Virtual Flowmeters and Analyzers are the New Eyes of Smart Plant Operations

Plant operates in dynamic with continuous changes occurring. Although often subtle or seemingly insignificant at normal conditions, nothing in operations remains stagnant. While many non-critical or non-required continuous measurement and monitoring for lines, equipment and devices remain unmeasured, even the main ones can experience measurement accuracy issues, posing challenges to obtain reliable operational data. Stepping up in data accuracy and granularity enhancement, virtual flowmeters and analyzers via metered data-driven process modelling have been established. The work execution is guided by a structured framework which includes identification of inputs and outputs for the system boundary, mass or gas volume balance establishment, simulation model and user interface development. By leveraging the reliable measurement data from Plant Information (PI) system, the gas balance results for a site facility are robust and credible. The integration of gas balance analysis with process simulation model which can accurately emulate plant operations by determining phase amounts and physical properties through multiphase flash calculations, making it a dependable virtual flowmeter that improves the representation of fluid compositions under actual field conditions. As part of PETRONAS’s commitment in transparent emissions reporting, enhancing the accuracy of methane emissions data is a key priority. This alternative methodology to direct measurement has been demonstrated to fulfil OGMP 2.0 Level 4 requirements in terms of both source-level granularity and high-resolution methane emissions quantification. One of the Upstream Malaysia Asset field operations has shown improved data to represent its low pressure (LP) vent rate with ~19% lower flowrate, indicating reduction in emissions reporting. The integration of continuous updates on process flow rates and gas composition profiles ensures dynamic and accurate emissions estimation under varying operational scenarios. In addition to that, each site facility presents unique challenges and the issues that had been tackled were not common from one site to another. The transparent methodology embedded in the framework addresses these challenges by providing a systematic, data-driven approach to validate assumptions, identify missing sources and ensure accurate flow allocation. Expanding the functionality of the established framework not only enhances the visibility of emissions data but also enables continuous monitoring and verification, thereby significantly increasing the reliability of the site’s emissions inventory and footprint. This enables clear visualization of emission pathways, uncovering opportunities for operational optimisation and emissions reduction.