oil and gas level customer presentation.pdf

7/23/2019 Oil and Gas LEVEL customer presentation.pdf

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Rosemount LevelOi l and Gas


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Level App l icat ions in Upstream /Midstream

Oil and Gas

Condensate oil and

water tanks

Separators

Cement and fracturing

blenders

Drilling rig mud pits,

water and fuel storage

and chemical tanks

Water and oil

skim tanks

Flare knock out drums

Liquified gastanks

Accumulators/

feed tanks


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Ups tream On-sho re Oil and Gas Well Head


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[File Name or Event]Emerson Confidential27-Jun-01, Slide 4

Separators

vertical

Horizontal

Why application is critical Effective separation ensures correct

fluid goes to next process Critical for equipment life and product

quality Poor separation sacrifices product

quality

Process Characteristics Medium: Gas and water or oil and

water Pressure: up to 40 bar (580 psi) Temperature: ambient Density can change with crude

supply

Conventional method:Displacers, floats

Mechanical device, movingparts, wear & tear

Impacted by changingdensities

Regular recalibration requiredto keep accuracy

Buildup on float and wires

High maintenance/cost

Benefits

Separate phases moreeffectivelyReal time dataof separator performance

Increases control of productquality

Reliable measurement

Reduced maintenance

Best Practice: GWR with

single probe Accurate and reliable Continuous Measurement Immune to density changes Easy installation/calibration No moving parts Easy retrofit on displacer

cage or can be installed

directly in vessel

Cost Effective Option: 2100 No moving parts Immune to density change Easy installation External status indicator


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Offshore Oi l Rig Decreases Unp lanned Shu tdow ns andMaintenance Cos ts w ith Guided Wave Radar Diagno st ics

CHALLENGE

Paraffin and other sticky materials can coat probeand cause false level measurement

Occasional hydrocarbon formation in bridles cancreate inaccurate level measurement

Operators could not diagnose problems withoutconnecting directly to GWR with laptop

SOLUTION

Rosemount 5300 with single lead probe,remote waveform monitoring (via AMS),Signal Quality Metrics diagnostics

Single lead probe can handle more coating

SQM and waveforms alert techs to change in conditions

RESULTS

No unplanned shutdowns due to levelmeasurements

Reduced safety risk

Minimized maintenance costs

ApplicationScrubbers andseparators

00830-2600-4530
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Scrubbers can form HC layer in chamber

HC layer will either:

Be Detected and Levelwill read higher than actual

Not be Detected and Level

will read lower than actual(water level is detected)

SQM and remote waveformmonitoring allows easy diagnosisInsulation and heat tracing ofchamber will preventcondensation of HCsOverall scrubber efficiencyimproves

Waterpeak

Hydrocarbonpeak is now

surface peak

Waterpeak

Cooler temperature in

chamber allows light

hydrocarbons to condense

on top of water/glycol layer


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Gas and Oil separators CHALLENGE

Previously used displacer which requiredfrequent maintenance due to deposit buildup

Density variations

SOLUTION

Rosemount GWR with HP probe

No moving parts

Immune to density changes

RESULTS

Increased material availability

Reduced operations and maintenance costs

Existing cages re-used for simple low-costretrofit

Installed and commissioned, with flawless startup

ApplicationHigh pressure inletseparator,Condensate/salt water700 to 1200 psi

Markwest EnergyUSA


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Offshore Separator Effic iencyImproved w ith 2100 sw itches

CHALLENGE

Previously use float switches for thisapplication Paraffin buildup resulted in erroneous readings

Maintenance required separator to be takenoffline

Reduced availability, higher operations &maintenance costs, increased safety risks

SOLUTION Rosemount 2100 Vibrating fork switch

No moving parts

Tolerant to paraffin buildup

Easy to install

External test allows easy functionality check

RESULTS Increased facility availability


Lowered safety risks and reduced cleanupcosts

Application

Gas/Oil Separator

North American oiland gas producer

00830-0500-4030


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Condensate Oi l andWater Produc t ion Tanks

GWR Radar with flexible probe,long stud on side mount

Conventional Method

Floats

Mechanical: moving parts createwear and tear

Impacted by changing densities

Regular recalibration required toretain accuracy

High maintenance

Build-up on float and wire

Customer Benefits Avoid costly environmental incidents

Get paid for every drop of condensate Reduce miles driven Minimize maintenance and calibration Level and interface with one device and

on-line inventory data Reduced operating costs

Best Practice: 3300 or 5300with single flexible probe, 2100

Accurate and reliable

Easy installation/calibration

No mechanical moving parts

Immune to density changes

Interface to RTU with analog,HART or MODBUS output

Can be solar powered

Diagnostic tools available

Application Background

Need Service only when tanks are full Real-time inventory data on water and

NGL volumes incl. alarm conditions Share level data to trucking company Well sites are often spread over large

geographical areas

Paraffin in oil demands singlelead probes

Application Characteristics:

Process: Condensate oil or water Max pressure: Ambient Max temp.: Ambient


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Oil and Gas Producer Impro ves Spi l l PreventionProgram and Reduces Field Operat ing Costs

CHALLENGE Well sites are spread over the Rocky Mountain regions

Paraffin and iron oxide is often present which can lead tosticking

Unreliable technology required driving to well site, climbingon tank and doing hand-dips resulting in high fuel andlabor costs

SOLUTION

3300 GWR with single lead probe* Level and Interface applications with single, low

maintenance device

Replaces high maintenance floats and eliminated manualchecks

Tank Data transmitted via SCADA

RESULTS Trips to field eliminated saving labor and transportation

costs

Lowered field operating costs for production tankmeasurement

Decreased risk of environmental spills

Diminished health and safety risks to operators

ApplicationProduced water andcondensate tanks,2-3 tanks per wellsite

Independent Oil

and Gas Producer

*metallic tanks only; if non-metallic tank, use 530000830-4300-4811


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Onshore Producer Decreases Safety andEnvironmental Risks

CHALLENGE

Managing inventory of remote condensate andwater production tanks

Point level switch for level alarm previously used

Increased labor cost and safety risks andenvironmental risk of tank spills

SOLUTION

Rosemount 5300 Guided Wave Radar LevelTransmitter

Flexible Single Lead probe

Long stud option

Strong signal

RESULTS

Decreased safety risks


Minimized environmental risks

Application

Condensate & WaterProduction Tank LevelControl.

00830-0800-4530


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Cleaner Water Returned To Ocean WithGuided Wave Radar

CHALLENGE

Previously used float system required highmaintenance

Long range (17m/ 56ft)

Low dielectric hydrocarbon condensate onseawater

Sea swells added uneven surface and rapidchanges

SOLUTION 3302 GWR with flexible probe Level and Interface applications with single, low

maintenance device

Replaced high maintenance floats and eliminatedmanual checks

RESULTS

Higher measurement accuracy and repeatabilitydespite sea swell conditions

Increases safety

Reduces potential for spillage and environmentaldamage

Eliminates maintenance

ApplicationAccumulator withNatural Gas condensatelevel on sea water

Offshore platform inSouth China Sea

00830-1400-4811


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Why application is critical

Serves as recovery unit and allows vessel toflare (burn) vapors

Part of emergency management system

Environmental fines for overspill

May serve as an accumulator

Common Characteristics

Max Temperature: 50oC (122oF)

Pressure: ambient

Medium: Water with oily contaminants May have rapid changes

Tank size and shapes vary widely

Benefits Safety

Controlled release of vapors

Overfill Prevention Response time critical

Conventional Methods

Best Practice5300, 5400 or 5600

Mechanical Systems Less accurate Density Sensitive High installation costs High maintenanceCapacitance

Frequent maintenance Less accurate

Flare Knock-ou t

Immune to vapor space changes Independent of density changes Maintenance Free Two Wire System- 24V DC-

possible Digital Communication, FF*/HART Stilling well or direct connection

possible Fast Response (5600)*not for 5600


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Using Non-contact ing Radar on UndergroundFlare Knockou t Tank Reduces Cos ts

ApplicationMixtureof hydrocarbons and

dirty water that tends toleave deposits; narrowdiameter stilling well

Industry or

customer image

CHALLENGE

Underground vessel has limited access and narrowdiameter stilling wells

Fluid tends to coat and caused sticking of floatsLack of automation diminished tank capacityLong probes often arrived at site bent which causedfalse targets when installed

SOLUTION

Rosemount 5402 can be installed directly on narrowwells

Trending capacity of Radar Master provides insight toprocess conditions

RESULTSSaved $10,000 per year in operation and maintenance

costsEnables automatic control of level, reduced flareemissions, and full use of tank capacity

Trending software enables correlation of levelmeasurement to process events

00830-0600-4026


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Water and Oil SkimTank

Customer Benefits Optimal use of storage capacities Overfill protection Remote unmanned operations Reduced maintenance and operations

Conventional Method

Best Practice5302 or 3302 Single point for level and interface Immune to vapor space changes

Independent of density changes Maintenance free Two Wire System- 24V DC Digital Communication, HART, FF

Mechanical technologiesor Magnetostrictive or DP and

radar combination

Less accurate High maintenance High installation costs Sensitive to density changes


Prevention of hydrocarbons into filters Measure Condensate/Water Interface and Level

Application Characteristics Process: Ambient Pressure and temp. Medium: hydrocarbons and water, density

changes


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Guid ed Wave Radar Saves $57,000 Annually ByImprov ing Measurement of Skim Tank

CHALLENGE 10 to 15,000 barrels of oil and water mixture per

day to separate Interface measurement important since filtered

water is re-injected into ground

Oil in water plugs up filters causing dailyreplacements

Previously used combination of DP and Radar todetermine interface; density variations causedinaccuracies

SOLUTION GWR to measure level and interface

RESULTS Reduced frequency of changing filters from three

times per week to once per week for annual costsavings of $57,000

Reduced amount of water to separator, resultingin longer life expectancy and improved efficiency

More consistent measurements

Application

30ft (9m) high condensate andwater skim tanks

Multiple Sites

00830-0800-4811


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Guided Wave Radar Upg rades the Measurements atPetro-Canada in Wildcat Hills

CHALLENGE

Needed to replace mechanical tape-style level which needed frequentcleaning due to coating

Limited time for switch over

SOLUTION

GWR to measure level RESULTS

Maintenance eliminated

Continuous online measurementsprevents overspills and provides reliable

measurement Minimized start-up time with easy to use

software tools and diagnosticcapabilities

ApplicationGas Condensate Skim Tank,

24 ft (7.3 m)

00830-3000-4811


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Natural Gas LiquidsStorage

Customer Benefits

Reliable control

Reduced maintenance

Best Practice: 3300, 5300 Coax probe if clean Single probe if in chamber /stilling well

Immune to vapor space changes Independent of density changes Not affected by temperature changes Maintenance free Stable output, no recalibration

Conventional Methods

Displacers, floats & DP Density changes impact

measurement Ferrites in liquid caused coating Maintenance

Frequent calibrations


Inventory, tank capacity Maximum temperature: varies Pressure: standard Medium: liquid & gas Common characteristics:

Low dielectricTurbulentChanging densityCondensing vapors


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Cut Maintenance Costs On Natural GasLiquid Tanks w ith Guided Wave Radar

CHALLENGE

Condensation in dry legs of DP causedmeasurement errors and createdmaintenance

Low dielectric fluid with condensingvapors

Tank capacity was not fully utilized

SOLUTION GWR was installed in bypass chamber

RESULTS Eliminated time consuming trips to the

remote parts of the plant

Annual maintenance savings of $17,188per tank

Accurate level reading allowed full useof tank capacity and known quantities

ApplicationNatural Gas LiquidLow dielectric (1.7) fluid

Multiple Sites

00830-4100-4811


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Accumulators/Feed tanks


Purpose is to accumulate process fluidsso that there is adequate supply fordownstream equipment.

Overfill / underfill control

Can be utilized for equipment cooling

Common Characteristics Process: Maximum temperature: Varies

Pressure: Standard

Medium: Liquids & gases

Tank size and shape varies: Installation varies

Customer Benefits

Ensures adequate supply of process fluid toprevent damage of downstream equipment

(ex. pump cavitation) Prevent spills, environmental impact, andclean-up costs

Conventional Method

Displacer High maintenance Mechanical drifts Costly spare parts Less accurate Density sensitive Vibration sensitive

Best Practice: 5300 with single probe

Measures reliably on both high

turbulence and low dielectric fluid Immune to density changes Easy retrofit in existing displacer cage No constraints from shape of cage No mechanical moving parts Digital communication HART, FF


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Guided Wave Radar Successfu l in Liqu idPropane Accumulator

CHALLENGE

Very turbulent, low dielectric,variable density application

Previous attempts with othertechnologies, including displacers,were unsuccessful

SOLUTION Rosemount 3300 with coaxial probe

RESULTS

$350,000 savings in upgrade costs

Provided a reliable measurement for

a problematic application Accurate level measurement was

detected immediately

We have never had a reliable

measurement out of that tank.

This is the first time that

system has worked efficiently

- CPU operations director

Application:Liquid Propane Accumulator

00850-0300-4811


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Compressor Stat ion

o i l /water sto rage


Overflowing the tanks is a reportable EPAviolation

Waste of capacity if tanks are not filled Process: Oil, virgin oil and accumulated

waste oil/water mixes Max Temp.: Ambient Pressure: ~20 PSIG / 2 bar

Customer Benefits

Spills prevented

Tank capacity optimized

Reduced maintenance

Best Practice: Guided Wave Radar Single or twin probe depending on nozzle

connections and process conditions

Level and interface measurement Reliable measurement No maintenance No calibration

Conventional Method

Mechanical systems or Capacitancetype RF sensors

Frequent maintenance needed Frequent Calibration required Unreliable


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Guided Wave Radar Prov ides Rel iable LevelMeasurement at Remote Compressor Stat ions

CHALLENGE: Overflow and tank leaks were potential environmental

risks Unmanned stations are located 50 to 100 miles apart

Minimal time and labor available for installation andmaintenance

SOLUTION: 3302 with flexible probe

Top down measurement eliminated concern about tankleakage

Measurement of both level and interface with single unitreduced tank penetrations

Tank content information was transmitted to centrallocation allowing efficient scheduling of haulers

RESULTS: Exact and more consistent measurement for better

scheduling of haulers

Improved ease of installation requiring only one person

Eliminated transmitter maintenance Eliminated environmental risk by reducing leak points

ApplicationLevel and interfacemeasurements ofcondensate and brineproduction tanks

Leading Gas Gatherer &Transmission Line Company

in U.S.

00830-1900-4811


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General tanks Fuel orChem ical Storage

Well head with chemical tanksinside box

Conventional MethodFloats, servo s, capacitan ce

High maintenance

Costly spare partsLess accurate

Density sensitive

Analog transmitters

Customer Benefits No adjustments needed if fluiddensity changes

Enables automatic control of leveland full use of tank capacity

Prevents overspill while ensuringadequate supplies

Best Practice: 5400,GWR*, 3100, Switches

Rosemount 5402 can be installeddirectly on small nozzles andthose with valves

Rosemount 3300 or 5300 can fiteven smaller nozzles

Rosemount 5401 can shoot thruplastic tanks

Rosemount 3100 offers costeffective solution for easyapplications

Switches for overfill protection

Teflon or exotic materials optionsmeet chemical compatibility

Application Challenge Can be a variety of materials

including caustic, acids, fuel,emulsifying agents, and other

chemicals Connections may be limited and

small Non-contacting often desired

Application Characteristics Widely variable

*Use only 5300 for non-metal tanks

5401 shooting thru domed roofof plastic chemical tank


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Oil & Gas Distr ibutor ImprovesInvento ry Management

CHALLENGE

Measurement of Ethanol levels in storage tanksrequired to reduce risk of spills

Manual approximations being made withoutintegration into control system

Risked overfilling and spills, safety risks topersonnel

SOLUTION SmartWireless THUM Adapter and Rosemount

3300 Guided Wave Radar Level Transmitter

Wireless technology

SmartWireless Gateway to get information to acomputer

RESULTS

Increased visibility of tank level measurement

Reduced safety risk to plant personnel

Lowered risk of tank overfill

Application

Volumetricmeasurement of ethanolstorage tanks

00830-0100-4075


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Guided Wave Radar Successfu l ly Measures Levelo f Anhydrous Ammon ia

CHALLENGE

Previously used displacer requiredfrequent repairs and partsreplacement

Heavy vapor and changing densityespecially as material changes phase

SOLUTION

3300 with coaxial probe

RESULTS

Accurate and reliable measurementdespite heavy vapors

Eliminated maintenance problems

Accurate level readings independentof density changes

Application

Ammonia Storage, -33oC

Kerteh Terminals

in Malaysia

00830-3600-4811


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Oil Producer Reduces Safety Risks, Equ ipmentDamage and Energy Costs

CHALLENGE

Difficulties maintaining adequate storagecapacity due to unreliable mechanical device

Heavy turbulence and some foam

Safety risks due to frequent manual checks

Environmental risks due to overflow

Equipment damages due to insufficient level SOLUTION

Rosemount 5400 non-contacting radar

Rosemount 2120 Vibrating fork switches

RESULTS

Decreased safety and environmental risks Reduced maintenance costs

Increased availability

Reduced energy costs

Application

Oil, water, and sandproduction tank

00830-3700-4026


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The Radar probe allows us to

observe the draw o f perl i te

from the tank, which indicatesi f the slurry m ix process is

functioning properly.

Oil Produ cer Decreases Del ivery Cos ts Throu ghImproved Process Con tro l

CHALLENGE

Measurement is needed to monitor inventory andtrigger replacement of material from a supplier200 miles away

If material runs out, production stops

Because of inaccurate measurements, supplywas often ordered too soon and only half loadswere needed

Previous method: Capacitance probes wherecoating impacted reliability and accuracy

SOLUTION

5303 with single flexible probe

Probe end projection was needed because of verylow dielectric

RESULTS

Reduced delivery costs

Reduced operations and maintenance costs withimproved process Control

Decreased safety risks

Application

Perlite solid measurement,

Low dielectric (1.35) andheavy coating.

00830-0400-4530


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Prevent Overspi l ls on Float ing Roof Tanks w ithAlarm Switch Ut il izing Wireless Technolog y

CHALLENGE

Floating roof challenges a switchinstallation

Overfill is possible

High installation costs for wiring

SOLUTION

Mobrey DS20D Vertical Switch withRosemount 702 Discrete InputWireless Transmitter

POTENTIAL RESULTS

Reduce environmental and safety risksfrom tank overfilling

Minimize capital and installation costs

Decrease risk of shutdown

ApplicationFloating Roof

00860-0100-4030


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Oil Producer Reduces Risk of Env ironmentalImpact and Equipm ent Damage

CHALLENGE

Oil Producer had difficulties monitoring the level inproduction vessel and were concerned about overand under filling the vessels

Instrument technicians were concerned about theharsh ambient temperatures

Risks of environmental pollution, product loss and

high operations cost due to damaged pumps SOLUTION

Rosemount 2120 Vibrating Level Switches

Explosion-proof and IP 66/67 ratings

Fork Fast Drip design

RESULTS Decreased risk of environmental impact

Reduced risk of incurring maintenance costs

Lowered risk of equipment damage

ApplicationTank level monitoring.

Pump protection.

00830-1100-4030


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[File Name or Event]C f

Robust Level Measu rement Prov ided for Lube OilB lend ing Tank

CHALLENGE

Need reliable device with uninterrupted level reading Base oil with low dielectric, requires heating and

blending using agitation with a pulsed air system

Heating and agitation cause surface turbulence andvapors

SOLUTION

Rosemount 5401 low frequency radar transmitterwith a 6-in. cone

Low frequency signal andcondensation resistant antenna handlecondensing vapors and turbulence

Dual port has better signal to noiseratio

False echo handling software is easyto configure

RESULTS

Reliable level measurement despite turbulence

ApplicationBlending Tank

oil and gas level customer presentation.pdf

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