Reliable Detection of Water Cut in Inlet Piping Under Stratified Flow Conditions for Mature Fields and WIO and OIW Emulsion Layers in Crude Oil Settling Tanks with Novel Sensor Technology

Objectives/Scope Mature fields operations, which are almost 70% of today's production have a high water cut content. For each barrel of oil produced there can be 3 or more barrels of water. This means that operational conditions are challenging and might not be ideal for the facilities. In crude oil tanks, one of the most crucial operation parameter is the settling time of oil and water. Especially with heavy oils and high water cut, the operational conditions can be challenging with the existence of emulsion/rag layers in the tank. Most common level detection instrumentation struggle with detecting the proper interface levels leading to faulty control that can cause costly remediation and loss of revenue. This paper presents a novel solution by applying electric tomography pipe and probe sensors. Methods, Procedures, Process In electrical tomography, multiple electrodes are attached on the surface of the sensor and excitations are applied to some electrodes and responses are measured from other electrodes. Assuming a fast separation in the following crude oil tank, the operator expects the flow being stratified already in incoming trunk line. In real life this is not often the case: The incoming flow is turbulent meaning that there is no clear water/oil interface. To overcome this a pipe sensor is needed to monitor the flow regime and hence there is a possibility to control the a) chemical feed and b) flow speed to get the flow stratified. As soon as the flow is stratified in a trunk line it will be guided to a crude oil settling tank for an additional separation. In this tank there is a possibility to apply a probe sensor to monitor reliably the emulsion layer between water and oil. This allows settling time, process parameters and chemicals to be optimized to get a clear separation and hence improving the oil and water quality for a further processing. Results, Observations, Conclusions Results from pipe sensor operation in crude oil pipelines will be shared. The results will show an accurate water cut profile across the pipe cross section even under stratified flow conditions. Additionally, probe sensor results in a crude oil tank operation will be shared and hence confirming the reliability and robustness of the probe sensor operation in tanks. One of the key features of the pipe and probe sensors is the full functionality even under severe contamination with deposits on the sensor surfaces. The operational principle of this method will be shared and verified by experimental results. Novel/Additive Information The sensor technology for the tank inspection and piping uses novel electrical tomography with compact electronic and fast-acting computation with high resolution. This type of technology for settling tank application is new.