The TRACERCO Profiler™The future of separator design and control
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Increase oil production, reducechemical usage and preventoverboard spillsIn what part of the offshore oil production process would greater
information yield the biggest benefits? This was the question we
asked major oil producing companies.
The TRACERCO Profiler™ measures in real time and high
resolution the vertical distribution of all phases within the separator.
This information gives operators the confidence to exert optimum
control, turning problems into opportunities:
• optimizing output
• cutting chemical costs
• eliminating maintenance
• keeping a clean environmental record.
From the North Sea and North America to the South China Seas, from
the Far East to West Africa, oil majors including bp, ChevronTexaco,
Shell, Exxon Mobil, Kerr McGee, Norsk Hydro, Statoil, ConocoPhillips,
Talisman, ADCO, CNOOC, PetroCanada, Syncrude, Total, Woodside,
Pemex and Petrobras have all benefited in better cost and
environmental performance due to The TRACERCO Profiler™.
The feedback identified the separation process as the key. “Let’s face
it, the basic function of an offshore installation is simply to separate
oil from the produced water and pump the valuable part back to
shore. Any advances in this process would be welcome.” Lack of
accurate measurement of the levels of oil and water - as well as any
sand, emulsion, foam, naphthenic acids, asphaltenes and scales -
meant that facilities are operated at less than their design capability.
As a result output was suffering; spend was high on effect chemicals;
maintenance was intensive; and there was a high risk of discharging
oily water to the sea.
Their greatest wish was for a way to see precisely what was happening
inside the separator vessels. We responded with the greatest step
forward in separator measurement and control in 40 years -
The TRACERCO Profiler™.
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“You cannot control whatyou cannot measure.”Lord Kelvin
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Over the course of 40 years Tracerco has become a world leader
in radioisotope technology to measure levels, interfaces and flow
rates for the petrochemical, chemical, oil and gas industries.
Tracerco is now part of Johnson Matthey, the global speciality
chemical company.
The TRACERCO Profiler™ supersedes the traditional single point
measurement method used for 40 years - a mechanical displacer
chamber, connected via bridle pipework, external to the separator,
which tries to mimic the interface between oil and water inside.
There is a time lag between real events and their representation in
the bridle chamber. The temperature in the bridle needs to match
that of the vessel so heat tracing is required. Sand and wax solids
can build up around the tapping point and inside the bridle chamber,
causing the displacer to stick and give a false reading. Operating and
maintaining bridle instruments is labour intensive and they are
susceptible to giving false readings especially during regular plant
changes such as swapping wells from test and clean-up, and flowing
new wells or following scale squeeze operations.
Conventional instruments are designed to give a single point
measurement not a profile. The conventional method cannot register
sand, emulsion or foam. Incorrect separation information can cause
too high a concentration of oil to be carried through the water outlet,
overloading downstream de-oiling equipment and causing oil slicks
to be discharged to sea. It can allow too high a concentration of water
to be carried over with the oil phase and hence cause downstream
knock-on separation problems. Foam carry over through the gas
outlet can cause rapid build up in downstream flare liquid knock
out vessels. Sand accumulation reduces the working volume of the
vessel and therefore its efficiency. All of these problems can result in
unnecessary trips, production and environmental problems. Excessive
amounts of costly and environmentally unfriendly anti-foam and
de-emulsifying agents must be added to ensure a safe margin and
generally the plant does not operate to its design capability.
In contrast with this, The TRACERCO Profiler™ not only measures the
interface but the extent of phase dispersion, that is, the quality of the
interface between any two phases. It brings you the complete solution.
Tracerco was proud to gain further recognition when
The TRACERCO Profiler™ was awarded The Queen’s Award
for Enterprise in the Innovation category. In Houston USA,
The TRACERCO Profiler™ was awarded the Offshore Technology
Conference (OTC) Spotlight on New Technology Award in 2004.
Trust TRACERCO to bring you thecomplete solution
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How The TRACERCO Profiler™ works
The emitter directs radiation through the fluid within the separator
to be picked up by the detector. Due to oil, water, sand, foam and
emulsion all having different densities, they will attenuate the signal
passing through them by different amounts. The density registered
by each tube is transmitted to a signal-processing unit housed in
the dome above the dip-pipes.
Profiler
Gas out
Weir
Water out Oil out
Inlet
oil/water/gas/sand
Foam Oil Emulsion Water Sand
A version of the Profiler had already proved its accuracy and reliability
on-shore in refinery vessels for a combined total of 20 years when
the technology was applied to separator measurement and control.
The TRACERCO Profiler™ comprises two or three titanium dip-pipes
installed within the separator through a nozzle of 2” or greater.
A narrow dip-pipe holds a vertical array of low energy gamma emitters.
The other dip-pipe(s) holds a corresponding array of gamma
detectors, Geiger Muller tubes. Each GM tube is matched to the
gamma emitter on the same plane.
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The information is converted into serial data and sent via fibre optic
cable to the plant computer. On the screen the fluid density at each
point is depicted in real time. For the first time ever you can see a
complete profile of the distribution of fluids within the separator:
• the interface between water and oil or oil and gas
• the quality of the separation
• the extent of foam build up
• the total liquid position
• the level of sand build-up
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Environmental benefitsare a top priority for allresponsible operators.
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At last you have total control
The TRACERCO Profiler™ makes possible the optimum use of effect
chemicals. It will not only detect the presence of foam but measure
its height; not only identify emulsion but its dispersion. Again for the
first time, the operator can see immediately the effect of dosing
anti-foam, de-emulsifier or acetic acids and therefore only the
minimum amount needed to achieve the desired effect is used.
As well as saving money, the environmental benefit of reducing the
amount of chemical and oil which is eventually discharged to sea
via the produced water is a top priority for all responsible operators.
The purpose of measurement is to provide an accurate basis for control.
Using information from The TRACERCO Profiler™, the process engineer
can set the interface and the overall liquid level at the optimum points
for efficient production. Production facilities can be operated safely and
confidently at their design limits.
Because the Profiler measures the average density between the
emitter and the detector, it is tolerant to build-up on the dip pipe
surface. Operational experience has shown that all other interface
measurement technologies will fail when subjected to surface
build-up. Even with heavy oils and calcium naphthenate precipitation
The TRACERCO Profiler™ has proved its worth with reliable service.
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Chevron Texaco Kuito
The Kuito field lies offshore Cabinda Province in Angola’s deep-water
Block 14. Kuito was Angola’s first deep-water oil field to come on
stream in December 1999. Oil is produced via an FPSO chartered
through SBM and Sonangol on behalf of operator ChevronTexaco.
Kuito is a heavy oil ranging from 18 - 22 API. The FPSO has two oil
production trains with a throughput of 100,000 bbls. oil per day.
Horizontal, gravity separation vessels are used to separate oil and
gas from produced water and solids. Following production start-up,
separation problems began to emerge, these were manifested in
numerous process upsets and shutdowns. Kuito oil can form
emulsions quickly and calcium naphthenate, or ‘Kuito Gunk’ as it is
referred to on the FPSO, is produced at higher temperatures and if
allowed to cool, solidifies. The traditional point instrumentation was
unable to detect these emulsion and naphthenate layers resulting
in the instrumentation becoming fouled and ceasing to function.
The TRACERCO Profilers were retro-fitted to three vessels and
operations were then able to identify the different layers within the
separators. This enabled oil production uptime to be increased and
chemicals, emulsion breakers and de-foamers, to be pro-actively
dosed before the plant became unstable.
The TRACERCO Profiler™ in Action
Feedback
“The TRACERCO Profilers have proved not only to be totally reliable
and basically trouble free but also a very important tool for managing
the levels within the process. Because the Profilers clearly identify
the emulsion phase within the vessels we are quickly alerted to any
adverse shift in chemical dosage rates and are then able to do
something about it in a proactive manner. Prior to the installation
of the Profilers, we would often find ourselves in an unstable or trip
condition before we realised there was a problem with the chemicals.
This is a huge advantage, being able to optimise chemical injection
i.e. not needlessly over-dosing expensive chemicals. There is absolutely
no doubt that we have kept the plant running longer and have
sustained fewer plant trips since installation of this equipment.”
Following the successful installation of 3 units, an additional 2 units
were supplied 18 months later.
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Figure 1 Vessel mimic. Operator can see different phases. Note downstream
of the weir the conventional instrument does not register the foam level
and gives a slightly incorrect measurement.
Figure 2. Screen shot showing vessel ‘A’ at start up, note the large water
layer and the small build-up of foam on top of the water.
Figure 3. 12 minutes later, note oil has been introduced and the large
build-up of foam.
Figure 4. 6 minutes later, de-foamer chemical injected and foam level
is falling.
Figure 5. 1 hour 39 minutes later showing foam level has gone; note that
there is not a clean interface. The residence time or emulsion breaker
dosage needs adjusting.
Figure 6. 2 hours 47 minutes later showing full production. Note the flat
profile of the water layer and oil layer. Operations can be confident that at
this residence time no more separation is taking place. There is opportunity
to increase flow, or reduce chemical injection.
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ConocoPhillips – Kuparuk North Slope Alaska
Located on the Arctic Coastal Plain, the Kuparuk facility is the
second largest oilfield in North America. When ConocoPhillips
brought on a new field with viscous oil and high solids content,
the 1st Stage production separator needed upgrading. The original
separator utilised displacers and differential pressure cells for both oil
and interface measurements and had also been fitted with guided
wave radar instrumentation.
In an environment where extreme winter temperatures of minus 60°F
are the norm, high reliability and maintenance-free operation is crucial
when specifying instruments. ConocoPhillips wanted to see how various
level measurement technologies performed under these conditions
while also dealing with oil production that is difficult to separate.
Feedback
The Tracerco Profiler™ was the only technology able to measure
interface and level reliably and accurately. The TRACERCO Profiler™
has been extremely helpful in identifying emulsion build-up, allowing
the Operator to attack the issue quickly with chemicals. The Operator
has also been able to improve the interface control tuning on the
water outlet valves. Sand monitoring capability was an unexpected
benefit. Operations suspected they would be able to see sand
production, but results have exceeded expectations. The Operator
anticipated sand-jetting the vessel about once per week, but with the
new viscous oil field producing more solids than expected, knowing
when to sand jet has been a huge advantage.
Vessel CPF1 Primary level. Screen shot showing 12-hour trend of all
phases - note sand build-up from 0 to 15% level over this 12-hour
period.
Screen shot showing actual levels for sand, water, emulsion, oil and
foam plus the trend from the previous hour.
Screen shot showing actual profile quality for separation for sand,
water, emulsion, oil and foam. Note lack of defined oil / water
interface causes radar to fail.
Screen shot showing 6-hour trend - note sand washing is now in
operation reducing the sand level to 0%.
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Installation
Each system, complete with field and safe area equipment, is custom
designed to fit particular processing conditions. There are two aspects,
software and hardware.
We will discuss with your engineering and operations staff the protocols,
colour of displays, running speed and all other specification details so
that we can configure the output of the Profiler to your control systems.
Installation requires a single nozzle on your vessel, there are no
valves, no bridles, no stilling wells, no heat tracing, no vents or drains.
A single Profiler can replace multiple conventional instruments,
saving you space, weight, design and installation time. Following
factory acceptance tests they are installed offshore by the operator
at a convenient vessel outage. Our engineers will supervise installation,
testing and commissioning. For a new build application, designed for
the next fifteen to twenty years what information would your operations
people prefer to see, a single point measurement or a complete profile?
The TRACERCO Profiler™ is the only level measurement system that
delivers payback.
Maintenance
There are no moving parts. The working elements are inserted into
titanium dip pipes (similar to thermo-wells), safe from any contact
with any material in the separator. Dip pipe internals can be removed
on line without depressurizing the vessel or shutting down the process.
Operator and maintenance intervention is zero.
Safety
The profiler is certified for use in hazardous areas where flammable
gases may occur. Each detector system is supplied through a galvanic
isolator housed in a safe area. The data signal is via fibre optic links.
The radiation source used in the system is similar to that used in a
domestic smoke alarm. Radiation readings cannot be detected anywhere
on the outside of the separator, even when the vessel is empty.
Source isolation for vessel entry is a simple external lever operation.
Cost effective installation andmaintenance-free safe operation
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Specifications
The TRACERCO Profiler™ Customer List
bp, Forties Delta Platform, UK
ChevronTexaco, Alba Northern Platform, UK
Shell, Tern Alpha Platform, UK
ChevronTexaco/SBM, Kuito FPSO Angola
Kerr McGee, Leadon GPIII FPSO, UK
Shell PDO, Tank Terminal, Oman
Norsk Hydro, Tune Platform, Norway
Norsk Hydro, Grane Platform, Norway
ExxonMobil, Ringhorne Platform, Norway
CNR, Ninian Southern Platform, UK
Syncrude, Alberta Oil Sands, Canada
Statoil, Snorre TLP, Norway
bp, Valhall Platform, Norway
bp, Clair Platform, UK
Conoco Belanak FPSO, Indonesia
Talisman/Bluewater, Bleo Holm FPSO, UK
bp, Schiehallion FPSO, UK
Norsk Hydro, Troll C Platform, Norway
Statoil, Statfjord B Platform, Norway
Sakhalin Energy/Shell, Sakhalin Island II, Russia
Statoil, Snorre TLP, Norway
Petro-Canada/Amerada Hess, Triton FPSO, UK
KMG/CNOOC, Bohai Bay CFD FPSO, China
Norsk Hydro, Fram Vest Platform, Norway
ConocoPhillips, Ekofisk, Norway
ChevronTexaco, Benguela Belize CPT, Angola
TengizChevroil, Kazakhstan
ADCO/Technip, Bab Field, Abu Dhabi
bp, Harding Platform, UK
bp, Greater Plutonio FPSO, Angola
ConocoPhillips, Kuparuk, Alaska
PGS/bp, Foinaven FPSO, UK
CNOOC, Nan Boa FPSO, China
Total, Dalia FPSO, Angola
Woodside Petroleum, Enfield FPSO, Australia
Pemex, Chac A Platform, Gulf of Mexico
Petrobras, P35 FPSO, Brazil
bp, Cherry Point Refinery, USA
PRI 146 series PRI 156 seriesPerformance
Vertical resolution 56mm single probe 30mm single probe
28mm dual probe 30mm dual probe
Density range 0-3000Kg/m3 0-3000Kg/m3
Max no. of density points 96 150
Update interval 1 to 15 seconds 1 to 15 seconds
Electrical
Safety code EEx ib IIC T4 EEx ib IIC T4
Operating temperature -20°C to +60°C (Probes -20°C to +125°C) -20°C to +60°C (Probes -20°C to +125°C)
Hazardous area approvals ATEX, FM, CSA ATEX
CE standards Shock/Fire hazard conforms to BS EN 61010 Shock/Fire hazard conforms to BS EN 61010
Electromagnetic compatibility complies with Electromagnetic compatibility complies with EMC Directive 89/336/EEC EMC Directive 89/336/EEC
Power requirement 100mA @ 10 volts DC 100mA @ 10 volts DC
Output from head RS232/485 signal, full duplex fibre optic RS232/485 signal, full duplex fibre opticcommunications link communications link
Detecting element Geiger Muller tubes Geiger Muller tubesStandard PLC option Allen Bradley Flexlogix Allen Bradley FlexlogixStandard communications protocol Allen Bradley Ethernet CIP or DF1 Allen Bradley Ethernet CIP or DF1Optional outputs Active 4-20mA analogue, digital volt free alarm Active 4-20mA analogue, digital volt free alarm
Intrinsically safe interfaces
Power Galvanic isolator giving 100mA @ 10volts DC Galvanic isolator giving 100mA @ 10volts DC
Isolator supply 14-35volts DC (24VDC nom.) Isolator supply 14-35volts DC (24VDC nom.)130ma @ 24volts DC 130ma @ 24volts DC
Mechanical
Vessel nozzle size Will fit 2” and greater Will fit 2” and greater
Dip-pipe casing Titanium (suitable for sour service NACE MR-01-75) Titanium (suitable for sour service NACE MR-01-75)
Operating pressure 115 Barg standard, 185 Barg UHP version 115 Barg standard, 185 Barg UHP version
Probe operating temp. +125°C standard, +200°C with cooling +125°C standard, +200°C with coolingjacket (subject to operating pressure) jacket (subject to operating pressure)
Design code PD5500, ASME VIII PD5500, ASME VIII
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The TRACERCO Advantagefor separator measurement and control
• Innovative, unique and patented technology
• The biggest advance in separator measurement and control
in 40 years
• Gives a profile of all phases, not just a single point
• Not wetted by the process, can be removed without
interrupting the process
• More cost effective to install in a new vessel than
‘conventional instruments’
• Simplify vessel design, reduction of nozzles, could justify
smaller vessel size
• Considerable weight reduction over bridle instrumentation
• High reliability, up to 150 individual measurements.
Can be used for trip, alarm and control functions
• No heat tracing required
• Not effected by sand blockage
• Environmental risk reduction
• Increased production throughput zero maintenance with
no moving parts, minimal cost of ownership over life of field
• Cost savings on chemical additives
• 40 years experience in process diagnostics and
specialist measurement
• World leadership in radioisotope detection technology
• Long established understanding of the needs of the world’s
petrochemical, chemical, oil and gas industries
• Dedicated team of specialists in offshore applications
• World-wide network of sales offices
How to find out more
There is no technology available which is comparable to The TRACERCO Profiler™. If you wish to gain the competitive advantages of lower costs,
higher throughput, zero maintenance and clean environmental credentials we invite you to contact us for further information.
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PO Box 1
Belasis Avenue
Billingham
Cleveland
TS23 1LB
UK
Tel +44 (0)1642 375500
Fax +44 (0)1642 370704
Chattan Mews Office
Suites 1 & 2
18 Chattan Place
Aberdeen
AB10 6RD
UK
Tel +44 (0) 1224 592527
Fax +44 (0) 1224 212641
1100 Hercules Avenue
Suite 200
Houston
Texas
77058-2759
USA
Tel +1 281 488 0039
Fax +1 281 488 1646
Tracerco Asia
Tracerco/Dialog Alliance
109, Block G,
Phileo Damansara 1
46350 Petaling Jaya
Selangor
Malaysia
Tel + 603 79551199
Fax + 603 79546953
www.tracerco.com [email protected]
TRACERCO and TRACERCO Diagnostics are trademarks of the Johnson Matthey Group of companies.
© 2005 Johnson Matthey Group
XM0019/0/E/JM334323
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