Loads that goes to zero require regulators capable of
tight-shut-off
For wider variation of loads, we would require higher
rangibility meters.
Special consideration should be given to select a meter
for continuous loads, such as process industries, city
loads etc. In these cases usually inferential meters which
does not block are more suitable. Sometimes to
omprove rangibillity multiple meter runs are installed
with switching equipments

Gas Conditions / Ambient Conditions

The pipeline quality gas should be dry and clean
If dust or other particles (condensate / higher
hydrocarbon) are present, filtering equipments should be
installed upstream of the station.
Dust filters are equipped with suitable mesh or
coalescing filter elements. It is good practice to install a
10 micron filter elements. The filters can be selected
from the tables according to gas loads and pressure.
If there are larger pressure cuts and ambient
temperature are expected to be low, the freezing of
measuring equipment should be considered. In such
cases adequate selection of heating tapes, indirect-fired
gas heaters, inhibitors like glycol injection etc.

Noise
A metering / regulating station should preferably
have noise level less than 85 db (decibel)

Metering
Station Survey
Survey of metering
station should be done
very carefully because
design of meter and
regulating station depend
on this survey. A poor
survey can result in
undersize or oversize
design.

Sample Station
Survey Forms

Selection of Dust Filter

%age of initial
Differential pressure

Dust filter should be installed at the inlet of the metering /

regulating station to protect regulator pilots / main valves,
meters etc.
Maximum flow rate at minimum inlet pressure
Maximum differential pressure = 2 psi
Maximum 10 microns solids
Design must meet ASME code and ANSI B16.34 code
Pressure Differential Vs Percent Plugged
400
300
200
100
0

25

50

75

100

Selection of Dust Filter

It has been experimentally established that filters when

clogged plugged to 50% had a 100% increase in differential
pressure, and 75% plugged element had a 400% increase
of differential pressure. It is therefore assumed that when
the differential pressure across the filter increases 100%
from the original differential , the filter elements are 50%
plugged and when the differential reaches 4 times the
original, the element are 75% plugged.
It is recommended that the filter should be replaced when
the differential pressure is of the maximum allowable
pressure drop
The 75% plugged condition is normally suggested. So the
initial differential pressure of the filter would be 1/4th of the
recommended differential pressure for filter replacement
(i.e. of the maximum allowable pressure)

Example
Conditions
Working Pressure = 100psig, Flow Rate = 60,000 ft3/Hr
Maximum Allowable Pressure Drop = 6 psig
Differential Pressure for replacement of elements =
= of Maximum Allowable Pressure drop =1/26= 3psig
Now 3 psig is the maximum pressure differential limit for filter
element replacement. According to 75% plugged rule 3psig
(80 in W.C.) differential will be experienced when filter
elements are 75% plugged. So the initial differential pressure
needs to be 80 = 20 in W.C.

Example
2 FA AND FS FILTER CAPACITY TABLE

In the table see the capacity at the intersection of 100psig inlet pressure
and 20 in W.C. differential pressure. The capacity is 66,000 ft3/Hr. which is
good for given conditions.

Removal of Condensate
Removal of condensate is accomplished by installing a
knock-out vessel at the inlet of the metering station.
Normally the direction of gas fluid is changed either by
putting an obstruction plate or by employing multiple
cyclones in parallel to remove liquid particles. The change
in velocity enables the liquid particles to drop down in the
bottom of the scrubber.

Line Heater

Increasing gas temperature at

constant pressure will bring
the gas stream in the right of
the Dew Point Boundary (i.e.
Gas Phase)

Pressure

These are used to prevent :

Hydrate condensate within gas stream to clog pilot line
and regulator orifice
Ice deposition around outside of regulator and control line

Gas
Condensate

Gas

Hydrocarbon Dew
point Boundary
Temperature

Line Heater
Line Heater Selection is based on :
Normal inlet station pressure
Minimum outlet station pressure
Design flow rate
Inlet gas temperature
Outlet gas temperature required
Maximum pressure drop across Heater Coil at design flow
(less than 10 psi)
The amount of heat required to raise the temperature of given
quality of gas to desired temperature is calculated from the
enthalpy curve.

Line Heater

At 500psig and 40F inlet temperature Enthalpy=8.5 Btu/ft3

At 500psig and 75F desired outlet temperature Enthalpy=8.9 Btu/ft3
Difference = 0.4 Btu/ft3
,
If the flow rate = 4 MMCFD = 166,666 ft3/Hr
Then amount of Heat Required = 166,666 0.4 = 66,666 Btu / Hr
By using this heating value the suitable size of Heater can be selected from the
manufacturers catalog

Regulator Selection
Regulators are required to control the downstream
pressure in the metering station at one or more points
Regulators are sized for maximum anticipated flow
requirement with the minimum inlet pressure
Although many regulators can operate over a wide flow
and pressure ranges, often it is necessary to consider
parallel runs to have better control, redundancy and
capacity increase
Regulators required to operate nearly closed position
over long periods of time will tend to have more valve
and seat damage, than a unit that is sized to have valve
open at least 10%
A small regulator can be installed in one line and the
larger regulator in the parallel line to handle larger flows
up to the required capacity

Regulator Selection
Adequate working space should be available for regulator,
plug valves maintenance
Regulators with an external control line should have
sensing point 5 10 pipe diameters. Control line may be
,1/2 or depending upon the types of regulator and
distance from the pressure sensing point to the regulator
Each regulator should have a separate sensing tap and
control line.
Sensing tap should not be installed on the fittings such as
expanders, Tees, Elbows etc.
Continuity of operation is the most essential consideration.
In case of fail to close regulators, freezing possibilities, it
is a good practice to have parallel regulator runs.

Regulator Selection
Pilots require clean and dry operating supply, heating
taps, small filters can be installed on the pilot lines
For safety of regulator operation normally, regulators
with relief valve or monitoring regulators are used. For
distribution system monitoring operation is preferred
whereas relief valve is used for remote locations in
general
Regulator by-pass and parallel legs are good for
performing routine maintenance
For fixed factor applications the droop should be in 1%
(accuracy). However, for field tapping up to 10% droop
is available.

Regulator Sizing
Most control valves are rated with a capacity term called C v,
which is defined as the number of gallons of water per
Minute that will flow through the valve with 1 psi pressure
drop across the valve.
Cv = Q / (P 62.4/6)
Where Q = quality of water in gpm
P= Pressure drop in psi
Normally Cv or K values of the regulators are given by the
manufacturers and formulae for calculating the regulator
capacity at critical and non-critical flows are given. The
capacity tables can also be used.
According to AGAs recommendation

Regulator Sizing
If P is less than 8% of (P1) inlet pressure than use formula:
Qh = 76.99Cv(P(P1)) MSCF/Hr formula - 1
Otherwise use formula
Qh = 54.5 Cv (P(P1+P2)/2) formula - 2
Capacity Formula as given by different manufacturers
ROCKWELL (Now SENSUS)
Q = K (P0(P1-P0)) for P1/P0 < 1.894
Q = K P1/2

for P1/P0 > 1.894

K factor for various orifices

Orifi
ce

Single Port

Double Port

1/8

3/8

3/4

2 1/8

33

132

292

520

850

1300

2000

4270

5450

8880

17740

Regulator Sizing
Example:
P1 = Minimum inlet pressure = 100psia
P0 = outlet pressure = 60 psia
Capacity = 200,000 SCF/Hr
P1/P0 = 100/6- = 1.66 <1.894 use formula 1
200,000 = K (60(100 60))
K = 4081, so from the above table we can select the
orifice size of 1 having K=4270
for monitoring total capacity of both regulators is
normally taken as 70% of the capacity of a single
regulator. So 2 dia regulator with an orifice size of 1
will be selected

Regulator Sizing
Find Q for K=4081
Q=4270(60(100-60)) = 209,230 SCF/Hr
If monitoring is required,
calculated K=4081 will become = 5830
Which means now we need an orifice size of 2 1/8 dia.
Which is available in 3 dia as RW-441-57S regulator. Its
MAOP is 175 psig which can handle inlet pressure of 100
psig
FISHER REGULATORS
Capacities can be calculated / regulator selected from
the
software developed by them
Capacity tables can be consulted

Regulator Sizing

(FISHER REGULATORS)

Formulas
(i) Q = P1(abs) (Cg) (1.29) when P0/P1 0.5
(ii) Q = (520/GT) Cg Sin (3417/C1 p/P1) DEG
When P0/P1 >0.5
where
P1 = Inlet Pressure
P0 = Outlet Pressure
C1 = C g / C v

, Cg = Gas Sizing Co-efficient, See tables

from Fisher catalog for 399 regulators

Important Considerations
A regulator is usually capable of having more than one orifice
size. MAOP of the regulator defines the maximum operating
pressure of the regulator body, but pressure rating for different
orifices may be less than MAOP. So great care should be taken
for the selection of orifice for a particular orifice size, otherwise
regulator would not provide tight lock-up.

Shutoff Valve Selection

Two types are generally used
Plug Valves
Ball Valves
PLUG VALVES
Reduced port
Lubricated
Recommended to be used downstream of regulator or meter
BALL VALVES
Full opening (lesser pressure drop)
Non-lubricated
Recommended to be used upstream of the meter / regulator

Shutoff Valve Selection

The capacities of the valve can be calculated from the AGA
formulas for regulators if Cv is given. However as a thumb
rule one step lower than pipe size can be used for valve size
(i.e. for 4 pipe 2 valve is normally OK. Some designers
prefer to use same size valves for symmetry and to avoid
fittings like reducers / expanders.
Block valves are installed on the inlet / outlet of the
metering and regulating stations, other locations could be.
Isolations of different sections such as filters, regulators,
meter stations, by-pass legs, blow downs, relief valves,
scrubbers etc.

Valve Joint Selection

Weld neck flanges are used for above ground
applications for ease of disassembly
Welded valves eliminate potential for leaks, these are
more suitable for underground applications
Thread valve joints have high potential for leakage,
these should be avoided as far as possible. Can be used
for small instrument valves

Pipe Sizing / Configuration

AGA recommend velocities in piping system from 50 ft/sec
to 200 ft/sec. Different companies use their own limits on
pipelines velocities. Lower velocities are used to have a
quieter system and to have low wear and tear of
instruments
SNGPL may use the value of pipeline velocity of 80ft/sec
for designing purposes
formula for calculation of velocity:
V = 0.75 Qh/D2Pf
V=velocity (ft/sec), Qh=volumetric flow rate (SCF/Hr)
D= inside diameter (inch), Pf=flowing pressure (psia)
From this formula we can calculate the diameter of piping
in various sections of the metering regulating stations
D= (0.75Qh/VPf)

Measurement
First of all determine the type of meter that will be best
suited for the load applications
In SNGPL following types of meters are generally used
Domestic / Low Capacity Commercial Metering Station
These consumers have very large variations in load which
require very high rangibility as such diaphragm meters
having rangibility of 1:100 are used
General Industry /High Pressure Large Capacity
Commercial Metering Stations
Comparatively lower fluctuations in load. Normally large
capacity diaphragm or positive displacement rotary meters
are used which have rangibility of 1:20
In case of process industry where it is not desirable to
have gas supply shutoff, turbine meters are more suitable

Measurement
Large Capacity Meter Stations such as fertilizers
Cement and Power
Normally inferential meters, orifice or turbine meters are
used for such applications
Orifice meters have a rangibility of 1:3.5 and turbine
meters have rangibility of 1:18 (at 40) and 1:44 at a
pressure of 75psig
For diaphragm and rotary meters there is no specific
requirement of straight upstream and downstream
piping

Measurement
Selection of Diaphragm and Rotary Meters
Load in SCF /Hr (maximum and minimum)
Metering Pressure (Minimum)
In diaphragm meters the capacity does not increase
corresponding to the pressure factor, as such consult
table against the maximum load and minimum metering
pressure to find select the adequately sized meters
Company is presently switching over to rotary meters
due to their sustained accuracy, smaller size and nonadjusting accuracy features

Measurement
Rotary Meter Selection
Calculate the pressure factor against the metering
pressure, suppose metering pressure = 40psig (min.)
P.F. = (40+14.65) / 14.65 = 3.73
Maximum load = 12,000 Cuft/Hr
Calculate uncorrected volume i.e. compressed volume of
the gas to be passed through the meter at metering
pressure = 12,000 / 3.73 = 3217 ft3/Hr
Divide this volume by 0.85 as a facor of safety = 3785
Capacities of rotary meters in company used are: RC3M175 = 3000 ft3/Hr , RC5M175 = 5000 ft3/Hr
RC7M175 = 7000 ft3/Hr , RC11M175 = 11000 ft3/Hr

Measurement

In this example the uncorrected flow rate is more than

3000 ft3/Hr and less than 5000 ft3/Hr, so we will select
meter RC5M175, the suffix 175 depicts its MAOP
Company has decided to go for the automatic Electronic
Volume Correction by use of Electronic Volume Correctors.
So meter RC5M175 with EVC will be selected
Similar principle shall be applied for the selection of
Turbine meters. However, great care should be taken to
have straight run piping upstream and downstream of the
meter as recommended in AGA-7
Normally 10 pipe dia upstream of the turbine meters and 5
pipe dia. Downstream are to be used
A dia by-pass line across the inlet valve of the turbine
meter leg is very essential which is needed for
commissioning of the meter

Measurement

Line & Valve

Orifice Meter Sizing

for sizing orifice meters formula
Q = C (hwPf) is used
Beta Ratio = =d/D =Orifice Dia / pipe dia = 0.5
may be used for design purposes
As a thumb rule C = Fb (AGA-3) 1.291
minimum value of hw may be taken as = 28 in H2O
pf = Absolute Static Pressure = 500 psia
Q = Fb 1.291 (28 500)

Measurement
Q = 167,000
Fb= 167,000 / (1.291 118) = 10970 (given value of about 7 orifice dia.)
Now find the value of orifice dia from the tables of AGA-3
report
Meter run dia can be found by using ratio=d/D=0.5,
hence D= d/0.5, D=7/0.5 =14 pipe dia for meter tube
The meter run can also be sized by using a computer
software programme developed by manufacturers
Normally 100 differential pressure recorder is used for
recording hw in the company
Provide maximum possible straight pipe upstream and
downstream of the orifice fittings as recommended in AGA-3
other pertinent instructions of AGA-3 should be followed

Normal Piping Arrangement of Distribution

Metering Stations
Regulators
Filter

ON/OFF VALVE

Gas Flow

Diaphragm /Rotary
Meters

ON/OFF VALVE

Pressure
Gauge

Regulators

Normal Piping Arrangement of

Distribution Metering Stations

Regulators

Regulators

Filter
ON/OFF VALVE

Meter

Gas Flow

ON/OFF
VALVE

Regulat
ors

Gas Flow

Regulat
ors

Mete
r

Filter

Normal Piping Arrangement of

Distribution Metering Stations

Large Capacity Metering Station

These stations normally have four blocks
1. Filtration
2. Regulation for the Meter
3. Meters
4. Regulation for the delivery pressure if required. Typical
sketches of piping of large capacity meters in the
company

Large Capacity Metering Station

Gas Flow

Large Capacity Metering Station

Gas Flow

Example

Load and Pressure Requirements

Load = 20 MCF/Hr
maximum
= 2 MCF/Hr
Minimum
Inlet Pressure = 90 psig maximum
= 40 psig
minimum
Outlet Pressure = 8 psig

Other Information
Type of Industry = General Industry in Private Sector
Monitoring Required = Yes, by way of Data Logging
Delivery Pressure Required = Constant
Gas Quality = Probability of Presence of Dust

Example
Proposal
Type of Measurement = Meter with EVC will be suitable
Filters = Filters will be required for the removal of dust
Regulation = Pilot Operated with minimum droop
Filter
Pressure (minimum) = 40 + 15 = 55 psia
Q(max) = 20 MCF/Hr

2 FA AND FS FILTER CAPACITY TABLE

Example
Regulators
P1/P0 = 55/23 = 2.39 >1.890
so, we will use Q = K P1/2 or K = 381
for K=381, orifice size of is suitable
for monitoring K=381/0.7 = 544 implied orifice size of
Consult Regulator catalog of various regulator manufacturers
and select regulator size with orifice or equilent
P0/P1 = 23/55 =0.41
use formula Q= Pabs Cg 1.29
Cg = 20,000 / 1.29 55 = 281
Fisher 1 399 at 60% has Cg =359
Fisher 299 has Cg=200 and has Cg=430
So Fisher 299 will be selected for monitoring

Example

Example
Meter
Rangibility = 2:20 i.e 1:10
Diaphragm or Rotary Meters can be selected.
since Rotary meters are more rugged and EVC is required,
we will go for Rotary Meter with EVC
Minimum Metering Pressure = 40 psig
Pressure Factor = 40+14.65 / 14.65 =3.73
Uncorrected Volume = 20 /3.73 = 5.36 MCF/Hr
maximum flow through the meter should be 0.85 of the
maximum rated capacity of the meter.
so uncorrected volume for design purpose = 5.36/0.85=6.3MCF
RC 5M = 5 MCF and
RC 7M = 7 MCF
So meter RC 7M175 with EVC or equivalent will be selected
which has connection size of 3

Example
Piping
Inlet Piping:
Inlet Pressure (Minimum) = 55
Qmax = 20 MCF/Hr
D = (0.7520,000)/(6555) = 2.00
Outlet Piping:
Outlet Pressure = 23
Qmax = 20 MCF/Hr
D = (0.7520,000)/(2350) = 3.16 4
To check if relative 2 dia section of pipe can be used
against calculated 4 dia pipe, assume pipe section = 1ft
Darcy Equation:
dp=(w/144)xfx(L/D)x(V2/2g)
dp=0.0471/1440.851/2(5050)/(232.17)
dp=0.0054 psig 0.148

Example
Filter
ON/OFF
P/VALVE

2 Pipe
32

Gas Flow
Diaphragm /Rotary
Meters

ON/OFF VALVE 2

32
Pressure
Gauge

Regulators

Example
Regulators
2 dia.
Filter
22
ON/OFF VALVE 1

Meter

12

12

6
3

Gas/Air Flow

Pipe Dia. 2
1/2 Needle Valve
(0 100psig)
Tee to be connected
with Air Compressor

1/2 Needle Valve

(0 100psig)

ON/OFF VALVE 1

Height from
Floor 42

Selection of shutoff valve

1.

For pressure drop in psig (subject to P=3% of Pinlet)

dp = 0.116F/PpsiaZ(Q/A)2 Q in MSCF

2.

For pressure drop in inches of water column

dp(inches of H2O) = 3.22F/PpsiaZ(Q/A)2
where dp = pressure drop
Ppsia = Absolute Static Pressure in upstream pipe
Q(SCFH)=Gas Flow in SCF/Hr
A = Pipe Flow Area in inches
Z = compressibility Factor

Selection of shutoff valve

Calculations
Inlet valve
since pipe sizing =2 so we will first analyze 2 dia valve
F=0.43 (from table)
Assume = dp=1psi , Q=20MSCF/Hr, Pressure=55psia
Z=0.98
Use dp=0.116F/Pabs Z(Qscfh/A)2
1=0.1160.43/550.98(20/A)
A2=0.355 or A=0.6
From table for A=0.6, 1 dia valve is sufficient. However for
symmetry 2 dia valve can also be recommended, which
will provide lower differential pressure.

Selection of shutoff valve

Downstream / Outlet Valve
dp=10 inches of H2O (as downstream pressure is very
low we have to keep pressure loss to be minimum)
Z=0.99
from graph
Since pipe size is 4 we will initially calculate A for 4
use formula F=0.7
dp (inches of H2O)=3.22F/Pabs Z(Q/A)2
10=3.22 0.7/23 0.99(20/A)2
A=1.6 from table again A=1.6, valve size b/w 1 to
1 1/2 is good, so we will select 2 valve.

Electronic Volume Correctors

WHY WE USE VOLUME CORRECTORS ?

The gas meters measure volumes at the metering pressures.
The correction factors such as pressure factor, temperature
factor, and super compressibility factor need to be applied on
the volume recorded by the meter in order to get the
corrected volume at base conditions. Volume Correctors
convert the actual volume of gas measured by gas meters to
reference conditions. Conversion is based on measurement of
values of volume, pressure and temperature by using the
formula:
Vb = V x P/Pb x Tb/T x Zb/Z
where
Vb = Converted volume
V = Primary volume ( from LF or HF meter output )
T = Absolute gas temperature at measurement conditions
Tb= Absolute temperature at base conditions
p = Absolute pressure at measurement conditions
pb= Absolute pressure at base conditions
Z = Gas compressibility factor at measurement conditions
Zb= Gas compressibility factor at base conditions

237

Emcorrectors: A mechanical Volume

Corrector

Prior to the use of EVCs

Emcorrectors were used

Emcorrectors are actually mechanical Correctors which senses and

apply the metering pressure on the uncorrected volume and gives
corrected volume.
Emcorrectors were not capable of applying Temperature factor

238

Electronic Volume Correctors

EMCORRECTORS

1. Electronic Volume Correctors

are capable of applying
pressure and Temp. factor

1. Emcorrectors were not capable

of applying Temperature
factor

2. Electronic Volume Correctors

have logging capabilities

2. Emcorrectos had no logging

capabilities

3. Electronic Volume Correctors

have quick response

3. Emcorrectors had much more

response time

4. It can detect meter tampering

4. Meter Tampering evidences

were not detectable

5. Logged Parameters prove

beneficial in determining
overloading and other
instances
6. Much more accurate

5. It does not have such

capabilities

6. Less accurate
7. Mechanical Recorders were
becoming obsolete

239

PRINCIPLE OF OPERATION OF EVC

EVC is a dedicated microcomputer that takes metered

volume in the form of pulses and uses transducers to
measure gas pressure and temperature and hence
corrects the metered volume.

Analog signals of gas pressure, gas temperature etc. are

multiplexed through the A/D converter and sent to the
microprocessor for processing. The microprocessor
converts the digitized analog signals to an equivalent
numeric value and stores this information in memory.

If any of the measured parameters are out of range, the

microprocessor jumps to an alarm subroutine.

After the alarm subroutine is complete, or if no alarm

conditions are present, the microprocessor computes new
correction factors based on the new measurements and
parameters already in memory. Parameters in memory
are items such as; Base Pressure, Base Temperature,
Specific Gravity, etc. The new correction factors are then 240
applied to the uncorrected volume input to obtain the
corrected volume. The amount of corrected volume just
calculated is added to the totalized corrected volume.

When the microprocessor has completed the updating of its

memory registers, it will update the LCD with the new corrected
volume information.

The device obtains data on the gas flowing through via impulses (N) from an LF or
HF sensor located in the gas meter.

The volume at the measuring conditions (V) is calculated from the number of
impulses (N) and gas meter constant (kp).

The

device obtains other data on the gas flowing through from the temperature and
pressure converters gas temperature (t) and absolute pressure at measuring
conditions (p). This data is used to calculate the conversion coefficient (C) which is
influenced also by these other factors: Absolute temperature at base conditions (Tb),

absolute pressure at base conditions (pb) and compressible factor of the gas at
base conditions (Zb).
Volume

at measuring conditions (operational volume):

Gas compressibility degree:

Conversion coefficient:

Volume

at base conditions (standardized volume):

Gas

compressibility factor expresses the deviation of properties of natural gas from

the properties of an ideal gas. By setting the parameters, it is possible to choose a
specific method for calculation of the compressibility factor pursuant to the standard
(AGA NX-19 mod, AGA8-G1, AGA8-G2, SGERG-88 or AGA8-92DC). A constant
compressibility

242

value can be used for other gases besides natural gas. If the
pressure or temperature value gets out of the limits of validity of the chosen
standard for calculation of compressibility, the device calculates using a default
compressibility value.

Operation of EVCs
V unc, Vflt,err
Volume

Alar
m

If P or T violated the
P T limits/range

A/D
Conve
r.

Micro
Proce
ssor

If P or T
within
limits

Low Batt
Alarm

Firm
war
e

V unc, Vb,
Volume
updated
in the
memory
and then
on LCD

EL-GAS EVCS
Normal Condition
Pulse

ERROR CONDITION

Pulse

Ve

P
T

V
Ve

Pd
Vb

Veb

Td

Vb

Veb
244

DRESSER EVCS
Normal Condition
Pulse

ERROR CONDITION

Pulse

Vf

P
T

V
Vf

P
Vb

Vb

245

Defined mode with life cycle of the

supply battery 4 years:

Archiving period of the data archive 1 hr

Communication with device 2 min/day
Showing on the display 2 min/day
Period of input impulses 10 Hz
Measuring period 15 s
Surrounding temperature 25 C

246

EVC COMPONENTS
An EVC typically consists of
enclosure
index or pulse-input device (normally a reed switch which
senses a magnet passing by it and generates a pulse
against each magnet rotation )
pressure transducer (a device used to convert the
pressure into electrical signals)
temperature transducer (a device used to convert
temperature into electrical signals, usually an RTD,
Resistance Temperature Detector)
display
keypad
electronic circuit boards
communication port
power supply

247

EVC COMPONENTS

248

Accuracy
. Computation: 0.3% of corrected volume reading
. Pressure transducer: 0.4% of full scale
. Temperature Sensor: 1.0F.
. Combined computation: 0.5% of full scale
(pressure & temperature)

249

METER READING THROUGH LCD

DRESSER EVCs

The LCD display is permanently active. Depending on the

configuration of the unit, following parameters can be
displayed on the LCD.
Corrected Volume
Uncorrected Volume
Correction Factor
Drive Rate
Line Pressure
Temperature
Uncorrected Volume Under Fault
Base Pressure
Pressure Factor
Atmospheric Pressure
250

Flow Rate
Supercomressibility
Battery Voltage
Current Date
Current Time
Corrected Residual
Uncorrected Residual
Firmware Version
Corrected and uncorrected volume may be scaled by a
factor of 10 or 100 to enable synchronization with
mechanical counters.
It is possible to specify which parameters are displayed on
the LCD and which one is displayed by default. We select
the corrected volume as the default parameter during
initial configuration of the units. However in the event of
an error condition the display defaults to give an error
message.
In alarm and/or fault conditions a message is displayed on
the LCD indicating the nature of the alarm/fault.

251

252

LCD AND ALARM CONDITIONS

LCD Alarm
Code

Alarm Condition

Additional
Symbols

HP AL

HIGH PRESSURE ALARM

N/A

LP AL

LOW PRESSURE ALARM

N/A

Ht AL

HIGH TEMP. ALARM

N/A

Lt AL

LOW TEMP. ALARM

N/A

HF AL

HIGH FLOW ALARM

N/A

LF AL

LOW FLOW ALARM

N/A

LCD Fault
Code

Fault Condition

Additional
Symbols

Lo bAtt

LOW BATTERY

BATTERY ICON

P FLt

PRESSURE FAULT

ALARM BELL
ICON

T FLt

TEMPERATURE FAULT

ALARM BELL
ICON

Int FLt

INTERNAL OPERATIONS
FAULT

ALARM BELL
ICON
253

ERROR AND ALARM CODES

The Error code is a decimal representation of a number built
from a series of flags where each flag represents a single bit in an
8 bit binary number.
The flags are set on the occurrence of any of these events and
remain until cleared.

Flag

Value

Condition

HIGH PRESSURE

>1.2 * Full Scale

LOW PRESSURE

< 0.8 barA or <-0.2 barG

HIGH TEMPERATURE

> 65 deg C

LOW TEMPERATURE

< -45 deg C

WATCHDOG

16

Timeout

CORRECTION
FACTOR

32

Any pressure or temp.

fault

Z CALCULATION

64

Z<0.9 or Z>1.1

LOW BATTERY

132

Low battery

254

MERCURY EVCs
The LCD of Mercury EVCs (Model Mini-Max AT) can display any
Mini-Max item but we configure it to display the corrected
volume by default. The LCD is also used to indicate alarm
conditions and to display the items in the Meter Reader List.
Normally we configure the Meter Reader List to display the
following parameters

Corrected Volume
Uncorrected Volume
Drive Rate
Unit Serial Number
Live Pressure
Live Temperature
Battery Voltage

The LCD will display decimal points between each numerical

digit when the instrument has recognized an alarm.

255

256

MINI-MAX ALARM CODES

ALARM DESCRIPTION

ITEM
CODE

E CODE

MAIN BATTERY LOW

099

.0.9.9.

INDEX SWITCH #1 FAULT

102

.1.0.2.

INDEX SWITCH #2 FAULT

103

.1.0.3.

A/D FAULT

104

.1.0.4.

PRESSURE LOW

143

.1.4.3.

TEMPERATURE LOW

144

.1.4.4.

PRESSURE HIGH

145

.1.4.5.

TEMPERATURE HIGH

146

.1.4.6.

DAILY CORRECTED
VOLUME

222

.2.2.2.

REPLACE MAIN BATTERY

.H.E.L.P.

.H.E.L.P.
257

ELSTER EVCs
The data display in the EK210 is structured in a tabular
form. The individual columns in the table contain the
following lists:
1.

User list

2.

Standard volume list

3.

Actual Volume list

4.

Pressure list

5.

Temperature list

6.

Correction list

7.

Status list

8.

System list

9.

Service list

10.

Inputs list

11.

Outputs list

258

259

STATUS LIST

Messages in system status

1

Restart ; The device was started without usable data.

Counter readings and archives are empty, the clock has not
been set.

Data Restored ; The device was temporarily without any

power supply. Data has been retrieved from the non volatile
memory.

Voltage too low : The voltage of the internal batteries is too

low to ensure trouble free device operation.

Data error ; During a cyclical check of the data an error was

found in the memory.

On account of the programming that has been carried out,

an unusable combination of settings arose, e.g. a value
which cannot be processed in a certain mode.

260

MESSAGES IN STATUS REGISTERS 1 TO 7

1
2
4
5
8

Alert for C,T and P

No usable input values for T and P
Output error at output A1 or A2
Error on pulse comparison on input E2
Warning for input E2 or E3

EK 210 and EK230 differentiates between four access parties:

Calibration lock
Manufacturer lock
Supplier lock

Customer Lock

261

El-Gas EVCs
The LCD display is normally in-active/off. On Pressing either of two
available buttons the LCD display becomes active/on. It has two list
of parameters that can be displayed on the LCD by pressing
respective Buttons. The following parameters can be displayed on
the LCD.
FIRST LIST

Base Volume Vb

Primary Volume V

Gauge Pressure

Absolute Pressure

Temperature

Compressibility Factor

Correction Factor

Status
262

Second List
Error Base Volume eVb
Error Primary Volume eV
Flow Rate
Gas Meter Constant: Drive Rate
%age Composition
Time and Date
%age Battery Power

In alarm and/or fault conditions a message is displayed on the

LCD indicating the nature of the alarm/fault.

The Error volume is generated in the event when pressure /

temperature of the flowing gas goes beyond the set limits

In the event of error volume, there is no mismatch

The Pressure limits are being set 18 150 psig so, if a EVC is to
be installed at sites where line pressure is likely to go beyond this
limit then please advise to change the limits
263

264

EL-Gas EVCs
Indication of Error State:

St 000000 (Normal, No Error)

St 100000 (Pressure Limits Exceeded)
St 010000 (Temperature Limits Exceeded)
St 001000 (Max Flow Rate Exceeded)
St 000100 (Drop of Battery below 10%)
St 000010
St 000001 (Hardware Error)

DATA DOWNLOADING USING COMPUTER

DRESSER EVCs
The micro correctors models MC & IMC have a non-volatile
(EEPROM) memory and on battery failure will retain the
totals obtained within the last hour of operation and all
settings of the corrector. These will be available and ready
for use as soon as power is restored. Data is continually
stored in memory with following capacity:

840 hourly logs

48 daily logs
15 monthly logs
The audit log is updated whenever a parameter identity
value is changed or user calibration occurs. Up to 128 audit
logs can be stored.
267

The data logging facility in Dresser EVCs model MC2 and

IMC/C2 provides the operator with 3 independent operator
configurable logging periods. The total number of logs
depends on the configuration of both the log parameters
and logging periods.
A data log may contain any of the following information.

Corrected Volume
Uncorrected Volume
Correction Factor
Uncorrected Volume Under Fault
Line Pressure
Temperature
Average Corrected Flow Rate
Peak Corrected Flow Rate
268

DRESSER EVCs INSTALLED OVER THE METERS

269

MERCURY EVCs
The Mercury EVC Model Mini-Max AT records operational
information of 40 days on an hourly or daily basis. At the
beginning of each interval, the instrument records four
items into memory. We configure the following four Audit
Trail Report Items for Audit Trail Memory.
(Any Mini-Max item can be selected for the Audit Trail)
1.

Corrected Volume

2.

Uncorrected Volume
Interval Average Pressure
Interval Average Temperature

3.
4.

270

MERCURY EVC INSTALLED OVER A METER

271

ELSTER EVCs
ARCHIVES
The EK 210 & EK230 have three archives:
Logbook (event logbook);
Here, the last 250 status changes are archived.
Changes logbook (audit trail);
Here, the last 200 settings changes are archived.
Measurement period archive;
Here, the counter readings and measurements are archived
in the cycle of the measurement period. The archive has
1500 data rows, corresponding to a memory depth of about
2 months for a measurement period of 60 minutes.
272

EVC TYPE

Manufact
urer

DRESSER

EVC READING DIGITS

CORRECTED READING

UNCORRECTED
READING

VOLUM
E UNITS

Dresser
Inc.

9 DIGITS
12345678 10

9 DIGITS
12345678 10

ft3
or m3

Dresser Inc.

9 DIGITS
1234567 100

9 DIGITS
1234567 100

ft3

DRESSER
(Older Version of
EVC/IMC )

(only if installed on 16M & above meter for other above configuration applies)
Dresser Inc.

8 DIGITS
12345678 1

8 DIGITS
12345678 1

m3

MERCURY

Mercury
Instrume
nts

9 DIGITS
12345678 Cuft 10

9 DIGITS
12345678 Cuft
10

ft3
or m3

ROMET

Romet
Intl.

9 DIGITS
12345678 Cuft 10

9 DIGITS
12345678 Cuft
10

ft3

El-Gas (up to 11M

El-Gas
Corp.

9 DIGITS
123456789.000 Cuft

9 DIGITS
123456789 Cuft

ft3

El-Gas
Corp.

10 DIGITS
1234567890.00 Cuft

10 DIGITS
1234567890 Cuft

ft3

8 DIGITS
12345678.0000 Cuft

8 DIGITS
12345678 Cuft

m3

CuM UOM)

El-Gas
Corp.

El-Gas on a RVG-

El-Gas

7 DIGITS

7 DIGITS

m3

meters)

El-Gas (16M &

above meters)

El-Gas (meter of

Configuration of EVC and Mismatch

Matching of EVC Readings with mechanical counter

reading of meter/EVC at the time of configuration.
Hence the Uncorrected Reading of the EVC should
always match with mechanical counter reading
If at any time the EVC uncorrected reading is found
less or greater than mechanical counter reading,
the phenomenon is known as MISMATCH
Since no two counters can match exactly so a
mismatch up to 1MCF is negligible and can be
ignored but any mismatch beyond this value (i.e.
1MCF) should be considered as MISMATCH
The difference of reading should be corrected by
the application of correction factors and +adjustment in the bill should be made

EVC RATIO

READING 1
CORR= 076658000
UNCORR= 004573600
Mech. CTR = 4573500
EVC PRESSURE = 75 PSIG
EVC Temperature = 63 F

READING 2 (AFTER 10-15 MIN)

CORR= 076659200
UNCORR= 004573800
Mech. CTR = 4573700
EVC PRESSURE = 72 PSIG
EVC Temperature = 61 F

DIFFERENCE OF CORR READINGS

076659200 076658000 = 1200

DIFFERENCE OF UNCORR READING

004573800 004573600 = 200

DIFFERENCE OF Mechanical Counter READING

004573700 004573500 = 200

AVG. OF EVC PRESSURE = (75+72) / 2= 73.5 PSIG

Pf = 6.02
AVG. OF EVC Temperature = (75+72) / 2= 62 F
Tf = 0.996
Total Factor = 6.0

RATIO of EVC Readings = 1200 / 200 = 6.0

RATIO of EVC Mech. Counter and EVC Corrected Readings = 1200 / 200 = 6.0

Example

READING 1
CORR= 087657000
UNCORR= 005673800
Mech. CTR = 5673300
EVC PRESSURE = 77 PSIG
EVC Temperature = 65 F

READING 2 (AFTER 10-15 MIN)

CORR= 087658200
UNCORR= 005674000
Mech. CTR = 5673500
EVC PRESSURE = 70 PSIG
EVC Temperature = 59 F

276