Profiler Brochure

The TRACERCO Profiler™The future of separator design and control

JM_344_323 bProfiler Brochure UK 7/2/05 11:58 am Page 2


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™.


“You cannot control whatyou cannot measure.”Lord Kelvin


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


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.


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


Environmental benefitsare a top priority for allresponsible operators.


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.


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.


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.


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%.


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


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


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.


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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