Multiphase Fluid Separation Using Level-Based Measurement
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Solution Overview
Problem
Conventional methods for separating and measuring multiphase fluid mixtures from hydrocarbon producing wells are inaccurate and labor-intensive, requiring multiple vessels and flow meters that need frequent calibration, leading to potential downtime and errors in measurement.
Innovation Solution
An automated process and apparatus that separates and measures immiscible fluids in a single vessel with internal compartments, using liquid level sensors and automated valves for continuous measurement and calibration, allowing for real-time operation without downtime, and employing machine vision for primary and secondary level measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional flow meters are used to measure each fluid stream, then measurement capability is provided, but measurement accuracy deteriorates and calibration downtime increases
Solution Approach 1:
The patent replaces mechanical flow meters with a level measurement-based system. Instead of using turbine meters or other mechanical flow measurement devices that require calibration, the system uses level sensors (such as guided wave radar, capacitive, or float sensors) to measure fluid levels in separated compartments. Flow rate is calculated by differentiating level changes over time, eliminating the need for mechanical calibration and improving measurement reliability.
Solution Approach 2:
The patent creates a virtual model of the separation process by continuously monitoring level changes in each compartment and calculating flow rates from these measurements. This virtual measurement system replaces physical flow meters and provides continuous calibration through the mathematical relationship between level change and volume flow, eliminating the need for periodic physical calibration of meters.
2Reliability
If multiple vessels are used for separation, then separation capability is improved, but device complexity increases
Solution Approach 1:
The patent divides a single separation vessel into multiple functional compartments using internal baffles or dividers. Each compartment handles a specific separation function (e.g., gas-liquid separation, oil-water separation), effectively creating multiple separation stages within one vessel. This maintains the separation capability of multiple vessels while reducing overall system complexity and footprint.
Solution Approach 2:
The patent combines multiple separation functions that would traditionally require separate vessels into a single integrated separation system. By implementing staged separation with internal compartments within one vessel, the system achieves the same separation performance as multiple vessels while reducing equipment count, installation complexity, and maintenance requirements.
3Reliability
If conventional separation methods are used, then separation is achieved, but measurement continuity is interrupted
Solution Approach 1:
The patent implements continuous measurement by using level sensors that operate throughout the separation process without interruption. The system continuously monitors fluid levels in each compartment and calculates flow rates in real-time, eliminating the need to stop measurement for calibration or maintenance. This ensures uninterrupted productivity while maintaining reliable separation performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate and continuous measurement of liquid hydrocarbons and water components without conventional flow meters, providing continuous calibration and alarm systems to prevent measurement errors, ensuring all fluid molecules are accounted for without interruption.
Implementation Method 1
a buoyant float sensor, operable within the compartment, for measuring a level of the liquid in the compartment
Data Source
AI summary
An automated process and accompanying apparatus simultaneously separates and measures the flow rate of any multiphase mixture of immiscible fluids. Such separation and measurement can occur in a single vessel, or multiple vessels. Liquid levels, together with a material balance analysis, are utilized to determine constituent liquid flow rates. The vessel(s) can be remotely operated and monitored in real time, while also allowing for automated or manual calibration.