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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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KUWAIT OIL COII'IPANY
LOWER FARS HEAVY OIL DB/ELOPMENT
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$lorany,eason, including, but not
timited to, negligence, to any othar pafty for any information or rcpresentation herein. The extent of any
wamnty orguanntee of this documentorthe ìnformatton contained thercin in favourof the Cusfomeris
ttmlted to the wananty orguamntee, if arry, contained in the contnct between the Customer anQ
WorteyParcons.
DOC. NO.11 Rev f Selection Guide.doc\,!aitgvPARsot'¡{l CUENT OAIEREI' OESCRIFnON ORIGI}'IATOR Rã/tÊ$, DATE
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M WorleyParsons EcoNomicS ffitesources & energy
KUWAIT OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
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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M WorleyParsonsresources & energy
[coNomicS ffiKUWAIT OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GU¡DE
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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Page 4 of 37
M WorleyParsonsresources & energy
€coNomici ffiKUWAIT OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
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.........
I 1C8972-0OlC-DEG-0001 Rev 'l lnslrument Selection Guide.doc
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M WorleyParsonsresources & enetgy
KUWAIT OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
EcoNomic$ ,m
9.4
9.5
10.0
1 1.0
Safety Relief Valves.
Choke Va|ves.........
TEMPERATURE M EASUREMENT
OTHER INSTRUMENTS........,....
35
35
..36
,,.37
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M WorleyParsons EtoNomicS .ffiresources & ener6y
KUWAIT OIL GOMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
¡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).
1 1C8972-0G|C-DEG-0001 Rev I lnslrument S€lection Guide doc P.(l¡407to9no13
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M UlforleyParsons EcoNomicS ffiresources I enerEy
KUWAITOIL GOMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
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.
'1'1C8972-0GlC-DEG-0001 Rev 1 lnstrument Select¡on Gu¡dè.doc
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M WorleyParsons ËcoNomicS ffiresources & energy
KUWAIT OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
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
11C8972-0GlC-DEG-0001 Rev 1 lnstrument Selectìon Gu¡de.doc
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M WorleyParsonsresources & energy
KUWA¡T OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
EcoNomicS ffi
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
. KOC-I-O10
o 11C8972-00-lC-SPC-0001
¡ 015-JH-1903
. 11C8972-00-lC-SPC-1903
o 11C8972-00-lC-CRT-0001
a KOC-G-007
74
11C8972-0GlC-D8G4001 Rev 1 lnstrument S€lection Guide.doc
4 07to9DO13
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
a
Data
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M WorleyParsonsresources & ener8y
KUWAIT OIL GOMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
EcoNomicS
(
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
EPF-O174
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M WorleyParsons ftoNomicSresources & energy
KUWAITOIL COMPANY
LOWER FARS HEAVY O¡L DEVELOPMENT
INSTRUMENT SELECTION GUIDE
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.
.ffi
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M WorleyParsonsresources & enerßy
EcoNomic$ ffiKUWAIT OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
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
002-00GPDF-806
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M WorleyParsons EcoNomic$resources & energy
KUWAIT OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GU¡DE
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
ffi
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M WorleyParsons EcoNomicSresources & energy
KUWAIT OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
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
5.3.2 Boiler Feed Water
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.
.m
'11C8972-0G|C-DEG-0001 Rev 1 lnsfument Selec,t¡on Gu¡dq.doc
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M WorleyParsons EcoNomicSresources & energy
KUWAIT O¡L COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
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.
,^m
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M WorleyParsons €coNomiciresources & energy
KUWAIT OIL COMPANY
LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
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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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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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.
002-00GPDF.806
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EcoNomicS ffi
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
7.2.1 Boiler Feed Water
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
EPF.O174
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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.
.ffi
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LOWER FARS HEAVY OIL DEVELOPMENT
INSTRUMENT SELECTION GUIDE
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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INSTRUMENT SELECTION GUIDE
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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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KUWAIT OIL GOMPANY
LOWER FARS HEAVY O¡L DEVELOPMENT
INSTRUMENT SELECTION GU¡DE
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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INSTRUMENT SELECTION GUIDE
€coNomic$ 'ffi
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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INSTRUMENT SELECTION GUIDE
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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