35285_Insert_Desalter_35285_Insert_Desalter 14/12/2012 16:06 Page 1

Real Time, Online Multiphase Separation

with The TRACERCO ProfilerTM
Desalter Applications: A Case Study

Within many refineries there is a growing
tendency to process heavier crudes or
blend these with lighter feed stocks.
During crude oil refining, it is
advantageous to optimise the blend to
reduce overall feedstock costs whilst at the
same time ensuring the final mix can be
adequately processed with minimal upset.
One fundamental need within a refinery process is the
efficient separation of wastewater from crude feedstock
using a desalter vessel after water washing the material
to reduce chloride levels and suspended solids. In order to
optimise this separation requirement, appropriate vessel
and internals design must be used alongside reliable level
and interface instrumentation.
When applied to the relatively dirty service experienced
within a desalter a number of existing interface control
instruments have been found to demonstrate many
shortcomings. Upon a request by a major oil refiner,
Tracerco redesigned its TRACERCO ProfilerTM instrument
that is commonly used in three phase separation devices
within the upstream oil and gas industry to withstand the
elevated operating temperatures typically experienced
within a desalter vessel.
This case study offers information on the development and
application of a profiling instrument that provides vertical
real time phase density measurement in desalter vessels.
It allows the position and extent of oil, emulsion, water and
solids to be measured.

Measurement Instruments and Servicing

35285_Insert_Desalter_35285_Insert_Desalter 14/12/2012 16:06 Page 2
Instrumentation used in Desalter Vessels
There are many types of interface instruments available
that are used to measure critical levels within desalter
vessels. The most common include displacement
systems, differential pressure, capacitance probes,
microwave, guided wave radar, ultrasonic, thermal
conductivity and nucleonic. From these, only four have
shown reasonable reliability for interface measurement.
These include displacement, capacitance, guided wave
radar and nucleonic. However, there are distinct limitations
for these instrument types when an emulsion band (rag layer)
occurs within the desalter separation process.
The principles of measurement of these instruments
are examined in more detail below.
Capacitance Probes
Capacitance probes measure electrical characteristics of
fluids in which they have contact. As an interface level rises
on the probe, the measured capacitance changes as the
probe goes from complete immersion in oil (0% on the
interface level range), to complete immersion in water
(100% on the interface level range). The problem with this
method is that if the electrical characteristics of either fluid
change significantly from the expected values, as will
happen when different feedstocks are introduced to the
vessel or when emulsions (rag layers) are formed, then the
capacitance measured may change. This in turn could be
interpreted incorrectly as a change in level to operators and
inappropriate control actions taken. In addition, capacitance
probes only measure a very small distance into a particular
fluid. If the process materials measured are dirty,
capacitance probes are rapidly rendered inoperable.
Therefore, this type of instrument is most suited to
measurement within fluids that are relatively clean and not
prone to coating surfaces. It is also advantageous to have
a well defined step change in density. In practice, this is
rarely the case in a desalter. It is also important to note that
this type of instrument only provides a single point
measurement at the probe position.
Measurement Instruments and Servicing
2
Displacement Interface Gauges
Displacement instruments are the most commonly used
instrument within desalters for interface level control over
many years. The instrument consists of a submerged body
(displacer) suspended in the fluids, the weight of which is
balanced by an upward force exerted on it by
a particular level of fluid. As the level changes, the force
increases or decreases and this results in a vertical
movement of the displacer indicating a change in interface
level. The force exerted depends on the density of each
fluid; therefore, if this characteristic changes significantly
the density change will be interpreted as a change in level.
If the displacer is immersed in an emulsion it will give an
output corresponding to the average density over its
range, thus giving a false interface reading.
Within desalters an internal displacer is normally installed
inside the vessel within a stilling well. The stilling well
provides protection for the suspended displacer tube and
some damping of the fluids being measured. The major
drawback with an internal displacer, as opposed to a bridle
mounted displacer, is maintenance. If a problem occurs
with an internal stilling well instrument, then the only way
to get access is to shutdown, depressurise the vessel and
remove the instrument. Obviously this is undesirable in
a continuous refinery operation.
Guided Wave Radar
Guided Wave Radar works in much the same way as
conventional radar. An electromagnetic energy signal is
transmitted from an antenna. When it reaches a definitive
interface point some of this energy is reflected back. Time
Domain Reflectometry measures the transit time to this
point and back, allowing calculation of the interface
position. The system utilises a guide that is in contact with
the liquids. This is used to transmit the electromagnetic
radiation pulses to reduce signal degradation through the
liquid. The technology relies upon back reflection of the
signal from the interface position. Unless there is a clearly
defined interface, there will be no point at which this will
occur. Unlike displacement, capacitance and nuclear
instruments which will measure an approximate or average
interface position when a rag layer is present, the signal
from Guided Wave Radar technology will continue to the
bottom of the vessel and no interface measurement will be
observed. An example of this is shown in figure 2.
35285_Insert_Desalter_35285_Insert_Desalter 14/12/2012 16:06 Page 3
Figure 1: General arrangement - Internally mounted source
Conventional Radiation Instruments
Conventional nucleonic interface gauges use a radioactive
source or sources, that are mounted internally using a
sealed dip-pipe that looks similar to a thermo-well. The
radioactive source is located at the end of the dip-pipe
inside the vessel. Figure 1 shows a typical arrangement.
One or more radioactive sources are located within a
sealed dip-pipe inside the vessel. When the source beam
shines through the phase of lower density, the signal
intensity at the external detector is high. When the more
dense material phase increases through the vessel the
radiation intensity at the detector is reduced. Through
calibration of the system using the densities of both fluids
involved, the interface position within the vessel can be
measured and controlled.
Measurement Instruments and Servicing
Figure 2: Rag layer presence resulting in Guided Wave Radar signal loss
However, if in the case of an interface where the two
phases are difficult to separate and hence an emulsion
band (rag layer) is formed, the system will continue to
measure bulk density at the detector.
Using its calibration algorithm the instrument will offer an
interface point. This point will be based upon the average
density position between phases and will not take into
consideration the upper and lower parts of the interface
gradient. In a worst case situation, if an emulsion band
spreads to a position greater than the vertical
measurement width of the detector, the system will
continue to select an interface position using the 50% bulk
density reading. This will occur even though the lower
phase is mixed and present above the average interface
measurement range and the upper phase is mixed and
present below the average measurement point.
3
35285_Insert_Desalter_35285_Insert_Desalter 14/12/2012 16:06 Page 4
Figure 3: Views of Density Profiler in a Desalter Vessel
Density Profiling Technology
Density profiling technology can define all fluids inside a
separation vessel to a greater degree than conventional
instruments. It measures the density and extent of different
phases within a vessel. It maps different densities of
materials such as gases, liquids and interface spans
between phases. These materials can be separated into
different user variable density bands or phases. The
interface of the various phases can then be calculated with
respect to the vessel height.
In place of traditional single point measurements for interface
and bulk level, an operator can measure the position of each
phase in real time and determine the quality of each interface.
This level of measurement gives the operator confidence to
increase fluid throughput and minimise the use of various
separation enhancement chemicals.
The information provided can also be used to
automatically control interface levels in a DCS system and
influence the injection of effect chemicals.
A density profiler is housed in dip-pipes (sealed pockets
similar to thermo-wells) installed within the vessel through
a single flange as shown in figure 3.
Measurement Instruments and Servicing
4
Figure 4: Detail of single source and single detector
A narrow dip-pipe holds an array of low energy gamma
emitters. The other dip-pipes hold a vertical array of up
to 150 radiation sensors. Each sensor is matched to the
radiation source on the same plane as shown in figure 4.
On the screen the fluid density at each vertical point is
depicted.
Principle of Operation
Radioactive level measurement methods are normally
based on absorption of radiation. The absorption principle
utilises the reduction in radiation passing through the
process material with increasing mass density. The
difference in the absorption coefficient for radioactive
materials between oil, water and solids is sufficiently
large to detect interface levels. Ion sensors detect the
radiation passing through the process material. An ion
sensor is a gas ionisation detector. An electric field is
applied between two electrodes in a gas (e.g. argon) filled
tube. The radioactive signal produces an ionisation
process in the gas and because of the electric field the
free electrons and positive ions produce an electric
current that is proportional to the amount of radiation.
35285_Insert_Desalter_35285_Insert_Desalter 14/12/2012 16:06 Page 5
Figure 5: Schematic diagram of a typical profiler system
Materials of Construction
Due to its density, titanium was chosen for the dip-pipes
as it is relatively transparent to the low energy radiation
emitted from the sources. If steel dip-pipes were used the
radiation employed would require a higher energy source.
This high energy radiation is less sensitive to density
changes. This would make it necessary to employ a much
larger source to detector separation, in the region of
500mm between the dip-pipes, i.e. more than one vessel
nozzle would be required. In addition, because radiation
from a higher energy source is difficult to shield, the beam
from each source would appear as a patch covering about
150mm vertical length on the detector assembly. This
would mean that vertical resolution would be at least
150mm for a higher energy source based profiler
compared with 30mm for lower energy emitting devices.
It is the use of low density, high strength titanium for the
dip-pipes that make it possible to use low energy sources
in the profiler. Lower energy sources are much easier to
shield, allowing a much smaller source/detector distance,
which allows a single nozzle on the vessel and allows
much improved vertical resolution, and hence provides a
better density profile.
Measurement Instruments and Servicing
The material between the two dip-pipes will attenuate the
radiation and so the intensity of radiation seen by a
radiation sensor is related to the density of the intervening
material. Each sensor produces a train of voltage pulses
as its output signal. The rate at which these pulses are
produced is directly proportional to the intensity of the
radiation incident on the sensor that is determined by the
density of the process fluid at the sensor elevation.
Pulses from the radiation sensor are counted in the signal
processor unit mounted above the dip-pipe assembly.
The count period is user selectable so that the random
nature of the radiation pulses can be smoothed out.These
counts are transmitted for analysis via a fibre optic link and
a converter to a PLC that collects the information and
calculates the density of the material for each individual
radiation sensor. Thus, a density profile of the vessel can
be achieved. Density bands are allocated for each of the
different phases, the top level of these phases can then
be calculated with respect to vessel or instrument height.
These heights and phase band thickness can then be
used for control loop process variables. Instrument set
up is shown in figure 5.
5
35285_Insert_Desalter_35285_Insert_Desalter 14/12/2012 16:06 Page 6

Figure 7: Showing desalter profiler output in the control

system. Green is oil and blue is the water phase

Figure 6: Showing installation of the profiler into the desalter vessel

Profiler Application in Desalters The operations team had stabilised

Over the last few years The TRACERCO Profiler has the interface level through use of The
been widely used in many upstream oil and gas separation
applications. However it had never been used within a TRACERCO ProfilerTM. This resulted in
desalter due to temperature limitations. Typical desalter a very small rag layer, clean outlet
temperatures are above the allowable intrinsically safe
certification temperature of 125oC. water and zero process upsets.
In 2004 a major refiner approached Tracerco to determine
if a profiling unit could be modified to operate at
temperatures up to 250oC. The solution was to use the
existing profiler design that had been well proven in the
field at lower temperatures with the addition of a cooling
system surrounding the detector tube.

Measurement Instruments and Servicing

6
35285_Insert_Desalter_35285_Insert_Desalter 14/12/2012 16:06 Page 7
Installation
The unit was commissioned in Spring 2005 as a part of
a Crude Unit Turnaround. The installation required an 8
nozzle to be fitted to the vessel at an appropriate position.
The system was designed to allow measurement within the
water phase up through the interface and into the lower
grid of the desalter vessel.
Operational Experience
The use of The TRACERCO Profiler started in Spring
2005. After a short period of time operations started to
utilise the device as the primary interface level indicator.
A diagram showing the instrument output from the desalter
is shown in figure 7.
By mid year 2005 the operations team had stabilised the
interface level through use of The TRACERCO ProfilerTM.
This resulted in a very small emulsion band (rag layer),
clean outlet water and zero process upsets. Operations
also used The TRACERCO Profiler to fine-tune chemical
usage and mud washing of the vessel.
Closely reviewing output data from The TRACERCO
ProfilerTM and running a series of tests the customer has
achieved the following:
Operator confidence to run the interface level at or within
the lower electrostatic grid thus optimising separation of
difficult blends
Increased upstream desalter mixing to enhance removal
of chloride carry over to downstream vessels thus
reducing corrosion and fouling issues. This has reduced
carry over of chloride levels from 3-4 ppm to 1-2 ppm
Increased blending ratios of lower quality crudes with
enhanced margin of refined products
Optimisation of emulsion and asphaltene reducing
chemicals within the desalting process leading to
considerable cost savings
The elimination of process upsets resulting from water
carryover or oil carry under from the desalter vessel
Measurement Instruments and Servicing
Closing Remarks
A density profiler system has been designed, manufactured
and used within a high temperature desalter system over a
seven-year time period. It has shown that the technology
allows the accurate measurement of phases including oil,
emulsion (rag layer), water and solids/sludge in real time.
The cooling system has also proven itself to be robust and
very efficient at maintaining detector temperatures at
appropriate levels. The experiences gained from use of the
instrument has resulted in a number of measurable benefits
to be realised including the elimination of unplanned desalter
shutdowns, reduced chemical usage, increased fluid
throughput and the capability to handle more challenging
crude blend ratios. The system has been adopted by many
other sites allowing them to obtain similar benefits.
References
R.P. Lees, Tracerco and J.S.Charlton, Tracerco The
Future of Three Phase Separator Control presented at the
SPE Asia Pacific Oil and Gas Conference and Exhibition,
Melbourne, Australia, 8 10 October 2002,
SPE 77891
P Hewitt, Tracerco Nuclear Gauging for Difficult Interface
Control, ISA Canada Technology Show, Sarnia February
22nd 2005
Presented in 9th Topical Conference on Refinery Processing (TA015) - #55
Advances in Desalting of the 2006 Spring A.I.Ch.E Meeting, Orlando, FL, April 23-27, 2006
Paul Hewitt and Scott Vidrine, Tracerco
The A.I.Ch.E. shall not be responsible for statements or opinions contained in its publications
7
35285_Insert_Desalter_35285_Insert_Desalter 14/12/2012 16:06 Page 8

Contact Us:
Tel: +44 (0)1642 375500 Email: tracerco@tracerco.com For more information on
For your local representative please visit our website: The TRACERCO Profiler TM

www.tracerco.com/contact-us scan the QR code.

Tracerco Limited is a subsidiary of Johnson Matthey PLC, 5th Floor, 25 Farringdon Street, London EC4A 4AB.
Registered in England No. 4496566. Tracerco is a trading name of Tracerco Limited.
TRACERCO, The TRACERCO Profiler, Johnson Matthey and the Johnson Matthey logo are trademarks of
the Johnson Matthey Group of companies.

XM0564/0/A

Measurement Instruments and Servicing