ROG.e 2024

Conference paper and oral presentation.

Title

Non-Intrusive Measurement of Levels in Process Vessels.

Authors

Dmitri Gorski and Uwe Lieske (Nicoustic), Robert Neubeck (Fraunhofer IKTS), Arne Ulrik Bindingsbø (Equinor).

Abstract

Level measurement in process vessels is a common technology in use on all offshore and onshore oil and gas installations. There are many available measurement principles, from simple floaters and differential pressure (DP) cells to advanced capacitative probes and profilers utilizing radioactive sources. Almost all level instruments in commercial use today, with very few exceptions, are intrusive. This means that a probe/sensor is mounted on the inside of the process vessel to measure level. Intrusive technology has several drawbacks. An intrusive sensor is exposed to the harsh environment inside process vessels, which can be erosive, corrosive, high-pressure, dirty and all of the above. This often leads to deterioration of the sensor and its readings. Examples of this are plugging of tubing connecting to a DP cell or growth of scale on a profiler that impends its function. Intrusive solutions can also lead to extremely costly installation and maintenance since production in the process vessel needs to be stopped. A downtime of 1-2 weeks can result in hundreds of millions in lost revenue for a large installation.

This paper describes a novel level measurement instrument where the measurement principle is based on Guided Elastic Waves (GEW). The main advantage of this measurement principle is that it is non-intrusive. The sensors are mounted on the outside of the vessel and no production downtime is required during installation and maintenance.

The technology is a result of cooperation between Equinor (Norway) and Fraunhofer IKTS (Germany) and the development is still ongoing. The solution is based on more than 20 years of experience that Fraunhofer IKTS has in ultrasonic wave research and applications and an Equinor innovation challenge, powered by the need of improved level measurement on its installations. Nicoustic is a spin-off company that was formed in June 2022 in order to commercialize the development results.

Technology Readiness Level (TRL) of the basic measurement is now 4 out of 7 on the API scale. This means that a prototype sensor was qualified by Equinor for an offshore trial. The trial will commence in Q1-2024 and the goal is to validate accurate non-intrusive measurement of sand and absolute liquid level in an offshore oil and gas separator. The technology qualification was performed at SINTEF Multiphase Flow Laboratory in Trondheim (Norway).

Research and development is still ongoing to reach advanced level measurement capabilities and to explore the potential to perform online vessel integrity measurement using the same hardware as for level measurement. This R&D project will start in Q1-2024 and is planned to continue for 3 years. The goal is to develop a fully capable and non-intrusive alternative to a traditional separator profiler that uses radioactive source or capacitative principle. Several operator companies are supporting the upcoming Joint Industry Project around this R&D.

If the development is successful, this technology will revolutionize level measurement in process vessels by significantly reducing CAPEX and OPEX for advanced level measurement solutions. This means that it will be possible to easily retrofit a profiler-type instrument on an asset in production, something that is prohibitively expensive with current technology. On older installations separators and often not equipped with profilers, while emulsions and sand production are an increasing problem. A non-intrusive profiler can be an enabling technology and a game-changer since it will allow much more accurate process control and increased production efficiency.

Key words

Guided elastic waves, guided ultrasonic waves, level measurement.

Citation (APA)

Gorski, D., Lieske, U., Neubeck, R., & Bindingsbø, A. U. (2024, September). Non-Intrusive Measurement of Levels in Process Vessels. In ROG.e. IBP.

Full text

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