SPE 77891
The Future of Three Phase Separator Control
J.S. Charlton, Synetix-Dialog Alliance and R.P. Lees, Synetix
Copyright 2002, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the SPE Asia Pacific Oil and Gas Conference and
Exhibition held in Melbourne, Australia, 8–10 October 2002.
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Abstract
In response to the expressed needs of Oil Producers, a novel
instrument has been developed for measuring and controlling
the performance of production separators. The instrument,
known as a Density Profiler, provides the operator with real-
time information about the vertical distributions of the various
materials inside the separator: sand, water, emulsion, oil, foam
and gas. This allows the operator to exercise fine control over
the operation of the separator in a way never before possible.
For example, the results of adding antifoam or demulsifying
agents can be visualized immediately in the control room so
that the effectiveness of these procedures can be monitored
and appropriate action taken.
Over twenty profilers have been installed to date at locations
around the world. They are highly reliable: the measurement
probes have no moving parts and have no contact with the
process fluids, thus minimizing the possibility of mechanical
breakdown.
This paper describes the instrument and focuses on its unique
mode of operation. Case studies are used to illustrate the
substantial economic benefits that are realized from
• Optimization of the separation process
• Elimination of unscheduled shutdowns
• Optimized levels of chemical additives leading to
reduced costs.
• Elimination of oil spills
• Elimination of damage to downstream equipment.
Introduction
Efficient operation of the separation train is of crucial
importance in the production of crude oil.
Crude oil, coming from the wellhead, is mixed with water, gas
and sand and must be separated from these components before
the oil can be sold.
In the case of an offshore oilfield, this separation is done on
the production platform in separators, which are generally
horizontal vessels, typically three metres in diameter and up to
twenty-five metres in length with a weir positioned near one
end. The mixed fluids from the well enter the vessel and, as
the mixture flows along it, the constituent parts separate,
progressively, under gravity, allowing the oil, water and gas to
exit from their appropriate outlets
That, at least, is what is meant to happen.
Unfortunately, in many cases the nature of the wellhead fluids
complicates the process to the point where efficient phase
separation is very difficult to achieve.
Excessive sand laydown, foaming and oil/water emulsification
are three contributing problems.
Sand accumulation reduces the working volume of the vessel,
thereby shortening the residence time of the fluids and
reducing separation efficiency.
Foam results in liquid hydrocarbon in natural gas, which can
damage downstream compressors.
Emulsification can cause oil to be discharged with the water,
producing slicks.
Additionally, emulsion carried over the weir can leave water
in the exported oil, which is unacceptable.
The “standard” method of measuring and controlling the level
and interface inside the separator has been a float chamber
connected to bridle pipework, but even under good conditions
such measurements may be unreliable as there is a time lag
between real events, happening inside the separator, and what
occurs in the bridle. Additionally, a relatively small amount of
sand build-up around the tapping points can cause the
displacer to register false readings.
These instruments are, of course, unable to measure
adequately or take account of foam and emulsion layers or
sand laydown.
Recently, a new type of instrument, known as the
TRACERCO ProfilerTM has been developed for separator
control.
Unlike conventional instrumentation, the Profiler does not
require a bridle. Instead, the measurement probes are
introduced into the separator through a six-inch nozzle. There
2 J. CHARLTON AND R. LEES
are no moving parts and the probes remain isolated from the
process fluid at all times, thereby guaranteeing high reliability.
The system allows a Process Engineer to maintain the
oil/water interface and oil level at optimum positions to
achieve efficient production. For the first time, the engineer
can determine how much sand has built up within the
separator, assess what effect this is having on throughput, and
jet wash the separator to rid it of sand if necessary. The
Tracerco Profiler makes possible the optimal use of effect
chemicals. It not only detects the presence of foam but
measures its height; not only identifies emulsion but its
dispersion. In addition, the operator can see the effectiveness
of anti-foam or de-emulsifier dosing, and is therefore able to
ensure that only the minimum amount is added to achieve the
desired effect.
As well as saving money, this reduces the amount of
chemicals released into the sea. It also enables comparison of
the performance of different brands of effect chemicals.
The instrument was developed in response to the identified
needs of clients in the offshore oil and gas industry.
The Tracerco Profiler
The Tracerco Profiler measures, and provides a visualization
of, the several different phases within the separator. It is based
on applied nuclear technology.
Principles of Operation The instrument is shown
schematically in Figure 1. It comprises a vertical array of
small, gamma ray emitting radioactive sources the radiation
from which is monitored by a vertical array of radiation
detectors. The source and detector assemblies are secured in
dip-pipes that project down into the separator. The radiation
beam from each source is collimated so that only the radiation
detector at the corresponding elevation detects it. The
attenuation of the beam in the process material between the
source and detector is precisely related to the density of that
material. Effectively, each source/detector pair is a density
gauge. If, after mathematical processing, the outputs from the
detectors are displayed as a function of their elevation then the
resulting distribution is the vertical density profile of the fluids
inside the separator.
The Technology. The configuration of the Tracerco Profiler
is shown in more detail in Figure 2. The instrument comprises
the following components:
Source Assembly. The radioactive sources contain the
radioisotope Americium-241 (the same radioisotope as is used
in smoke detectors). The sources are fitted into holes drilled
diametrically through a vertical length of steel rod. The rod is
fitted into a steel sleeve with two small holes drilled at each
source location. These holes collimate the gamma radiation
emitted by each source. (Figure 3) One narrow beam of
gamma rays is directed upwards at a small positive angle to
the horizontal centre-line through the source; the other narrow
SPE 77891
beam is directed downwards at a small negative angle to the
horizontal. Thus, each source directs radiation to two sensors,
one at an elevation immediately above the source and the other
at an elevation immediately below it.
The collimator is provided with an external shutter
mechanism that allows it to be moved vertically relative to the
source rod. With the shutter in the “closed” position, the
collimator holes no longer match source elevation. With the
shutter closed, the collimator absorbs virtually all the
gamma radiation.
Detector assembly. The Profiler can provide a
maximum of 96 independent measurement points. These are
mounted in two separate detector assemblies, 48 in each. Each
assembly is housed in its own sealed titanium dip-pipe. Within
each assembly, the vertical separation between adjacent geiger
sensors is 56 mm, but the sensors in one dip-pipe are offset
relative to the sensors in the other dip-pipe so that, with the
dual dip-pipe assembly, a separate measurement point is
provided every 28-mm. The two beams of radiation coming
from each of the radioactive sources are directed to a pair of
sensors, one immediately above the source elevation, and one
(contained in the other dip-pipe) immediately below the
source elevation.
The detectors operate at high voltage (430v-dc) and this is
generated, within each detector, from a 10v-dc power supply.
The associated electronics have been designed in such a way
that the complete instrument is certified as intrinsically safe,
suitable for use in Zone 1 hazardous areas.
The eiger sensors are rugged, reliable and stable, with a
15-year design life. Each produces a train of voltage pulses as
its output signal. The frequency of these pulses is directly
proportional to the intensity of the radiation incident on the
sensor, which is determined by the density of process fluid at
the sensor elevation.
After conditioning, the sensor output is transmitted to a
counting unit (one for each detector assembly) which is
housed in a protective enclosure immediately above the
detector dip-pipe.
Dip-pipe Assembly. The three dip-pipes (one for sources,
two for detector assemblies) are connected together in parallel
and fitted to the separator through a 6” nozzle.
Signal Processor. The voltage pulses produced by each
eiger are transmitted to a counter located above the dip-pipe
assembly. This counts the pulses produced by the sensors over
a user-selectable time period and transmits count information
down a fibre optic link to a Programmable Logic Controller
situated in the control room.
Programmable Logic Controller. The role of the PLC is to
perform all the calculations and make the settings necessary to
set up, calibrate and operate the Profiler. In it, the count
information received from the signal processor is converted
into 96 separate density measurements, one per sensor. This
SPE 77891 THE FUTURE OF THREE PHASE SEPARATOR CONTROL
information allows the density profile to be constructed. Using
visualization software that is installed either in the plant’s
supervisory computer or in a stand-alone PC. When connected
to the PLC, this computer will allow the operator to select and
view a number of different screen displays including:
• A density profile (histogram) showing how density varies
with elevation
• A vessel mimic diagram showing how the various
materials and mixed-phase regions are distributed in
relation to important vessel features such as outlet nozzles
and the weir.
The PLC also produces digital and analogue outputs that
vary with the elevation of each selected boundary between
adjacent phases. The client can use these analogue outputs
to operate valves and control the level or volume of the
various phases in his vessel.
Case Studies
The operation of the profiler and the economic benefits
derived from it are best illustrated with reference to
case studies.
Case Study 1. Chevron Kuito FPSO. The Kuito field,
discovered in April 1997, lies offshore Cabinda Province in
Angola’s deep-water Block 14. Kuito produces a heavy oil
ranging from 18 - 22 API. On Kuito, well fluids are routed to
two parallel Production Separators. These vessels are long
horizontal cylinders, 3.6 metres in diameter and 12 metres in
length with a weir positioned at one end, 7 metres from the
inlet. Often, in the separators there was not a distinct interface
between the phases, but rather a continuous graduation from
one phase to another, e.g. from water to emulsion to oil, or
from oil to foam to gas. In these cases, phase identification by
simple interface detection is difficult or impossible with
conventional instrumentation. To aid separation, expensive
chemicals, emulsion breakers and defoamers are injected into
the well streams.
Existing Level Instruments. Level measurement was
performed with conventional separate, single point instrument
transmitters for oil / water interface and bulk oil level.
Capacitance type probes were installed inside stilling wells to
measure the level and interface. Two stilling wells, each 6”
diameter, were located approximately 1 meter upstream of the
weir for interface control and trip functions. Two stilling
wells, again 6” diameter were installed 2 metres downstream
of the weir for bulk level control and trip functions. A level
sight glass was installed upstream and downstream of the weir.
At 2 metres upstream of the weir, 5 try-cock valves were
located vertically to cover the interface.
Capacitance Probes. The original capacitance probes,
operated by measuring electrical characteristics which were
dependent on the levels of fluids in contact with the probe. As
an interface level rises on the probe, the measured capacitance
changes as the probe goes from complete immersion in oil
3
(0% on the interface level range), to complete immersion in
water (100% on the interface level range). The problem with
this method is that the electrical characteristics of either fluid
can change significantly from the expected values, as happens
when different wells are introduced to the vessel or when
emulsions are formed. This will be interpreted incorrectly as a
change in level resulting in misinformation being presented to
the operators and inappropriate control actions. These
instruments are only suitable where a well defined step change
in densities is evident i.e. a step change from 100% oil to
100% water, in practice this was rarely the case on Kuito.
Operational Problems. One of the problems with the
capacitance instruments was that the stilling wells blocked up
with naphtenate and the probes were coated in this substance
rendering them ineffective. The operators had to constantly
manually check where the interface was, based on samples
taken at the try-cocks on the side of the vessels. Incorrect, or
lack of, separation information caused numerous process
upsets and shutdowns due to high concentrations of oil carried
through the water outlet, overloading downstream de-oiling
equipment. It caused high concentrations of water to be carried
over with the oil phase and hence caused downstream knock-
on separation problems. Solids accumulation reduced the
working volume of the vessel and therefore its efficiency. All
of these problems resulted in unnecessary trips and production
problems. As a result, output, quantity and quality, suffered;
spend was high on effect chemicals; maintenance and operator
input was intensive.
Profiler Installation. After Kuito’s first year of difficult
production, discussions were started to replace the existing
level instruments with Tracerco Profilers. Orders were placed
in mid 2001 and in August /September 2001 during a planned
shutdown the stilling wells and interface capacitance
instruments in the 2 production separators and the test
separator were replaced with Tracerco Profilers. The three
profilers were commissioned in September 2001. The profiling
instruments defined all the fluids inside the vessel to a far
greater degree than the conventional instruments. In place of
the traditional two single points, oil / water interface and bulk
oil level, the operators could now see all the phases and the
quality of the interfaces.
The Profiler in Operation. Figures 4-8 are screen shots
showing what the operator could see in real time on Kuito,
during start-up and production. Figure 4 shows the density
profile of vessel ‘A’ at start up. Note the large water layer and
the small build-up of foam on top of the water.. This shot is
timed at 12:29am on the 11th September 2001.
Figure 5 shows the profile 12 minutes later. Note that oil has
been introduced into the vessel causing a large build-up of
foam and possibly giving rise to carry over of liquid droplets
to the next stage. Figure 6 shows the profile 6 minutes later.
De-foamer chemical has been injected and the foam level is
falling. Figure 7 shows the profile 1 hour 39 mins later. The
foam level has gone, but note that there is not a clean
4 J. CHARLTON AND R. LEES
interface. There is a gradual change in density from water to
oil. The residence time or emulsion breaker dosage needs
adjusting. Figure 8 is the profile taken 2 hours 47 minutes later
showing full production. Note the flat profile of the water
layer and the flat profile of the oil layer. Operations can be
confident that at this residence time separation is complete.
There is an opportunity to increase flow, reduce residence time
or reduce chemical injection.
Feedback. After six months of production, post profiler
installation feedback from the operators, SBM, and
ChevronTexaco is that “The Tracerco Profilers have proved
not only to be totally reliable and basically trouble free but
also a very important tool for managing the levels within the
process. Within the process system on Kuito, water knock out
is an important aspect. Water knock out can only be achieved
effectively with the correct dosage of emulsion breaker
chemicals into each train. Because the Tracerco Profilers
clearly identify the emulsion phase within the vessels we are
quickly alerted to any adverse shift in chemical dosage rates
and are then able to do something about it in a proactive
manner. Prior to the installation of the Profilers, we would
often find ourselves in an unstable or trip condition before we
realised there was a problem with the chemicals. The same
applies for the defoamer chemical. It must be understood that
the profilers will not see the chemical, but the effect the
chemical is having upon the process. This is a huge advantage,
being able to optimise chemical injection i.e. not needlessly
over-dosing expensive chemicals. There is absolutely no doubt
that we have kept the plant running longer and have sustained
fewer plant trips since installation of this equipment. It is also
worth pointing out that the way this information is displayed
within the DCS, it is very easily understood by all users
including trainees. This is an important aspect of their
application due to the amount of operations personnel that are
trained on Kuito for the first time on DCS systems.”
It is estimated that the total purchase and installation costs for
the three Tracerco Profilers has been recouped in the first six
months of operation, due to improvements in ‘uptime’,
chemical usage reductions and saving in operator and
technicians interventions.
Case Study 2. The Shell Tern Incremental Project (TIP)
The project. In September 1998 the Shell Tern Incremental
Project (TIP) received approval to start topside engineering
development work on Tern ‘A’ platform in the UK sector of
the North Sea. The objective was to substantially increase the
gross liquid handling capacity of the platform. Primary
production separation systems, produced water handling,
water injection pumps and gas lift systems would all need to
be upgraded.
Cost Challenge. This work was put on hold in March 1999
when reappraisal of the reservoir potential concluded that the
incremental recovery would be less than previously envisaged.
SPE 77891
The Shell Tern Asset Team was tasked with reducing costs
whilst keeping as close as possible to the original design
capabilities and flow rates. In addition to reduced oil benefits,
these reappraisals were to be carried out against the (then)
prevailing background of $10 oil screening criteria.
To meet the economic screening, ‘normal’ processing
facilities were challenged and a re-assessment made of what
facilities could do if really squeezed. Much of the reduction
was to be to the discomfort of operations staff, who, in the
final reckoning, agreed to a fairly radical reduction in facilities
and to operate systems “at the edge”.
Due to the radical process simplification, control of both
oil and produced water levels within the new vessel was seen
as being particularly important in terms of environmental
performance and oil export quality.
Profiler justification. Following consultation with Shell’s
technology group the Tern Asset Team decided to utilise the
Synetix Tracerco Profiler to monitor and control the interface
levels on the upstream side of the vessel. The TIP profiler was
to be a first for Shell worldwide. Historical problems with
displacer technology and potential environmental issues
concerning the large volume of crude oil, within the separator
vessel, that could flow to the produced water treatment plant if
interface control was compromised, demanded a high integrity
instrument was used for the TIP separator application. This
was the main contributing factor in justifying the installation
of the Tracerco Profiler on Tern. The ‘zero operator
intervention’ with the Profiler also fitted in perfectly with
Shell’s minimum intervention philosophy.
Feedback from Shell Tern ‘A’ Platform Operations
“The Tern Tracerco Profiler has been in operation for over six
months. Initial indications are that it is an extremely accurate
source of vessel ‘real time’ operating data. The Profiler is
enabling us to more accurately dose chemicals. It has
prevented unnecessary trips and prevented overboard water
quality excursions. Even minor excursions in upstream
demulsifier-chemical injection dosing rates have been quickly
and correctly diagnosed by the indication of an increase in the
depth of the emulsion phase and evidence of stratified
emulsion layers within the produced water phase.
On Tern ‘A’ we look forward to decreased chemical
injection spend, increased environmental performance,
reduced risk of interface related trips, improved asset
utilisation and lower maintenance costs related to our new TIP
production separator. I would recommend the use of a density
profiler is pursued in all cases where separator performance is
considered critical.”
Conclusions
The important features of the Tracerco Profiler may be
summarized as follows:
1. The instrument measures the vertical distribution of the
various phases in the separator and provides information
on the extent of interphase mixing.
SPE 77891 THE FUTURE OF THREE PHASE SEPARATOR CONTROL 5

2. Up to 96 individual density measurements are made

simultaneously. The accuracy of each density
measurement is approximately +/- 10 kg/m3 in the range 0
– 3000 kg/m3. The measurement update period is
selectable, but is typically 3 seconds. PLC Cabinet

3. The vertical resolution (pitch between measurement

points) is 28-mm minimum. Fibre Optic Link

4. Easy installation requires only a single 6” vessel nozzle Fibre Optic Link

and a single galvanically isolated power supply (1000mA Signal Signal +10VDC
Modbus
Protocol
@ 10v dc). Processor
box A
Processor
Box B -0VDC
5. There are no moving parts, leading to essentially RS232
Converter
RS232
Converter
maintenance-free operation, +10VDC
RS232 RS232
Copper Copper
6. The system conforms to highest world standards in -0VDC
Cables Cables

Probe A

Probe B
electrical and radiological safety Port B Port A
Modbus Module
7. Powerful visualisation software exposes the behaviour of Alen Bradley PLC
Analogue
process material in real time. +24VDC Output Card
Communication
8. Analogue and digital outputs are provided to optimise Hazardous Area
Link to DCS or
Safe Area SCADA 4 or 8 Analogue Outputs
process control.

At the time of writing, 20 systems are installed at locations Fig. 2—Schematic drawing of the instrument
around the world. A similar number is on order and many
more potential applications are at the discussion stage.
Feedback from the operators has been excellent and we feel
confident in asserting that the Tracerco Profiler represents the
future of three-phase separator control.

Acknowledgments
We thank Block 14 Operations for their permission to publish
the Kuito material. The Block 14 partners, and their equity
shares are ChevronTexaco (Operator) 31%, Sonangol 20%,
TatalFinaElf 20%, Agip 20% and Petrogal 9%.
We thank Shell Tern (Operations) for permission to
publish the Shell case study.

Fig. 3—Detail of single source and detector

Fig. 1 - The density profiler. A typical installation geometry

6 J. CHARLTON AND R. LEES SPE 77891

Fig. 4. - Screen shot from the Kuito Profiler at start-up

Fig. 5—Screen shot from the Kuito Profiler 12 minutes after the introduction of oil into the vessel
SPE 77891 THE FUTURE OF THREE PHASE SEPARATOR CONTROL 7

Fig. 6—Screen shot from the Kuito Profiler shortly after the commencement of defoamer addition.

Fig. 7—Screen shot from the Kuito Profiler approximately 1.5 hours after the commencement of defoamer
addition.
8 J. CHARLTON AND R. LEES SPE 77891

Fig. 8—Screen shot from the Kuito Profiler at full production