PROCEEDINGS 2003

American School of Gas Measurement Technology

2003 PROCEEDINGS PAGE xxv AMERICAN SCHOOL OF GAS MEASUREMENT TECHNOLOGY FUNDAMENTALS OF GAS LAWS John Chisholm Texas A&M University — Kingsville Chemical & Natural Gas Engineering Kingsville, TX 78363

INTRODUCTION steam molecules completely fill the confining vessel. In normal measurement conditions natural gas is always in In the gas industry a standard unit of measure is required. the vapor phase. In the English system it is the standard . In the metric, it is the standard cubic meter. This standard unit The phase of a pure substance is determined by the is the basis of all exchange in the gas industry. When the temperature and . Figure 1 is a phase diagram unit of purchase is the energy content (BTU) we achieve of a pure substance such as ethane. At low temperatures it by multiplying the BTU content of a standard cubic foot the material exists as a liquid and will occupy a specific times the number of cubic feet delivered to the customer. volume at the base of its container. As a pure substance So we must obtain standard cubic feet or meters. changes from liquid to vapor there is a sudden change of volume as the liquid changes from its minimum volume A standard cubic foot is defined as one cubic foot of gas to the volume of the confining vessel. As the temperature at a pressure and temperature agreed upon by the buyer increased across the line on Figure 1 the material changes and seller. Common standard conditions are 14.73 psia from liquid to vapor and this sudden change of volume and 60° Fahrenheit. The gas passing through a meter is can be observed. However, there is a pressure above rarely at standard conditions. It is necessary to convert which no sudden change of volume is observed. The the gas in the meter from the metered conditions to “liquid” completely filled the vessel and then the “vapor” standard cubic feet. The tools we have for relating volume completely filled the vessel. So, an observer cannot tell to pressure and temperature are Equations of State or, whether the material is a liquid or a vapor. However, as simply, the Gas Laws. the material completely fills the vessel, we can treat it as

a vapor either way. This critical pressure, Pc, is specific to The Gas Laws serve two purposes. They allow the a given material. There also exists a critical temperature, conversion of a gas stream from metered conditions to Tc, above which only one phase can exist. The critical standard conditions. They also provide an understanding temperature and pressure become important in the of what the gas is doing and why. This paper will briefly determination of the compressibility factor, z, which will present the Gas Laws and the physical properties of gas be discussed later. which the Gas Laws describe. Natural gas is not a pure substance. Figures 2 and 3 are ABSOLUTE UNITS phase diagrams for hydrocarbon mixtures. Whenever a mixture of gases exists at intermediate energy levels, two The very first thing you need to know is that all calculations phases, liquid and vapor, can exist at the same using the Gas Laws are in Absolute Units. Absolute temperature and pressure. The shape of the two phase pressure starts at zero psia, an absolute vacuum. Absolute region depends on the composition of the mixture. If the temperature starts at zero degrees Rankine, approxi- confining vessel is transparent, an obvious liquid phase mately -460°F, where theoretically no molecular motion will occupy the bottom of the vessel and the remainder of exists. It is an error to perform calculations using psig the vessel will be filled with the vapor phase. As the energy or °F. is increased, the mixture eventually goes to pure vapor completely filling the vessel as a single phase. There exists COMPOSITION OF NATURAL GAS a temperature and pressure at which an observer watching as the mixture reaches that point would report Matter can exist in three phases, solid, liquid, and vapor. that the mixture went to a single phase occupying the The phase of a pure substance such as water is controlled entire volume of the containing vessel. The unique aspect by the energy of the molecules. For example, water at of that temperature and pressure is that the moment low energy forms a crystalline solid, ice. At higher energy, before, any combination of liquid and vapor may have it is liquid water. The molecules have too much energy to existed in the chamber. This is the point where all the remain bound in a crystalline structure, but the attractive lines in the two phase region come together. For example, forces between the molecules cause them to assume a if the mixture were 75% liquid and 25% vapor, the observer minimum volume. Liquids will conform to the shape of the would announce that the mixture suddenly became single lowest parts of a vessel, but maintain the same volume. phase occupying the entire volume. Whether the material is now 100% liquid or 100% vapor, the observer would As the energy increases the vibration of the molecules be unable to tell. (Given which side of the two phase region overcomes the attractive forces and the water boils. The this point is on, one might hazard a guess.) However, as

2003 PROCEEDINGS PAGE 1 AMERICAN SCHOOL OF GAS MEASUREMENT TECHNOLOGY the single phase fills the entire volume of the vessel it The real gas law simply includes the compressibility can be treated as a gas. These values of temperature factors. P V P V and pressure are called the pseudo-critical temperature 1 1 = 2 2 and pressure, T and P . The word pseudo is from the p c p c z1T1 z2T2 Greek and means false, counterfeit, or lie. However it has

the property that it resembles the genuine. The pseudo- Solving this equation for V2 yields critical point is the point where all combinations of phases P1 T2 z2 can exist simultaneously. The pseudo-critical properties V2 = V1 can be determined for any mixture of gases and are used P2 T1 z1 to determine the compressibility factor. This equation is widely used to convert between two Natural gas consists of molecules of hydrocarbons. conditions as in the calculation of line pack, for example, Usually this is predominantly . Other gases may and to convert flowing conditions to standard conditions. be present as contaminants such as water, oxygen, nitrogen, carbon dioxide, and hydrogen sulfide. PRESSURE AND THE KINETIC THEORY OF GASES

THE IDEAL AND REAL GAS LAWS Pressure is the force per unit area. The force on the wall of a container containing gas is the number of impacts of The is given as gas molecules on the wall. So, anything that increases PV = nRT the number of impacts or the velocity of the impacts will increase the force, and, hence, the pressure. and the real gas law as PV = znRT The Kinetic Theory of Gases states that the kinetic energy where P = pressure, psia (KE) of a molecule is directly proportional to its V = volume, cubic feet temperature. z = compressibility factor, dimensionless KE(T) = 1 mv 2 = cT n = number of moles of gas, lb mol 2 T = temperature °R 3 ° R = 10.732 psia ft /(lb mol R) for this system of Where m is the mass of the molecule, v is the molecule’s units. (The value of R will change depending velocity, and c is a constant. on the system of units.) The Ideal Gas Law can be derived using the Kinetic The difference between the ideal and the real gas law is Theory. And the derivation explains a great deal about the compressibility factor, z. The ideal gas law assumes what pressure is and how gases react. that the molecules of gas have no volume and there are no attractive or repulsive forces acting between the Consider a cubic container with sides of length L, molecules. At very low z =~ 1.0 and gases behave as if they are ideal gases. At higher pressures the attractive and repulsive forces (often called the dynamic pressure) are significant and the behavior of gases deviates from the ideal. The compressibility factor is often called the gas deviation factor or, simply, the z-factor. L Early experiments were conducted at low pressures and the gases tested acted as ideal gases. Boyle’s Law states that at a constant temperature the product of the pressure L and the volume is a constant, so any two conditions, 1 L and 2, of a gas were related by In a container of fixed volume, the velocity controls how P1V1 - P2V2 long it will take a molecule to travel from one side of the Charles’ Law states the ratio of volume to temperature container to the other and back again. is constant at constant pressure, V V Length of a round trip = 2L 1 = 2 T T 1 2 The number of impacts on a given wall is then: These can be combined into one of the most common v Number of impacts per unit time = expressions of the ideal gas law. 2L P V P V 1 1 = 2 2 where v is the average velocity of the molecule. Each T1 T2 molecule of gas hits the wall at v and rebounds at –v. The

PAGE 2 2003 PROCEEDINGS AMERICAN SCHOOL OF GAS MEASUREMENT TECHNOLOGY momentum of a molecule is its mass times its velocity, The Kinetic Theory shows that each impact contributes so the change of momentum at the wall is given by: to the pressure. If the temperature increases, the velocity increases, the round trip time goes down, and the number ∆ momentum = m’v - m’(-v) = 2m’v impacts goes up, hence, more pressure. If the number of molecules in the container increases, the number of where m’ is the mass of each molecule and the ∆ stands impacts increase and the pressure increases. Finally, if for “change”. Consider a ball thrown at a wall. The wall the volume of the container is reduced, it takes less time must first stop the bal’s momentum (m’v) and then send for the molecules to travel back and forth, so each it away again with momentum m’v. So from the point of molecule makes more impacts in a unit of time. More view of the wall it had to impart to the ball 2m’v, half just impacts produced more pressure. The reverse of each of to stop it and half to send it away. these events produces less pressure.

The change in momentum of a molecule per unit time is Both Charles’ and Boyle’s Laws have been derived from given by: the Kinetic Theory. Some other very useful laws can be ’ 2 2m’v * v = m v derived from the Kinetic Theory. (For the record, the Laws 2L L were determined experimentally before the Kinetic Theory n’ was developed.) Avogadro’s Law states that, at the same Only a third of the molecules, in the box are hitting 3 temperature and pressure, equal volumes of an ideal gas each wall. contains the same number of molecules. Also the volume containing one molecular weight of a given gas will be The force acting on a wall is the number of molecules equivalent to the volume containing one molecular weight times the change in momentum per unit time. of another gas at the same temperature and pressure. n’ m’v 2 There are 2.73 x 1026 molecules per pound of an F = 3 L ideal gas. And pressure is the force per unit area. When the Kinetic Theory is extended to mixtures of gases, 2 2 Dalton’s Law of Partial Pressures can be found. Dalton’s P = n’ m’ v 1 = n’ m’ v 3 L L2 3L3 Law states that the pressure on a surface by a gas is the sum of the pressures that would be exerted by each Now, L3 = V, the volume of the cube, so: component in the gas if it were alone, n’ m’ v 2 n’ m’ v 2 P = or PV = P = P + P + P + ... 3V 3 total A B C The beginning assumption was that the kinetic energy and that the partial pressures are proportional to the mole was a function of temperature alone. fractions of each component. The partial pressures become especially important if liquid water is in contact Then, with the gas. The partial pressures can be used to 2 n’ m’ v = 2cT and PV = 2cT determine what fraction of each gas is in solution in the 3 liquid. If significant quantities of CO2 or H2S are present, where c is a constant. they will produce corrosive acids in solution with water.

THE DYNAMIC PRESSURE AND THE Z-FACTOR Before completing the derivation, consider some consequences of the equation above. If the temperature The Kinetic Theory assumes no attractive or repulsive is held constant, then PV = a constant, which is Boyle’s forces are acting in the gas. This allows the Kinetic Theory Law. If pressure is held constant, then V = a constant, to derive the ideal gas law. However, these forces do exist which is Charles’ Law. T and at higher pressures cause gases to deviate from ideal behavior significantly. These forces are called the dynamic If we set A = Avogadro’s number, the number of molecules pressure. The gas deviation factor is just the ratio of the in one mole, then actual volume of a gas to that which would be predicted by the ideal gas law. n’ 2 PV = cA T V A ( 3 ) z = ACTUAL Now VIDEAL n’ 2 = n and we set cA = R As the pressure increases from near atmospheric, the A 3 molecules are pushed closer together. Both gravitational Then, and electrical attractions cause the molecules to pull PV = nRT towards one another with the result that the volume occupied by the gas is less than that predicated by the which is the ideal gas law. gas law. The z-factor becomes less than one.

2003 PROCEEDINGS PAGE 3 AMERICAN SCHOOL OF GAS MEASUREMENT TECHNOLOGY As the pressure continues to increase, the molecules, and molecular weights of the individual gases are which have a real volume and velocity, begin to interfere available from any gas handbook. with the other molecules in the gas. Personifying the gas, one can think of each molecule fighting for its own space. EXAMPLE 1 – A turbine meter indicates that 4,000 macf This results in repulsive forces. So the z-factor begins to of gas passed through it in one day. The line pressure increase and returns to and then exceeds 1.0, so that at and temperature were 500 psia and 122°F. The gas high pressures the gas will occupy more volume than stream was 85% methane, 9% ethane, 4% propane, and that predicted by the ideal gas law. 2% butane+. What volume of gas in mscf was delivered that day? As many pure gases and mixtures of gases were tested it was observed that their behavior matched that The calculation of the critical properties of this gas is given described above. Although the z-factors for methane in Table 1. followed the same trends as that of ethane, the z-factors were by no means identical. To unify these relations all 122°F + 460 = 582°R the tests were related to the reduced temperature and pressure. pTr = 582°R / 384.5°R = 1.51 pPr = 500 psia / 664.2 psia = 0.75 Tr = T and Pr = P T P c c z = 0.925

For mixtures, the pseudo-critical properties can be used Pline Tsc zsc Vsc = Vline in these calculations. When plotted for each and every P T z hydrocarbon gas the z-factor lines now tracked together. sc line line This discovery is commonly called the Law of Corresponding States. This allowed a generalized 500psia 520°R 1.0 V = 4,000 macf compressibility factor chart to be developed. sc 14.7psia 582°R 0.925

Many mathematical correlations have been developed V = 131,417 mscf to calculate z-factors. The current methodology in AGA 8 sc should be used unless another method is specified in a EXAMPLE 2 – LINE PACK gas contract. Each day a pipeline must be balanced as to reciepts and The pseudo-critical properties can be calculated using deliveries. A pipeline also represents a large storage unit for gas. At a constant temperature, if the pressure of the PTc = Σ yj Tcj and pPc = Σ yj Pcj pipeline is different at the end of the day than at the beginning, then the reciepts and deliveries will not balance where yj is the mass fraction of each component of the because the amount of gas stored in the pipeline has mixture. Values of yj are obtained from gas changed. Determining the amount of that change is often chromatograph readings. called a line pack calculation.

The density and specific gravity of a gas can be Consider the gas of Example 1. The pipeline runs 39 miles calculated using of 8 inch pipe with a total enclosed volume of 70,000 ρ ρ cubic feet. If we start the day with an average pressure of ρ MWg g MWg = and SGg = = 500 psia and 122EF and end it at 600 psia and 122EF, g ρ zRT air MWair how much additional gas is in the pipeline? ρ where MWg is the molecular weight of the gas and g is Initial gas in the pipeline: the density of the gas. Values of the critical properties Ppipe Tsc zsc Vsc = Vpipe Psc Tpipe zpipe Table 1. Pseudo-Property Calculation for Example 1.

Component Mole Fraction Tc yjTcj Pc yjPcj yj °Rankine °Rankine psia psia C1 0.85 343.3 291.8 666.4 566.4 C2 0.09 549.9 49.5 706.5 63.6 C3 0.04 666.1 26.6 616 24.6 C4+ 0.02 830.0 16.6 482 9.6 384.5 664.2

PAGE 4 2003 PROCEEDINGS AMERICAN SCHOOL OF GAS MEASUREMENT TECHNOLOGY 500psia 520°R 1.0 V = 70,000 acf sc 14.7psia 582°R 0.925

Vsc = 2,127,311 cubic ft = 2,127mscf

At 600 psia, pPr = 0.903 and z = 0.905. So,

600psia 520°R 1.0 V = 70,000 acf sc 14.7psia 582°R 0.905

Vsc = 2,820,744 cubic ft = 2,821 mscf So, 2,821 – 2127 = 694 mscf more gas is stored in the pipeline at days end than at the beginning.

REFERENCES

McCain, William D., Jr., The Properties of Petroleum Fluids, Penn Well Books, Tulsa, Oklahoma, 1990.

Thompson, Roger G., “Fundamental Gas Laws,” Proceedings of the 29th Annual American School of Gas Measurement Technology, Houston, Texas, September 19-22, 1994.

Gas Processors Suppliers Association, Engineering Data Handbook, Tulsa Oklahoma, 1972.

Standing, M.B. “Volumetric and Phase Behavior of Oil Field Hydrocarbon Systems,” SPE of AIME, Dallas, Texas, 1977.

Standing, M.B. and Katz, D.L., “Density of Natural Gases,” Transactions AIME, 146, 1942.

John Chisholm

2003 PROCEEDINGS PAGE 5 AMERICAN SCHOOL OF GAS MEASUREMENT TECHNOLOGY FUNDAMENTALS OF ORIFICE METERING Bill Buckley Daniel Measurement and Control P.O. Box 19097, Houston, Texas 77224

INTRODUCTION circular, flat device, which is held in the flowing stream by a holding device. Typically, it is made of a durable The purpose to this paper is to discuss the fundamental metal such as stainless steel. Orifice plates come in components used in orifice measurement basically two types, the paddle plate and the universal plate. The paddle plate is held in place by flanges, while BACKGROUND the universal plates fit into the various types of holding devices. AGA #3 standards spell out specific The general concepts of head meters, which include the requirements for the orifice plates, including the orifice, have been known for centuries. The orifice has concentricity of the orifice bore, the surface finish, been in commercial use since the early 1900’s. The flatness of the plate, and edge thickness. While the orifice device is used to create a differential pressure that relates plate is the least expensive of the components in orifice to the velocity of the gas from which a flow rate can be measurement, its importance should not be overlooked. calculated. As the following gas passes through the restriction in the line caused by the orifice plate, the difference in the upstream and downstream pressure can be measured at set points, called taps, and a flow rate at the point can be determined

FIGURE 2. Orifice Plates

ORIFICE DEVICES

There are primarily three different types of devices used FIGURE 1. Head Meter to help center an orifice plate in the flowing medium. The first and least expensive is the orifice flange union. STANDARDS AND IMPORTANCE This is a pair of flanges, which has been tapped to provide a differential reading. While it is the least expensive to Orifice measurement is guided by the standards of purchase, it requires a higher maintenance level since several organizations. Primary among these is the the line must be bled down and the flanges spread apart American Gas Association and the American Petroleum in order to remove the plate. Institute. The AGA #3 report is the standard that provides guidelines for the construction and installation of orifice The next device type is the single chamber orifice fitting. meters. All orifice plates, holding devices and meter tubes The single chamber device has an advantage over should be manufactured adhering to this standard in flanges in that it makes removal of the plate easier and order to help insure that the end product is an accurate safer due to the prevention of spillage that occurs when measurement device. flanges are spread apart. Like flanges, however, the simplex device requires that the line pressure be bled ORIFICE PLATES off before the plate may be removed. The simplex device utilizes universal type orifice plates. The most fundamental component of orifice measurement is the orifice plate. This is typically a

PAGE 6 2003 PROCEEDINGS AMERICAN SCHOOL OF GAS MEASUREMENT TECHNOLOGY STRAIGHTENING VANES AND FLOW CONDITIONERS

Straightening vanes are bundles of small diameter tubing, which are placed inside the upstream section of a meter tube. They are commonly of two types, flanged and in- line. The flanged types are held in the line between a pair of flanges in the upstream. The in-line vane is held in place inside the tubing by setscrews. Their purpose is to facilitate the smoothing of flow going into the orifice plate while allowing for shorter upstream tubing lengths.

FIGURE 3. FIGURE 4. Orifice Flange Union Single Chamber Fitting

The third device is the dual chamber orifice fitting. This fitting allows for the removal of the universal orifice plate without first bleeding down line pressure. This is accomplished through the use of internal valves, which isolate the upper (non-pressure) chamber from the bottom (pressured) chamber. The senior type is the most expensive of the plate holding devices to purchase, but FIGURE 7. Straightening Vanes could be the most economical when compared to the overall cost of the installation since isolation valving is not required to allow plate removal.

FIGURE 8. Flow Conditioner

The flow conditioners eliminate swirl like a straightening FIGURE 5. Dual Chamber Fitting vane and also generates a near fully developed flow profile. The conditioner also reduces the amount of required METER TUBES upstream tubing needed to meet AGA #3 requirements.

A meter tube basically consists of upstream tubing, the SECONDARY DEVICES orifice fitting or flanges and downstream tubing. The purpose of tubing is to insure as smooth a flow profile, The orifice fitting with its orifice plate is known as the going into the orifice plate, as possible. The AGA #3 primary devices in the orifice measurement package. standard has very specific requirements for meter tube There are other devices known as secondary devices, pipe, including the smoothness of the inside surface of which translate the raw information from primary devices the tubing and minimum lengths required under particular into more useable information. The most common of installations. If these standards are not met in the these are pneumatic chart recorders and flow computers. manufacture of the meter tube, then degradation in measurement could result.

FIGURE 6. Three-Section Meter Tube FIGURE 9. Secondary Devices

2003 PROCEEDINGS PAGE 7 AMERICAN SCHOOL OF GAS MEASUREMENT TECHNOLOGY The pneumatic chart recorder presents the information are usually AC or DC powered and provide not only the from the differential pressure, static pressure and same calculations capability as the solar –powered units, temperature transmitters in a graphical form, usually but also have advanced flow control and alarm circular charts. The chart usually represents a 24-hour capabilities. or 8 day time period, which can be integrated later to provide volume figures. CONCLUSION

Flow computers have increased in use in recent years The new AGA #3/API 14.3 measurement standard has due to the requirements for measurements information greatly tightened the tolerances for the manufacture of on a more “real time” basis. Flow computers, like the orifice devices and meter tubes. It is very much in the pneumatic chart, take the flow information from the best interest of the users of these devices to have sound differential pressure, static pressure and the temperature maintenance programs in place to insure that the like- transmitter and calculates flow volumes. Unlike the chart, new quality of the tubes be maintained for as long as flow computers do not have to go through an integration possible. The primary device, whether a fitting or flange, step to come up with these figures. There are several cannot be expected to provide accurate, reliable flow levels of sophistication available in flow computers. The information if the orifice plate is bowed or otherwise battery-powered, solar charged devices have the best degraded in some way. The vast body of data supporting utility as field devices, which can store the flow orifice measurement over the years becomes information on site, do the volume calculations and then meaningless if the guidelines for the design, manufacture, send that information on to a higher device such as a installation and maintenance of these devices are not mainframe computer. The higher-level flow computers followed.

Bill Buckley

PAGE 8 2003 PROCEEDINGS AMERICAN SCHOOL OF GAS MEASUREMENT TECHNOLOGY