How IoT-Integrated LACT Metering Skids Transform Oil & Gas Operations

Transferring high volumes of crude oil from oil fields to reservoirs is a colossal task involving multiple error-prone challenges. The impact of even the smallest error can be significant, severe financial loss, issues with quality and quantity, and even compromise of safety protocols. 

The traditional way of managing such transfers has been measuring what’s going in or out. LACT metering skid solutions are widely used to control the flow.

Like any other measuring device, a LACT metering skid is built to regulate the flow of a massive quantity of liquids like crude oil. It’s akin to a modern-day toll booth, monitoring fluid flow, measuring the exact quantity being transferred from one platform to another. 

The device has evolved from analog meters with limited automation to meters with digital control instruments with maximum automation. Despite the advanced features, today’s skid meters fall short of adapting to the growing complexities of oil and gas operations.

Key Challenges in Managing Oil Flow Control

The staggering demand for oil and gas worldwide is making oil distribution a far more complex affair than ever before. This has led to mounting pressure on the system, with skid meters taking the brunt. 

For instance, overusing skid meters can sometimes render them inaccurate or non-functional, triggering unplanned downtimes and system shutdowns. Such failures may also occur due to centralized system failures, such as SCADA/PLC system failure, network communication breakdown, security breaches, software glitches, etc.

Foreseeing skid meter conditions is a major requirement for preventing disruptions. This is possible if they can be monitored remotely for early fault detection and other predictive maintenance. Enabling this is a significant challenge today.

With a rise in production and supply, keeping a tab on the oil data flow has become more crucial than before. The flow rate data must be monitored continuously to ensure no flow irregularities leading to under- or over-deliveries or leakages. 

However, data in modern-day skid meters remains siloed, making integration with plant-wide control systems difficult. As a result, delayed decision-making is common. Ensuring data sharing in real-time is the other big challenge.

A significant drawback to the lack of data integration is the non-optimization of skid meter usage. This can lead to an imbalance in meter usage—a few meters are overused while a few are underused. 

The overused meters undergo faster wear and tear and start giving inaccurate readings with time. On the other hand, the underutilized meters add to the maintenance cost without contributing to system efficiency. Therefore, ensuring proper load distribution across skid meters by tracking usage patterns is yet another big challenge.  

Added to these challenges is the need to adapt to demand fluctuations. Modern-day skid meters are not built to respond proactively to sudden changes in demand. In a volatile world order, skid meters must be more intelligent and adaptive.

IoT Integration for LACT Metering Skid Solutions

Skid meters can be made more intelligent by connecting them to a central system, enabling them to work as an integral part of a larger operational system. This way, it becomes possible to share actionable information in real time across the entire system. 

For example, the device can report to the central command in real time that 500 liters have flowed between a stipulated time, prompting the command to send updates such as “slow down” or “ramp up” to meet a specified threshold.  

To convert skid meters to smart meters, they must be connected to smart sensors, connectivity modules, and data processing systems. Integrating these features will enable the meter to capture and transmit critical fluid data, such as flow rates, pressure, temperature, etc., continuously and in real time. 

In other words, these integrations transform the skid meter turn into a live node within a plant-wide digital network, making it possible to foresee even the smallest changes for quicker coordinated action.  

Here’s how IoT-integrated LACT Metering Skid Solutions transform plant operations:

Remote Monitoring

The data generated by skid meters can be monitored remotely. This makes it possible to spot anomalies no sooner than they arise and take proactive measures to rectify them without physical inspection. This eliminates downtime and guesswork.

Dynamic Load Balancing

This involves analyzing usage patterns in real-time and distributing the workload across the system for even load taking. As a result, no single meter is overworked, extending equipment life and enhancing system efficiency.

Dynamic Recalibration

IoT integration enables skid meters to regulate the flow of liquid automatically. Based on a pre-figured command, they can analyze data flow in real-time, respond immediately to sudden changes in pressure, temperature, etc., and adapt to immediate requirements.

Enhanced Security

Integrating IoT loops skid meters into a secure digital infrastructure. As a result, they can be safeguarded against cybersecurity attacks, such as unauthorized access, data tampering, or other malicious interference.  

IoT Integration in Skid Meters

Many oil & gas companies are beginning to introduce IoT-integrated skid metering to gain more control over their systems. For instance, Badeal FZE in the UAE implemented IoT-enabled gas skid systems (PLC/HMI panels and 4G VPN-based remote monitoring) to enable efficient scheduling and remote monitoring of operations. 

Similarly, Petronas, through its Sabah Oil & Gas Terminal (SOGT) project, has integrated IoT to enable predictive maintenance and centralize operational control.

Like these two big names, several skid-mounted natural gas compression systems in the US have incorporated IoT gateways to enable remote diagnostics, receive automatic alerts, and develop trend-based fault prediction. 

The improvements witnessed across all these companies are fewer operational disruptions, greater control over operational accuracy because of real-time monitoring, and enhanced decision-making due to centralized data access.

The Road Ahead for Oil & Gas Leaders

While integrating IoT in skid metering provides several unbeatable advantages, implementing it seamlessly presents many challenges. These include integrating IoT with complex legacy infrastructure, investing in secure communication protocols and robust encryption, and controlling costs for large-scale deployments.

A proven way to overcome these challenges is to look for IoT-based LACT metering solutions. Transitioning to such a system should include a comprehensive review of current systems, executing transitions to an IoT-based system in small phases, developing a custom cybersecurity policy with robust encryption and access controls, and allocating strategic budgeting for large-scale deployment.

As the oil and gas industry makes greater strides toward digital transformation, IoT-integrated skid systems will be the key differentiator in enabling smarter and more sustainable operations. They will introduce a strategic shift and arguably become the mainstay of the energy ecosystem.