11 c8972 00-ic-deg-0001

WorleyParsons EuoNomicSresources & energy

KUWAIT OIL COMPANY

lnstrument Selection Guide

'l 1C8972-00-|C-DEG-0001 Rev 1

9, July 2013

LOWER FARS HEAVY OIL DEVELOPMENT FEED

WorleyParsons Canada Services Ltd.Caloarv Division Heaw Oil Business Units¿ù- iz' Avenue s\ /Calgary, AlbertaT2R OH4

Telephone: (403) 508-5300Facsimile: (403)508-5301www.worleyparsons.comABN 61 001 279 812@ Copyright 2010 WorleyParsons

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INSTRUMENT SELECTION GUIDE

SYNOPSISThis document presents lhe Instrument Selec{ion Guide forthe Kuwait Oil Company Lower Fars Heavy Oil

Development Feed Projec-t.

Dlsclalmer

Thls Design Guide is ænceptuat in naturc and reprcænts the work of WorleyParsons performed to røcognized

engineering Nínciptes and pnctices apprcpriate for conceptual engineeñng work and the terms of rcfercnce

prcvided by WortøyParsons' contnctual Customer, Knait Oíl Company (the "Customef). This dæument may

not be retted upon for detaited imptementation or any other purpose not specifrcally identilled withln this

documøn¡ This document is conÍidentiat and p¡eparcd solely for the use of the Customer. The contents of this

dæument may not be used or retied upon by any party otherthan the Customer, and neitherWorleyParsons,

ffs suö ¿pnsultanfs northeirrcspective employeas assun?e any liabil$lorany,eason, including, but not

timited to, negligence, to any othar pafty for any information or rcpresentation herein. The extent of any

wamnty orguanntee of this documentorthe ìnformatton contained thercin in favourof the Cusfomeris

ttmlted to the wananty orguamntee, if arry, contained in the contnct between the Customer anQ

WorteyParcons.

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CONTENTS

{.0 SUMMARY..

2.0 INTRODUCTION TO INSTRUMENT SELECTION

3.0 DEFtNtTtONS .............

4.0 GENERAL CRITERIA

General

lnstrument Material Selection

Diaphragm Seal Assemblies...............

5.0 FLOW METERING,........

General

4.1

4.2

4.3

5.1

5.2 Flow Meter Technologies

5.3 Service...........,.....

5.3.1 Acid and Caustic

5.3.2 Boiler Feed Water..........

5.3.3 De-Oi|edWater..................

5.3.4 Disposal Water..........

5.3.5 Emulsion

5.3.6 Filtered Produced Water..........

5.3.7 Flare Gas

5.3.8 FuelGas......

5.3.9 Hydrocarbon Gas - Wet And Dry

5.3.10 Hydrocarbon Liquids.........

5.3.1 1 Oily Produced Water........

5.3. 1 2 Produced Soft Water.....................

5.3.13 Raw Potable Water

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5.3.14 Sales Oil.............

5.3.15 Skim Oil

5.3.16 Sludge..

5.3.17 Steam.........

5.3.18 Steam Condensate

6.0 LEVEL MEASUREMENT.,..............

General .....

17

18

18

18

18

20

206.1

6.2

6.3

6.4

Level Measurement For Vessels

lnterface Level Measurement ....,

.20

.21

.22

.23

.23

.23

.23

Tank Level Measurement And Gauging

6.5 Service..

ô.5.1 Boiler Feed Water Tank

6.5.2 Chemical Storage Tank ................

6.5.3 De-Oiled Produced Water Storage Tank

6.5.4 DisposalWaterTank...

6.5.5 Free Water Knock Out, Treater and De-Salter Vessels

6.5.6 FuelGas Drum KO Drum

6.5.7 Oily Produced Water Storage Tank......

6.5.8 Oil Storage/Shipping Tank............

6.5.9 SteamSeparatorVessel

6.5.10 Skim Oil Tank............

6.5.11 Slop Oil Tank ............

7.0 PRESSURE MEASUREMENT...........,.

7.1

7.2

General

Service...

7.2.1 Boiler Feed Water

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7.2.2 Disposal And Blowdown Water.....

7.2.3 Emulsion

7.2.4 HydrocarbonCondensate

7.2.5 Oily Produced Water........

7.2.6 Produced Water..........

7.2.7 Sales Oi|......

7.2.8 Skim Oil And SloP Oil...

7.2.9 SlopWater.......

7.2.10 Sludge And Slurry.

7.2.11 Steam

7.2.12 WasteWater

7.2.13 Wet Gas..............

8.0 ANALYTICAL MEASUREMENT......,...

8.1

8.2

8.3

8.4

8.5

8.6

8.7

8.8

8.9

Water Cut....

Basic Sediment And Water..........

Salt ln Oil

Oil ln Water.

Turbidity

Dissolved Oxygen........

Water Hardness.......................

TotalDissolved Solids

Steam Quality

9.0 VALVES......

9.1

9.2

9.3

General

Control Valves

ESD And Switching Va|ves.........

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9.4

9.5

10.0

1 1.0

Safety Relief Valves.

Choke Va|ves.........

TEMPERATURE M EASUREMENT

OTHER INSTRUMENTS........,....

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¡NSTRUMENT SELECTION GUIDE

I.O SUMMARY

The Lower Fars Heavy Oil development is targeted at a large heavy oil accumulation of approximately

7 to 15 billion banels of oil located in a desert area of some 1200 square kilometers in northern Kuwait.

This project will develop in phases. This is Phase 1 of the development and involves well gathering

systems, wells, an lnfield Satellite Station (lSS) and the Central Processing Facility (CPF).

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2.0 INTRODUCTION TO INSTRUMENT SELECTION

The objective of this guide is to provide insight for instrument selection that is specific to the requirements

of the Lower Fars Heavy Oil Facility. This is achieved by describing the advantages/disadvantages of the

various instrument technologies available and recommending the best technology for the service

conditions that will exist in this facility. This document is not an instrument specification. WorleyParsons

will define a measurement technology guide that will provide reliability, performance, accuracy and

economícal considerations.

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3.0 DEFINITIONS

ASTM

4C.....

BFW..

BS&W

cST

dp

DC

FWKO...................

GWR.....................

tGF .......................

tP..........................

NACE

NTU..

American Society for Testing and Materials

Alternating Cunent

Boiler Feed Water

Basic Sediment and Water

Centistokes - measure of viscosity

Differential Pressure

Direct Current

Free Water Knock Out

Guided Wave Radar

lnduced Gas Flotation

lngress Protection

National Association of Corrosion Engineers

Nephelometric Turbidity Units

nanometer

Parts per billion

Parts per million

Scale to measure acidic or basic of oil

Pounds of salt per thousand barrels - salt concentration

Stress Corrosion Cracking

TotalDissolved Solids

TotalSuspended Solids

Microsiemen per centimeter - measure of conductivity

Nm.................

ppb

ppm

pH..

PTB

SSC

TDS

TSS

uS/cm

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4.0 GENERAL CRITERIA

4.1 Gene Rnl

Basic environmental design data is as per KOC 'Statement of Requirements'. Kuwait is subject to

sandstorms and heavy rainfall. The atmosphere is generally dusty and corrosive and in some areas may

contain traces of hydrogen sulphide. For electrical equipment design, ambient temperature shall

be -3"C to 50"C for all indoor and outdoor equipment. Where instruments are located outdoors a sun,

shade will be provided. Field-mounted instruments shall be moisture and dust proof, suitable for the area

classification and meet the specified lngress Protection (lP). Minimal acceptable standard of protection

against water or dust ingress is lP 65.

All instruments shall be certified for the appropriate area classification, gas group and temperature class

by a recognized European testing authority to BS 5501 or equivalent. Transmitters, on a service that

contains combustible fluids, shall be provided that have integral secondary seal arrangement.

lnstrument signals will generally be Foundation Fieldbus for process control applications and HART for

shutdown applications. Allfield instruments shall be powered from the control room interface cabinets

and shall be intrinsically safe. Conventional or HART electronic transmitters may be used for process

control with prior approval from KOC.

A¡ devices which are part of a Safety lnstrumented Function (SlF) shall be certified for the appropriate

SIL level as confirmed per SIL study by KOC approved organization as per KOC-|-017.

lnstruments shall meet the following KOC standards, project specific criteria and addendums:

KOC-t-001

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KOC Standard for lnstrumentation and Control System

Design

KOC Standard for Control and Shutdown Valves

Project Specific Criteria To KOC Standard forlnstrumentation and Control System Design

General lnstruments

Addendum to KOC Specification General lnstrumentation

lnstrumentation, Control And Telecommunication Design

Criteria

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Note: The reference to industry standards can be found in the above documents.

4.2 lrusrnumeNT MATERlAL SELEcrloN

The standard vendor offering for the wetted material of instruments shall be 316 SS or better with NACE

certification. The KOC standard for instrument's process fluid wetted parts materials in oil/gas facilities

requires latest NACE certification. This materialwill be suitable for most applications within the heavy oil

facility. The exceptions are as follows:

The produced water services in the facility will have high chloride concentration and

temperatures ranging from 90"C up to 300"C. The use of 316 SS in any of the de-oiled

produced water services is not recommended. For instrument installations there are two

options that can be considered. The first option is to provide the instrument wetted parts,

tubing system and manifold valves in an upgraded material, which is immune to chloride

stress corrosion cracking such as inconel, monel, titanium, hastelloy or duplex. The second

option is to install a diaphragm seal anangement to isolate the 316 SS instrument from the

process.

ln the high temperature, high pressure steam service hydrogen permeation is a concern

with stainless steel diaphragms. The transmitters should be upgraded by adding gold

plating on the diaphragm.

ln the water softening process there may be acid and caustic services where instruments

will require a material upgrade.

4.3 D¡lpsnncM SEAL AssEvtsl¡es

lnstrument may require to be provided with integral or remote diaphragm seals in lieu of impulse line.

Diaphragm seals may typically be applied in the following applications:

As an alternative for impulse line in viscous, waxy, sticky or plugging services. The

viscosity in impulse lines should be below 200 cSt under all normal and abnormaloperating

conditions. At ambient temperatures below 40'C the viscosity of the Lower Fars Heavy Oil

and emulsions, with lower water-cut, will exceed the recommended viscosity for impulse

lines.

a

a

a Lethal or corrosive service process fluid shall not be introduced to impulse sensing lines or

instrument body.

lf the fluid temperature under any normal or abnormal operating condition exceeds the

re of the instruments sensing element. Some instrumentsa

maximum allowable temperatu

may have a maximum process

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LOWER FARS HEAVY O¡L DEVELOPMENT


Fitting liquids shall be .ål""t"O in consultation with the party responsible for the process design and with

the manufacturer. The seal filling liquid shall be suitable for the upper and lower pressure and

temperature limits of the process and shall not harm the process upon rupture of the diaphragm. Filling

fluids for capsules and diaphragm seals shall not present a hazard to the environment in the event of a

diaphragm failure.

Special attention shall be paid to the use of diaphragm seals handling small ranges (typically 50 mbar or

smaller) and interface level measurement.

Facilities connections such as flush rings shall be provided to test and calibrate the diaphragm seal type

transmitters. This is essential on applications where process fluids can accumulate and solidify on the

sensing element or impulse tubing.

The use of diaphragm seal and capillary systems should be carefully considered because they represent

a significant cost and negatively impact the sensitivity/reaction time of the process measurement.

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5.0 FLOW METERING

5.1 Ge¡¡ennu

ln a heavy oil facility the flow measurement of the oil and emulsion will be very difficult with standard

instrumentation. The oil has a high viscosity. The emulsion will also have a high viscosity and may have

entrained sand/silt that can cause plugging and erosion of flow elements. Produced water will have

enough oil in it to cause plugging and coating issues. Even the wet produced gas will contain enough oil

particles to cause plugging and coating.

ln the water treatment process of a heavy oil facility there will be slurry and sludge flows that present a

problem for flow metering with conventional instruments.

5,2 Fr-ow Meren Tecxnouoe les

Orifice plates are typically the first choice for a flow measurement device. The installation is inexpensive if

kept simple regardless of the line size. The turn down is poor and the installation requires a lot of straight

piping length for upstream/downstream. Orifice plates are not good in applications with viscous fluids or

fluids with entrained solids.

V-cones are a differential pressure flow element that provide better turn down than most differential

pressure flow elements with very little requirement for upstream/downstream piping. V-cones can work

with vapours and liquids. They willwork with liquids that contain entrained solids. V-cone meters find a

lot of application in poor quality steam service and clean liquid services. The meters are available in any

line size.

Wedge meters are differential pressure flow elements that are designed for viscous liquid services and

liquid services with entrained solids. They require substantial upstream/downstream piping and provide a

poor turn down. Wedge meters find a lot of applications in the heavy oil emulsion service.

Electromagnetic flow meters will only work on liquids that are electrically conductive. These meters are an

inline meter. They require no consideration for upstream/downstream piping and are bi-directional. They

are not suitable for water/oil mixture because the oil will coat and foul the sensors. Cost increases

substantially with line size and pressure rating.

Vortex meters work in gas or liquid services. They require substantial upstream/downstream piping but

provide good turn down. They will not work in viscous liquids or in flows with low Reynold's number. Cost

increases substantially with line size and pressure rating. A vortex meter measures the pressure

fluctuations in the vortices of the fluid as it moves bar. The vortex meter will not be

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suitable in oil/water mixture applications because the heavy oil viscosity will cause fouling of the pressure

sensors, especially in the lower temperature conditions. They are available up to a 12 inch size. Gas and

entrained sediment may also provide difficulties for flow measurement using this type of meter.

Ultrasonic flow meters will work in gas or liquid services. There are two technologies available, transit

time and Doppler that are used to determine the fluid velocity. They provide excellent turn down but

require substantial upstream/downstream piping. ln liquid service the line must be full, and with a

minimum of entrained solids. Ultrasonic meters can be inline or clamp on to the external piping. The

transit time unit works by bouncing an ultrasonic signal off the wall of the pipe and measuring the transit

times against and with the fluid flow to determine the velocity. ln general they are designed for measuring

homogenous fluids. There are clamp on units that will work in two phase liquid flow but only if one of the

phases is less than 10olo of the total volume because the interface points between the two liquids causes

scattering/interference of the ultrasonic signal. The ultrasonic flow meter presents no obstruction to the

flow. Three path inline meters are available for plant accuracy metering. Five path ultrasonic meters are

finding application in custody transfer because of the high accuracy and huge turn down capabilities.

A Coriolis meter provides a mass flow measurement and a density measurement and is capable of

measurement in most fluids including liquids, gases and slunies. Coriolis meters find application from

general process to custody transfer. lt also determines fluid density. The Coriolis meter manufacturer's

literature has indicated that accuracy ol O.'lo/o is available. The meter has a tum down of better than

100:1. The meter operation and accuracy is not affected by the fluid properties. lncreasing viscosity of the

fluid will require large pressure drops. Coriolis meters are available in line sizes up to 12 inch. Larger line

sizes may require external power to operate. There are Coriolis meters approved for custody transfer.

A positive displacement meter is a fixed volume rotating mechanism that will measure the total actual

volumetric flow by counting the number of rotations of the fixed volume compartments. The meters are

designed for liquid and vapour services. They are generally designed with very tight tolerances, suitable

for clean services and find application in custody transfer. They will provide very good accuracy with large

turn down capability. The meter operation is not affected by the range of viscosity, density or the

presence of two phase flow. The vapour volume in a liquid flow will be counted as part of the total

volume. As the viscosity of the fluid increases the accuracy of the positive displacement meter improves.

Sonar meter is a new technology that provides a volumetric flow measurement of liquid continuous

process flows. The meter uses passive sonar technology. An array of peizometric sensors wrapped

around the exterior of the pipe measures the strain induced on the pipe by the flow vortices and then by

analysing the flow turbulence in the process stream is able to determine the flow velocity. Flow

measurement using this technology is independent of the properties of the liquid. lt does require a

minimum velocity and that the pipe is full. lt is capable of determining water cut by measuring the sound

speed through the fluid. lt is also capable of measuring entrained gas up to 20o/o by measuring sound

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INSTRUMENT SELEGTION GUIDE

speed through the fluid. This meter operation is not affected by solids being carried in suspension.

Turndown is very good. Accuracy is good. Available only in a clamp-on configuration. These meters are

expensive in any size.

5.3 SeRvrce

5.3.1 Acid and Caustic

The acid and caustic flows are a good application for a magnetic flow meter


Boiler Feed Water (BFW) contains high levels of chlorides that will cause stress cracking on stainless

steel if temperatures are elevated. The BFW temperature ranges from 90'C to 196'C.

Clean water is an easy service and it can be handled by many flow meter technologies. For large lines

the V-cone meter or orifice plate is recommended. Transmitter and tubing materials need to be upgraded

and tubing should be a minimum of 2 meters in length to allow enough cooling to eliminate the high

temperature at the transmitter.

For smaller line sizes a magnetic flow meter or vortex meter are a better choice because they provide

much better turn down. With a vortex meter at the high temperatures, it must be considered if flashing

across the meter will occur with the slight pressure drop as this would affect the accuracy.

5.3.3 De-Oiled Water

De-oiled water from the IGF unit contains maximum 20 ppm oil, chlorides, dissolved oxygen and silica.

Besides the high level of chlorides there is also a potential for a build-up of silica. The line size will be

large. A clamp on ultrasonic flow meter is a good choice for this application.

5.3.4 Disposal Water

Disposal water contains high levels of chlorides. For larger line size an orifice plate or clamp-on ultrasonic

flow meter are good choices. For smaller line sizes a magnetic flow meter or vortex meter are good

choices because they will provide much better turn down.

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5.3.5 Emulsion

Emulsíon is oil water mixture with water content that can vary from 20o/o to 857o. Emulsion can also

contain up to 1% by volume of sand/silt. This is a very difficult service. The wedge meter finds a lot of

application in this service because it can handle the entrained solids and the higher viscosity. The Coriolis

meter is also a good choice for this service. For larger flows the sonar technology may be a good choice.

5.3.6 Filtered Produced Water

Filtered produced water from the oil removal filters will be clean of most oil particles but will contain a high

level of chlorides. For large lines a clamp-on ultrasonic flow meter is a good choice. Orifice plate or

V-cone meter with upgraded materials for instrument and tubing is also an option but with poor turn down.

For smaller line sizes a magnetic flow meter or vortex meter is a good choice.

5.3.7 Flare Gas

Ultrasonic meters are available that are especially designed for flare applications. The meter provides a

very high turn down in the range of 3000:1.

5.3.8 Fuel Gas

Fuel gas is dry pipeline quality gas. This is a very easy service for many flow meters. For plant service on

smaller lines a vortex meter is a good choice. For larger line sizes in the plant an orifice meter can be

used. For custody transfer an inline ultrasonic flow meter is a good choice.

5.3.9 Hydrocarbon Gas - Wet And DrY

Hydrocarbon gas directly off a process vessel such as the Free Water Knock Out or Treater vessels will

contain enough oil particles to cause plugging and coating issues. Orifice meter with diaphragm seal

arrangement is a good choice for wet gas but with limited turn down.

Vortex meter is a good application for dry gas flows

5.3.10 Hydrocarbon Liquids

Light end hydrocarbon liquid flows can be measured with orifice plate, vortex meter or clamp on

ultrasonic flow meters.

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5.3.11 Oily Produced Water

Oily produced water from a Free Water Knock Out vessel for example also contains chlorides and silica.

This is a difficult application due to the viscous nature of the oil and the entrained solids which can

combine to plug small sensing lines. A good choice for this application is the clamp on ultrasonic flow

meter or the Coriolis meter. The silica concentration is not high enough to be a concern with an ultrasonic

flow meter. There is no cost impact in the small (4") size and a cost saving in the larger (10") size for the

clamp on ultrasonic.

Wedge meters have been used in these applications but problems have been identified with the poor turn

down of the wedge meters. Tum down of a wedge meter is typically no better than three to one.

5.3.12 Produced Soft Water

Produced soft water is a clean fluid which contains high levels of chlorides. Material selection for the

instrument needs to be considered. Depending on the line size a magnetic flow meter is a good choice for

this application. Other good options are a clamp-on ultrasonic flow meter, a vortex meter or an orifice

plate.

5.3.13 Raw Potable Water

Clean raw water. Magnetic flow meter is a good choice as long as line size is smaller. Other options are

vortex meter, clamp-on ultrasonic flow meter or orifice plate.

5.3.14 Sales Oil

The heavy oil product is quite viscous. lnside the plant to meter the heavy oil product a clamp-on or inline

ultrasonic flow meter or Coriolis meter are good choices that will provide high accuracy and good turn

down. Wedge meter and orifice plate, with diaphragm seals to prevent sensing lines from plugging, are

also choices, but with limited accuracy and turn down.

For custody transfer an in-line ultrasonic flow meter is a good choice. A Coriolis meter is a good choice

for smaller line sizes. A positive displacement meter is also a good choice that can handle the viscosity,

provide high accuracy and turn down.

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5.3.15 Skim Oil

Skim oil can contain anywhere from 500/o to 90% water. A wedge meter or an orifice plate, with

diaphragm seal arrangement to prevent sensing lines from plugging, is the best choice. lf line size is

small, a Coriolis meter could be considered,

5.s.'t 6 Sludge

Normal expected solids range from 107o lo 25o/o. Magnetic flow and Sonar meters are a good choice for

this application because they present no obstruction to the flow.

5.3.17 Steam

Steam flow measurement depends on the quality of the steam. Vortex meter is a good choice for high

quality steam and meter sizes below I inch. Ultrasonic flow meter is also a good choice for high quality

steam. V-cone meter, flow nozzle or venturi is a good choice for lower quality steam.

5.3.18 Steam Condensate

V-cone meter is a good choice for this application. Vortex meter is also a choice but the possibility of

flashing across the vortex meter must be checked as the flashing will cause inaccuracy and possible

damage.

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Flow Meter - Service Selection Table

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GoodGoodOkaySteam Condensate

GoodGoodGoodSteam

BeslGoodSludge/Slurry

BestGoodOkayOkaySkim Oil (s0% WC)

GoodGoodGoodSales Oil

GoodGoodGoodOkayOkayHeavy O¡l - Plant

GoodGoodGoodGoodGoodRaw Potable Water

GoodGoodGoodGoodGoodProduced Sofl Water

BestGoodOily Produced Water

GoodGoodGoodGoodLight Hydrocarbon Liquids

GoodGoodOkayHydrocarbon Gas - Dry

GoodOkayHydrocarùon Gas -Wet

BestGoodFuel Gas - Custody Transfer

GoodGoodGoodFuel Gas - Plant

BestFlare Gas

GoodGoodGoodGoodFiltered Produced Water

GoodGoodGoodOkayEmulsion (20% to 85% WC)

GoodGoodGoodGoodGoodDisposal Water

BestGoodGoodDe-Oiled Water

GoodGoodGoodGoodGoodBoiler Feed Water

BestAcid And Caustic

SonarPDCoriolisUSonicVortexMagWedgeV-ConeOriflceTitle

Flow Meter Technology

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6.0 LEVEL MEASUREMENT

6.1 GeHrRal

The high viscosity of the heavy oil will cause problems with plugging of sensing lines and coating of

instruments that are in contact with process.

The heavy oil has a density very close to that of water. Because of the small difference in density

between the heavy oil and water the interface between oil and water in a gravity separator vessel is not

wetl defined. There tends to be a rag layer (mixture of the two liquids) that builds up between the two

liquids and can extend for over 1 meter in larger vessels. This makes interface measurement between

water and oil a difficult service for standard interface level instrumentation. ldeally, the point that should

be controlled is the point where the water content is 100o/o because you only want water to be dumped

out the bottom of the vessel with all oil going out the top.

6.2 Level Mensunr¡UENT FoR Vessels

The industry standards for level measurement are the displacer-type instrument for smaller ranges up to

2.5 meters and the differential pressure (dp) transmitter for larger ranges. The dp transmitter should not

be used for small measurements of less than 1 meter. Both instruments are limited by the density of the

fluid and if the fluid is subject to temperature changes. The change in density of the seal liquid with

ambient temperature range will also affect accuracy. ln heavy oil and emulsion services the measurement

leg and the reference leg should use a diaphragm seal arrangement.

Radar technology measures the reflection of high frequency radar pulse signal that is directed down on to

the top of the liquid. Guided Wave Radar (GWR) detects the reflection of a wave down a wave guide

(probe or coaxial cable) into the fluid. As the pulses impact the medium surface the characteristic

impedance changes and part of the emitted pulse is reflected. The time required between pulse launching

and receiving is measured. GWR can be used for measuring the top of the liquid or the top of the lower

liquid by adjusting the frequency to reflect based on the dielectric of the liquid that is of interest. Radar

technology is very accurate and does not have any dependence on the density of the liquid. GWR would

normally be mounted on the top of the vessel but can also be mounted on an external chamber.

Magnetically coupled floats provide a direct level measurement that is independent of the fluid properties.

Ultrasonic level measurement is based on a time of flight principal where the instrument emits ultrasonic

pulses which hit the surface of the liquid and reflects back to the instrument. Not impaired by liquid

properties such as dielectric constant, conductivity or density.

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INSTRUMENT SELECT¡ON GU¡DE

A capacitance probe may be compared to an electric condenser. As the tank is filled the probe

capacitance increases. Only works in conductive liquids. Good for aggressive fluids such as acids and

alkalis.

Conductive level measurement measures the resistance between two measuring electrodes which

changes by the presence or absence of a conductive medium. Also available in single rod probes where

the electrically conductive tank wall serves as second electrode.

6.3 lHrenrlce Lev¡l MensunemENT

Magnetic float or displacer type can be used to measure top of liquid or top of bottom liquid (i.e. interface)

if the difference between the two liquid densities is significant enough. The float is located in an external

column that is flanged to the top and bottom of the vessel and it is tracked by a magnetic pickup outside

the instrument column. This technology is limited by the fact that the liquid in the column might not be

representative of the liquid in the vessel. ln an interface application this technology is limited to a

difference between the density of the two liquids being greater than 0.1 specific gravity. For this project

the heavy oil has density of 0.960 which is to close to water to use this technology.

Microwave adsorption technology has been used in Western Canada heavy oil facilities to detect the

interface between water and hydrocarbon liquids on FWKO and Treater vessels. The water molecule will

adsorb the energy of the microwave frequency waves but the hydrocarbon molecules will not. The

limitation of this technology is that the measurement is really an average of the water content over the

length of the probe. The exact interface point can not be determined within the dimension of a single

probe therefore it requires several probes to approximate the interface. The analogue output from this

type of instrument is not effective in continuous control of the water level in the bottom of the vessel but,

these instruments are very good at providing a point detection of the 100% water content for a shutdown

or ovenide control.

Capacitance probes may also be used for detecting water level in emulsion because oil has very low

capacitance and water has very high. Similar to a microwave probe the single capacitance probe is

limited because it determines the average water content over the length of the probe. There are however,

profile probes that contain many individual capacitance probes that can provide a water/oil profile of the

vessel or tank. These profile probes can also be provided with an insitu cleaning system that utilizes high

pressure water (700 Psig) that will prevent fouling. These profile probes have found extensive service in

Western Canada. They presently have a temperature limit of 130"C maximum, which should be suitable

for the LFHO facility.

Guided Wave Radar has also been used in Western Canada heavy oilfacilities for measuring the

oil/water interface. The top of the lower liquid is measured by adjusting the frequency to reflect the radar

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¡NSTRUMENT SELECT¡ON GUIDE

signal based on the dielectric of the liquid that is of interest. ln a heavy oil emulsion service like the

FWKO and Treater vessels it does not find the 1000/o water point rather it tends to find the point where the

rag layer turns from oil continuous to water continuous. The analogue output from this type of instrument

will be effective for continuous control of the water level and can track this over the entire height of the

probe/cable which can be designed to extend the entire height of vessel.

Nuclear technology has also been used in Western Canada to determine the density profile of a liquid. A

nuclear source is installed inside the vessel in the liquid. Several receivers are located on the outside of

the vessel and they measure the amount of energy that reaches the detector. The greater the density of

the liquid the less energy reaches the detector. The more sources and detectors the better the density

profile. For our application with the FWKO and Treater vessels this technology can also see the amount

of sand/silt built up on the bottom of the vessel. Nuclear technology has seen limited application in heavy

oil facilities in Western Canada because of the cost.

6.4 Tnnx Level MelsuneMENT A¡¡o Gauelne

Differential pressure measurement is commonly used in industry for plant accuracy tank level

measurement. Accuracy is dependant on the density of liquid in the tank being a constant. Density of the

liquid will change with composition and operating temperature of the tank. Temperature compensation

can be applied. Direct mount transmitters should be mounted directly on the tank flange. lt is not

necessary to connect the reference leg to measure the tank blanket pressure as this is constant and only

represent inches of tank level. On tanks containing the heavy oil product a diaphragm seal arrangement

with flush ring for cleaning and calibrating is required.

Float and cable is the old standard for tank level measurement. This technology is available in plant

accuracy or custody transfer accuracy.

Radar technology measures the reflection of a radar frequency pulse that is directed down on to the top

of the liquid. Open path radar detects the reflection of a wave emitted from a horn on to the fluid. The time

of flight of the reflected radar pulse is directly proportionate to the distance travelled. lf the tank geometry

is known, the level can be calculated from this variable. Radar technology is very accurate and does not

have any dependence on the properties of the liquid. The advantage of this technology is that the

instrument does not come in contact with the fluid. ln a tank service there are two concerns. The

concerns are the amount of mist in the vapour space that can interfere with the radar pulses and

interference from internal tank components. This technology is available in instruments that provide

standard plant accuracy and in instruments that provide custody transfer accuracy.

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6.5 SeRvrce

6.5.1 Boiler Feed Water Tank

Direct mount differential pressure transmitters, mounted on the side of the tank near ground level or open

path radar are a good choice for this application. For the open path radar application the amount of mist

in the vapour space must be taken into consideration. Mist can disrupt the operation of a radar

instrument.

6.5.2 Chemical Storage Tank

Radar transmitters mounted on the top of the tank to avoid contact with liquid is a good choice for this

application. Direct mount differential pressure transmitters with seal, mounted on the side of the storage

tank near ground level is also a good choice.

6.5.3 De-Oiled Produced Water Storage Tank

Direct mount differential pressure transmitters, mounted on the.side of the storage tank near ground level

or open path radar are a good choice for this application.

6.5.4 Disposal Water Tank

Direct mount differential pressure transmitters, mounted on the side of the storage tank near ground level

or open path radar are a good choice for this application. A high level of chloride is present in the disposal

water therefore the instrument should be isolated with a seal or have upgraded materials.

6.5.5 Free Water Knock Out, Treater and De'Salter Vessels

ln a typical Free Water Knock Out Drum there are two compartments, the inlet compartment and the oil

collection compartment. ln the inlet compartment we would need to measure the overall liquid level and

the oil/water interface level. ln the oil compartment we would need to measure the oil level. Recommend

a GWR for overall level and a second GWR for oil/water level interface mounted directly on top of the

vessel. ln the oil compartment a GWR can be used to measure the oil level. lt is also recommended to

consider a nuclear level measurement system or a capacitance profiler in the inlet compartment to

provide density profile across the entire vessel including the depth of the rag layer.

The Treater vessel level measurement should be very similar to the FWKO described above.

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The de-salter vessel runs flooded. The only level measurement requirement is to measure the oil/water

interface level. Recommend a GWR for oil/water level interface control. Also would recommend a nuclear

level measurement system or a capacitance profile instrument to provide density profile across the entire

vessel.

6.5.6 Fuel Gas Drum KO Drum

A simple liquid level measurement can be handled by either a differential pressure transmitter or a

displacer type level transmitter in an external chamber, depending on the range of level.

6.5.7 Oily Produced Water Storage Tank

Direct mount differential pressure transmifters with seal arrangement, mounted on the side of the storage

tank near ground level or an open path radar are both a good choice for this application.

6.5.8 Oil Storage/ShiPPing Tank

Direct mount differential pressure transmitters with seal arrangement, mounted on the side of the storage

tank near ground level or open path radar are both good choices for this application. lf high accuracy is

required then the open path radar would be the better choice.

6.5.9 Steam SeParator Vessel

A magnetic float or Guided Wave Radar (GWR) in an external cage are both good choices for this

application.

6.5.10 Skim Oil Tank

The skim oiltank has an oil compartment inside the tank. The oil/water interface should be controlled

below the weir on the oil compartment.

To measure the overall tank level, open path radar on top of the tank or a direct mount differential

pressure transmitter with diaphragm seal on side of tank at the bottom are both good choices for this

application.

The oil level inside the oil compartment shall be controlled. lnside the oil compartment a differential

pressure transmitter with diaphragm seal arrangement mounted at the bottom of the compartment on the

side of the tank is a good choice.

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To measure the oil/water interface a GWR on top of the tank with a microwave instrument for point level

detection on high water level mounted at the same level as the weir.

6.5.11 Slop Oil Tank

The slop oil tank operates in a batch mode. Once the tank is full of slop oil then it is run through the

treater.

To measure overall tank level an open path radar is a good choice. To measure the oil/water interface a

GWR on top of the tank is a good choice. Also recommend a microwave instrument for point level

detection on low water level just below the drain point for the slop oil.

Level Measurement - Service Selection Table

GoodGoodGoodGoodSteam Separator

GoodOkayGoodSales Oil Tanks

OkayGoodRaw Potable Water Tank

GoodGoodGoodFuel Gas Drums

GoodOkayOkayFlare KO Drum

GoodPo¡nt

OnlyGoodGood

Emulsion Rag Layer Oil/

Water lnterface FI/VKO,

Treater, etc.

GoodOkayFWKO - Total

OkayGoodDisposal Water Tank

GoodGoodDe-Oiled WaterTank

OkayGoodBoiler Feed Water Tank

GoodGoodChemical Storage Tank

NuclearMicrowaveCapacitanceOpen Path

RadarGWR

Float-

Magnetic

Differential

PressureDlsplacerTltle

Level lnstrument Technology

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7,O PRESSUREMEASUREMENT

7.1 GerueRnu

The high viscosity of the heavy oil will cause problems with plugging of sensing lines and coating of

instruments that are in contact with process. Sand/silt in emulsion will cause plugging problems for

sensing lines. High level of chlorides in hot produced water represents corrosion issues. High

temperature fluids can overheat instruments and cause damage.

Diaphragm seal arrangements can be added to the transmitter installation to isolate the transmitter from

high temperature fluids, corrosive fluids or from viscous fluids that would tend to plug the sensing lines.

Cooling tower style diaphragm seals can be added to isolate the transmitter from temperatures higher

than 120'C. The seal fluid must be specified to operate over the range of temperature from maximum

process temperature to the minimum ambient of -3'C. Extending the length of the sensing line to a

minimum of 2 meters can also provide enough cooling to protect the transmitter from high temperatures.

Water with high chloride content is conosive to stainless steel if temperatures are above 60'C.

Transmitters, gauges, tubing, fittings and instrument valves are available in upgraded materials that are

immune to chloride Stress Corrosion Cracking (SCC).

7.2 Se Rvlce


Boiler feed water has a high concentration of chlorides. Transmitters and gauges in produced water

service should have their material upgraded or be provided with seals to prevent corrosion.

7.2.2 Disposal And Blowdown Water

Disposal and blowdown water has a very high concentration of chlorides and large variations of ph.

Transmitters and gauges in disposal and blowdown water service should be provided with a sealto

protect transmitter from corrosive hot water or have their material upgraded.

7.2.3 Emulsion

Emulsion is a hot viscous fluid that will plug up sensing lines. The transmitters and gauges in emulsion

service should be installed with a diaphragm seal.

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7.2.4 HydrocarbonCondensate

Hydrocarbon condensate tends to be viscous from the bitumen. Gauges installed in a hydrocarbon

condensate service should be installed with a seal to prevent plugging.

7.2.5 Oily Produced Water

Transmitters and gauges installed in oily produced water service should have a seal to prevent plugging.

7.2.6 Produced Water

Produced water has a high concentration of chlorides. Transmitters and gauges in produced water

service should have their material upgraded.

7.2.7 Sales Oil

Transmitters and gauges in sales oil service should be provided with seals to prevent plugging.

7.2.8 Skim Oil And Slop Oil

Transmitters in skim oil and slop oil service should be provided with seals to prevent plugging.

7.2.9 Slop Water

Slop water has a high concentration of chlorides. Transmitters and gauges in slop water service should

have upgraded materials to prevent corrosion.

7.2.10 Sludge And SlurrY

Recommend using the inline seal on all transmitters/gauges in a sludge or slurry services to prevent

plugging of sensing lines.

7.2.1'l Steam

Transmitters installed on steam service should be provided with a siphon to prevent over heating of the

transmitter.

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7.2.12 Waste Water

Waste water has a very high concentration of chlorides and large variations of ph. Gauges installed in

waste water shall have upgraded materials to prevent corrosion.

7.2.13 Wet Gas

Transmitters installed on a FWKO Drum in the vapour space are subject to gas laden with bitumen and

should be provided with seals to prevent plugging'

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8.0 ANALYTICAL MEASUREMENT

8.1 Wrren Cur

There are three methods of analysis used. They are microwave, infrared and capacitance.

At the wells the water cut can range from 2Ùo/o lo 850/0. Microwave and infrared technologies are capable

of full range measurement. Salinity will affect the microwave type. Water cut implied by density

measurement will also provide reasonable accuracy over a full range'

ln the oil separation unit the oil from the FWKO has a concentration of water as high as 150/o.

Out of the oil treater vessel the oil should have a water cut of less than 0.5% water. For the low range

applications allthree technologies willwork but the capacitance will provide the highest accuracies.

ln the de-salter vessels the water content must be reduced to that required for custody transfer. At this

level of water content the analysers are referred to as Basic Sediment and Water (BS&W) analyser.

BS&W analysers are covered in the section below.

8.2 Brsrc Seot¡vle¡¡r Aruo WlrgnBasic Sediment and Water (BS&W) is a similar measurement to water cut but only concerned with the

lowest range of water in oil. Sales oil will typically target 0.'t o/o (1 000 ppm) water in the sales oil. For the

heavy oil facility this measurement is not any different than any other typical oil facility measuring sales oil

for water content. Capacitance type meters, such as Delta C, offer very high accuracies and resolution

down to 10 ppm. Microwave instruments such as Roxar offer a low range water cut version which will

measure ranges from 0 to 15% down to 0 to 1% water.

8.3 Srlr l¡¡ OllHigh levels of chlorides, up to 28,000 ppm, are present in the emulsion recovered from the Lower Fars

formations. Excessive chloride left in the crude oil can result in higher corrosion rates in the down stream

refining unit and can have a detrimental effect on the refining process. The de-salter vessel is required to

reduce the salt concentration below 7 PTB.

A salt in oil analyser will measure the performance of the de-salter. Conductivity measurement based on

the ASTM method D5927 will provide continuous measurement with ranges down to 0 - 15 PTB. These

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analysers work on a cycle and involve sampling handling, sample conditioning, measurement system and

rinse/cleaning. The analysers are complicated and require routine maintenance.

8.4 O¡l lru WlrenThe produced water is processed to remove the oil out of the water such that the water can be sent to the

disposalwells.

Ultrasonic type oil in water meters, by Roxar for example, will measure down to 0 to 1000 ppm range of

oil. A highly focused acoustic signal is transmitted directly into the produced water flow. ln the focal

region, individual solids, oil droplets and gas bubbles will reflect the acoustic energy and each reflected

signalwill hold particle specific information. Based on a large number of measurements, the monitor

calculates full size distributions for oil and sand. From the size distributions, corresponding concentration

values are calculated.

Another common technology, which is used by Arjay, is fluorescence. A continuous sample flow is tapped

or pumped off the process line and directed through the 'HydroSense' chamber. lt passes behind the

non-contacting UV light source and is targeted with filtered light energy. The soluble and emulsified oils in

the water will excite from this light energy and fluoresce light energy back out of the water at a signature

wavelength. The intensity of light energy at this wavelength is measured to provide an indication of the

concentration. Ranges down to 0 - 10 ppm are user selectable with instrument accuracy of 0.1 ppm.

8.5 TunetolrY

ln the treatment of the water to be used for steam production it is important to filter all of the particles out

of the water before water is used in steam production. Turbidity is the cloudiness of a fluid caused by

individual particles (suspended solids) that are generally invisible to the naked eye.

A property of the particles, that they will scatter a light beam focused on them, is considered a more

meaningful measure of turbidity in water. Turbidity measured this way uses an instrument called a

nephelometer with the detector setup to the side of the light beam, More light reaches the detector if there

are lots of small particles scattering the source beam than if there are few. The units of turbidity from a

calibrated nephelometer are called Nephelometric Turbidity Units (NTU). To some extent, how much light

reflects for a given amount of particulates is dependent upon properties of the particles like their shape,

colour, and reflectivity. For this reason (and the reason that heavier particles settle quickly and do not

contribute to a turbidity reading), a correlation between turbidity and Total Suspended Solids (TSS) is

somewhat unique for each location or situation.

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8.6 D¡ssolveo Oxvcen

Because of the high levels of chlorides it is important to insure that there is no oxygen in the water

because the high level of chlorides in the presence of oxygen will result in chloride stress corrosion

Dissolved oxygen levels need to be maintained below 7 ppb.

Díssolved oxygen analysers use three common types of dissolved oxygen sensing probes. They are the

polarographic sensors, galvanic sensors and optical fluorescence sensors.

polarographic sensor technology uses an extemal voltage. The difference in potential between the

cathode and anode is less than 0.5 volts.

A galvanic probe requires no extemal voltage. The difference in potential between the cathode and anode

is greater than 0.5 volts. Galvanic probes are more stable and more accurate at low dissolved oxygen

levels than the polarographic probes. Galvanic probes often operate several months without electrolyte or

membrane replacement, resulting in lower maintenance cost.

The optical fluorescence sensor does not use up oxygen during the measurement; therefore, it does not

require stirring. The device is extremely suitable for long-term measuring periods in groundwater. lt is not

sensitive to contaminants, sulfurous compounds, or aging. The sensor has a special coating with

fluorescent properties. When light is exposed to the coating it causes fluorescence. After the exposure of

light, the coating continues to produce a short afterglow. The level of oxygen present in the water

determines the duration of this fluorescence or afterglow.

The galvanic technology probes are more stable and accurate at the low dissolved oxygen levels required

for this application.

8.7 Wlren Hnnoruess

Water being used for boiler feed water must maintain minimum hardness before using otherwise it could

plug up tubes and damage the steam generator. Water hardness would need to be below 0.2 ppm for a

drum type boiler. Water hardness analysers tend to require extensive maintenance.

ln fresh waters, the principal hardness-causing ions are calcium and magnesium; strontium, iron, barium

and manganese ions also contribute. Although hardness is caused by cations, it is often discussed in

terms of carbonate (temporary) and non-carbonate (permanent) hardness. Carbonate hardness refers to

the amount of carbonates and bicarbonates that can be removed or precipitated from the solution by

boiling. This type of hardness is responsible for the deposition of scale in hot water pipes and tea kettles.

Water hardness is the measurement of the amount of ions which have lost two electrons (divalent

cations) dissolved in the water and is therefore, related to total dissolved solids. The more divalent

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cations dissolved in the water the "harded'the water. Generally the most common divalent cations are

calcium and magnesium, however other divalent cations may contribute including iron, strontium,

aluminum, and manganese. Typically the other divalent cations contribute little to no appreciable

additions to the water hardness measurement.

Non-carbonate hardness is caused by the association of the hardness-causing cations with sulphates'

chlorides and nitrates. lt is also referred to as "permanent hardness" because it cannot be removed by

boiling.

The hardness analyser uses calmagite and Mg-EDTA as a reagent for colorimetric measurement of

hardness at a wavelength of 520 nm. The analyser measures total soluble hardness as CaCO3' Analyser

accuracy is typically t 5olo and measure from 50 to 10'000 ug/L.

8.8 Torll DlssouveD SollDs

Water being used for boiler feed water must maintain minimum amounts of dissolved solids for drum

boiter apptication. Total dissolved solids should be below 50 ppm. Total Dissolved Solids (TDS) is a

measure of the combined content of all inorganic and organic substances contained in a liquid that are in

a molecular, ionized or micro-granular (colloidal so} suspended form. High TDS levels generally indicate

hard water, which can cause scale build-up in pipes, valves, and filters, reducing performance and adding

to system maintenance costs. The TDS measurement is a better reflection of the total mineral content of

the water rather than a water hardness measurement. However, for estimation purposes, the water

hardness can be roughly calculated by dividing the parts per million (ppm) measurement of the TDS

by 10 giving a hardness value with minimal error'

Electrical conductivity of water is directly related to the concentration of dissolved ionized solids in the

water. lons from the dissolved solids in water create the ability for that water to conducl an electrical

current which can be measured using a conventional conductivity meter or TDS meter. Conductivity

increases with increasing ion content, which means that in most cases it gives a good approximation of

the TDS measurement using the conversion factor of 1 ppm = 2 uS/cm. Conductivity is temperature

sensitive and is typically standardized to 25"C.

Using the conductivity method for measuring water hardness is reliable but it is not a direct indication of

water hardness. lt has the drawback of combining all ions in the measurement, including those that do

not contribute to the water's hardness. This hardness approximation gives an error similar to the TDS

measurement of 2-3 French Degrees of Hardness.

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8.9 Srelm QunllrvThere are several technologies that have been investigated with some success for this application and in

some cases there are registered patent applications and field evaluations. However, there does not seem

to be a commercially available in-situ analyser that is capable of measuring steam quality.

A neutron densitometer, based on the principle of the neutron transmission is capable of measuring the

density of most fluids flowing in a pipe. From the density of the homogenous fluid and knowing the

density of the vapour and water phases the quality of the steam can be calculated.

Separating calorimeter requires a sample stream to flow through a helical device to separate the vapour

from the liquid then the two flows are measured and the quality calculated.

A dielectric steam quality instrument measures the overall electrical impedance of the wet steam and

relates the overall impedance to the known dielectric constant and resistivity of the water and steam

vapour to determine a liquid volume fraction and the steam ratio'

Radiation absorption technology utilizes selective absorption of various forms of radiation. lnfrared

radiation, for example, is presently used in a very similar application to measure the presence of moisture

in air.

Absorption spectroscopy with diode lasers technology has been developed and tested that uses tunable

diode laser and multiple broadband lasers to measured absorbance of water and water vapour phases.

From these two measurements the volumes of each component can be determined and hence the steam

quality.

There is commercially available a system that indirectly can calculate steam quality by utilizing an orifice

plate and a choke nozzle in series in the flow stream or in a slip stream. The nozzle is designed to

operate in sonic flow. Knowing the sonic flow and measuring the differential pressure individually across

both devices and by solving independent equations for the two devices simultaneously the density of the

fluid can be calculated. Knowing the density of the fluid, the density of the steam vapour and of water the

steam quality can be calculated.

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9.0 VALVES

9.1 Geruennl

Particular to the Lower Fars Heavy Oil Facility the concerns for valve application are in the heavy oil,

emulsion, sludge and high pressure water services. The concern for the heavy oil and emulsion is the

high viscosity and the presence of up to 1% solids in the emulsion. The sludge flows that come out of the

water treatment process can contain a very high level of solids. The concern in the produced water

service is the high level of chlorides that will cause stress corrosion cracking in stainless steel

components.

9.2 CorurRol Vnlves

Controlvalves in the emulsion applications especially at the plant inlet and the produced water service off

the bottom of FWKO and Treater vessels may see sand/silt so consideration should be given to the

possibility of erosion and plugging. Butterfly and V-ball style control valves are a good choice for this

service.

Control valves in sludge service are subject to plugging because the fluids may contain up to 107o solids.

Pinch or rotary style control valves are a good choice for sludge service.

ln the produced water service, with the high level of chlorides, consideration should be given to upgrading

control valve trim and body materials from stainless steel.

ln the disposal water and high pressure boiler feed water services the pressure drop across the minimum

flow recirculation valve is very high. Multidrop/multistage trims such as drag valves are a good choice for

these severe services to prevent cavitation damage to the valve.

Because there will not be instrument air available at the well patterns consideration should be given to

using electric sliding stem aqtuators for any control valve requirements.

9.3 ESD At'¡o Swlrcnlnc VALvES

Switching valves in emulsion or produced water service from the bottom of the FWKO or Treater vessels

may see sand/silt. Sand can be caught in between seat and ball and cause damage to the surface of the

ball or the seat. Consideration should be given to a rising stem ball valve. This type of valve has a rising

stem that lifts the ball away from the seat before turning so that the seats are protected from wear and

degradation from the rotation.

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Switching valves in sludge service are subject to plugging because the fluids may contain up to 10%

solids. Rotary style valves are a good choice for sludge service.

The sectioning valves along the pipeline will utilize piston actuators powered by nitrogen bottles.

Consideration should also be given to an electro-hydraulic actuator on the sectioning valves at these

remote pipeline locations because of the low power requirement and the high availability of this type of

actuator.

Because there will not be instrument air available at the well patterns consideration should be given to

using electro-hydraulic actuators on the ESD valves for isolating the steam pressure from the reservoir

The electro-hydraulic actuator requires minimum power and provides a high availability.

9.4 Sl¡erv REuer Valves

Relief valves in emulsion and heavy oil applications should consider the use of a rupture disk to isolate

the relief valve from the heavy oil that may cause plugging due to the high viscosity of the oil. This is also

true for vapour associated with the heavy oil.

ln sludge service a rupture disk should be considered due to the possible plugging of the relief valve.

9.5 Cnoxe VtlvesThe injection of wet steam at the wells is a good application for a choke valve due to the high potential for

erosion from high velocity liquid droplets in the wet steam and the potentialfor high pressure drops

through the valve.

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1 O.O TEMPERATURE MEASUREMENT

IO.I GENERAL

Temperature measurements are made by Thermocouples or RTD's. A brief comparison of the two

devices is listed below:

Thermocouples have a number of key strengths:

r Wide variety of measuring ranges, including very high limits;

. Many physical sizes and configurations;

. Fast response times;

. T¡ny measuring point;

o Moderate price; and

. Very simple configuration (You can even make your own!)

However there are drawbacks:

. Medium accuracy and sensitivity;

. Linearity is only fair;

. Specifìc types have to have matching cable (e.9., type K thermocouple hasto have type K

cable.); and

. Signal strength is very low and prone to EMI problems

RTDs have characteristics that compare well against thermocouples:

. More stable;

. More accurate;

. Greater repeatability;

¡ Better sensitivity and linearity; and

o More robust signal less prone to EMI problems (although can still benefit from a transmitter)

Other RTD attributes don't compare as well against thermocouples:

. Narrower measuring range, particularly at the high end;

o More expensive;

. Require an external power source;

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r Slower response time; and

. At some temperatures, the reference voltage can actually heat the sensor and throw it off.

ln summary, thermocouples have greater range, are more rugged, and have lower initial cost (this is

offset by the requirement to run thermocouple wire and terminals from thermocouple to transmitter), while

RTD's have greater accuracy, better linearity and higher cost. The preferred measurement device on

this project is the type K thermocouple. RTD's shall be used when the range is less than 750oC and

accuracy of 1oC ¡s required. Example measuring heat exchanger efficiency.

Most transmitters from major manufacturers' now accept both RTD's and various types of thermocouple

inputs so generally one transmitter can be used project wide

Alltemperature measurements and instruments shallfollow KOC engineering specification 015-JH-1903,

General lnstruments, and 1 1 C8972-00-|C-SPC-1 903 Addendum to 01 5-JH-1 903.

II.O OTHER INSTRUMENTS

All other instruments, not described in this document, shall be designed, specified and installed per

international and KOC standards. Those instruments shall be subject to KOC approval during each

phase of design, specification and installation. The Contractor shall conduct a thorough study for

selecting analyzers (pH, GC's, Fuel Gas Caloric Value, Conductivity, Oz, Flue Gas), F&G sensors,

Condition Monitoring Systems (CMS) and instruments, Packaged Equipment instruments, emissions

monitoring and all advanced instruments as they are added throughout project.

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Environment