INTRODUCTION
Multiphase level measurements exist throughout the process industries and are particularly relevant in the Oil & Gas and Petrochemical sectors due to the value derived from effective water and hydrocarbon separation. While level instrumentation has come a long way in measuring liquids of all varieties, multiphase level measurement is often considered the greatest challenge and opportunity that exists today. This is evidenced by over half of separator failure modes being attributed to level instrumentation per Offshore Reliability Data (OREDA, 2002).
Many technologies attempt to tackle multiphase measurement but all have direct and/or ancillary limitations:
Radiometric and nucleonic technologies can profile multiphase media conditions, potentially without intrusion into the process vessel; however, they come with high upfront costs, regulatory burdens and increased safety requirements.
Multi-technology approaches using Guided Wave Radar (GWR) and Capacitance may be able to provide total level and interface measurement, but there are still limitations within the technologies; such as capacitance calibration shifts, buildup concerns and emulsion thickness limitations.
Sensors measuring discrete segments (tomography) are limited in resolution by the dimensions of those segments along with other limitations based on the technology utilized (e.g., conductivity).
Multi-probe arrays are available that measure oil/water percentages but require multiple points of entry into the process vessel and surrounding piping; often complicating maintenance, increasing costs and adding potential leak points.
Solids detection (i.e., sediment or sand) often requires separate instrumentation from the interface level transmitter.
While this proves there has been considerable effort by instrumentation manufacturers to measure multiphase levels, only now is there a cost-effective TDR-based multiphase level detector capable of widespread adoption.
2 / EMULSION IN THE FIELD: The Genesis of TDR Multiphase Level Measurement
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