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www.elsevier.com/locate/flowmeasinst
Received 29 July 2004; received in revised form 24 January 2005; accepted 14 February 2005
Abstract
This paper provides an overview of research activities conducted and results obtained within an industrially driven research programme
managed through UMIST (currently The University of Manchester) over the recent years. Its main objective was to design, construct
and demonstrate new instrumentation technologies which could allow reliable measurement of the separation process in the oil and gas
extraction industries with the view of transferring the technology developed in academia into the oilfield environment. The paper describes
the developments starting from the early work, which aimed at the laboratory qualification of the distributed electrical capacitance sensors
embedded in the parallel-plate interceptor of the transparent oilwater separator located at the university Pilot Plant. This is followed by the
description of the design, analysis and industrial evaluation of the pre-prototype capacitance probe, containing 24 distributed sensors, in the
live oilfield conditions of the BP Exploration facility at Wytch Farm, Dorset, UK. Finally, the most recent advances, including industrial tests
of the prototype multi-electrode capacitance probe carried out in the National Engineering Laboratory in Glasgow are reported. The probe
was designed and built to include a mechanical deposit prevention system and to meet the flame proof standards of the oil and gas extraction
industry. The three case studies presented demonstrate the process of evolution of the measurement technology, which originally stemmed
from ECT, and its transfer into the live process environment.
2005 Elsevier Ltd. All rights reserved.
114
21 + 2 2cv (1 2 )
.
21 + 2 + cv (1 2 )
(1)
115
(2)
(3)
(4)
(5)
C = 0 +
j 0 d
where 0 is the dielectric permittivity of the vacuum. Thus
complex permittivity is defined as
= j
(6)
= j .
=+
j 0
0
Following the analysis originally conducted by Wagner [14], it can be shown that the complex permittivity of
the mixture is linked to the volume fraction of dispersed
spheres of one fluid (with permittivity 2 ) in another (with
permittivity 1 ) by the following equation
21 + 2 2cv (1 2 )
21 + 2 + cv (1 2 )
l
l h
+
= h +
1 + j
j 0
= 1
(7)
= 1
(8)
116
2
;
3
mw = water
2
.
3
(10)
117
118
Fig. 9. PPI viewed from the separator downstream end. Two plates in the
centre are embedded with sensors.
119
Fig. 10. Measurement output on the control PC. Oilwater interface was kept at 15 cm below the weir. (a) Static test; (b) dynamic testtotal flow rate of
120 l/min; oil contents 25%.
The measurements were made using a commercial capacitance meterPTL 120, capable of collecting measurements
from 64 individual channels with an accuracy of 1 fF. The
measurement frequency of the meter was 1 MHz (square
wave). The sampling time per channel was 150 ms. Fig. 4
shows the capacitance meter (contained in a metal box) connected to the plates inside the separator by a series of miniature coaxial cables. These were attached to the edges of the
PCBs and fed through three nozzles in the separator wall.
The output from the measuring unit was displayed in numerical and graphical form on the control PC, located in the
safe area of the Pilot Plant, about 30 m from the separator.
4.1.3. Sample results
The measurement system was subject to extensive static
tests reported fully elsewhere [32,34], and not repeated here.
In these tests, the positions of the interface levels inside
the pack of plates were established simply by looking for
the sharpest local increase in the capacitance between two
neighbouring electrodes (Cn Cn1 ). The accuracy of
interface detection in this way was approximately half of
the electrode height in the vertical direction (in this case
better than 10 mm). The levels determined agreed very
well with the visual observations through the transparent
separator walls, which could be made with an accuracy of
approximately 34 mm.
During the tests in dynamic flow conditions, the mixture
of oil and water was pumped into the separator vessel. The
progress of the separation process was monitored on-line
using the capacitance sensors and recorded by the control
PC. Typically, the oil fraction within the mixture was fixed
at 25%, 50% or 75% by volume. The total flow rate through
the vessel was varied between 60 and 160 l/min. During
each experiment, the outlet conditions from the vessel were
controlled such that the oilwater interface level was kept
at a steady and fixed position at the downstream end of the
separator vessel. The purpose of this procedure was to obtain
steady-state flow conditions through the vessel.
Fig. 10 gives an example of the measurement output
as seen on the screen of the control PC. This comprises
three charts, one for each sensor array. Each chart contains
the electrode number, value of measured capacitance and
120
Fig. 11. Illustration of the separation patterns for varying oilwater interface levels. Total flow rate 120 l/min; oil content 25%.
121
Fig. 12. Cross-section of the reference probe [1] (a); equi-potential linesprobe in medium of = 1 (b); equi-potential linesprobe in medium of = 80 (c).
Fig. 13. Cross-section of the probe designed in the current study (a); equi-potential linesprobe in medium of = 1 (b); equi-potential linesprobe in
medium of = 80 (c).
122
Fig. 15. Bridport separator (top); probe inserted into the separator and the
box of electronics (bottom).
Fig. 14. PCB boards used as electrode arrays in the probe (a); assembled
UMIST probe (b).
123
Fig. 17. Correlation between UMIST probe readings and displacer readings.
Fig. 18. Photograph of the probe removed from the separator.
probe is plotted against that from the float device (Fig. 17).
Most of the experimental data lie close to the regression line
marked in the figure, whose equation was determined as:
HUMIST = 0.981UFLOAT + 115.3
(11)
124
The probe was equipped with a mechanism for online and in situ deposit removal, inducing a mechanical
excitation of sensor surfaces to prevent deposition on the
surface [35].
The probe was equipped with a purpose built capacitance
measurement circuit (to replace the PTL120 capacitance
meter) working on a similar principle but with enhanced
robustness and suitable for housing in a flame proof box.
Overall the probe described has been designed to meet
flame proof equipment specification as follows: EEx m II
T6 Tamb 0 C to 80 C.
4.3.1. Probe description
The photograph of the sensing part of the probe is shown
in Fig. 19. It contains 16 detector electrodes embedded
within a 4 mm thick PCB (in the left half of the probe)
and a single excitation electrode (in the right half).
The detector electrodes are distributed along the sensing
length of 400 mm, which provides the spatial resolution
for interface measurements of about 12 mm. The PCBs are
positioned within the steel body of the probe in such a
way that there is a 12 mm wide gap, which can be entered
by the fluids for the purpose of interface measurements.
A more detailed description is not provided because the
overall measurement technique is similar to that described in
Sections 4.1 and 4.2. The flange which can be seen at the top
of the sensing part of the probe mates with a similar flange
on an extension a circular pipe with appropriate flange
125
Fig. 23. Correlation between OTL probe and pressure transducer readings.
Fig. 24. Capacitance profile for water cut of 30% and the flow rate 60 m3 /h.
126
127