Level Profiler
A “virtual window” into separators and vessels.
While DP and guided wave radar level transmitters – and even mechanical floaters and visual gauges – serve their purpose in light, sweet crudes and generally when water separates easily from oil, heavier and more viscous crude oils introduce much more complex layers and less defined levels in production separators.
With tight emulsions, long settling times and severe foaming, operators need better information to optimize separator throughput, and still avoid excess water on the oil outlet and liquid carry-over on the gas outlet.
The Stolway Level Profiler is the only technology on the market able to provide this level of detail and seamless representation of complex separator layers without any nuclear sources.
Features
The Stolway Level Profiler employs a series of SeCaP sensors allowing operators to “see through the walls” of the separator:
- Accurate location of water, emulsion, oil, foam and free gas layers relative to top of weir plate
- Seamless gradient color for varying water cut across emulsion layer
- Customization of vertical resolution to customer requirements (1 cm resolution possible)
- Optimization of resolution at critical levels in separator (e.g. just below top of weir plate)
- Optional flushing capability for effective cleaning of sensors without affecting production
Technical Specification
MECHANICAL SPECIFICATIONS – PROFILER ROD | |
Rod diameter & length | 80 mm OD (typ.), max. 30 m for one profiler rod (vertical) |
Rod material | SS 316L, Duplex, Super Duplex, Inconel 625 or others upon request |
Construction | Machined sections up to 3.5 m, bolted together in situ for longer rods |
Process connection | Flanged, minimum 4″ ANSI/API, 150# – 900#, RF/RTJ |
Number of sensors | Selected by customer based on separator height and required resolution |
Design temperature | 125°C, 175°C, 225°C |
Design pressure | Up to 450 bar (depending on process connection pressure rating) |
Enclosure protection | IP66 (profiler rod terminals housing) |
Protective coating | Not applicable |
MECHANICAL SPECIFICATIONS – CONTROLLER UNIT ENCLOSURE | |
Dimensions | 375 x 265 x 108 mm3 (14.8″ x 10.4″ x 4.3″) |
Material | SS 316 |
Mounting | Stand-alone |
Enclosure protection | IP66/IP67 |
Protective coating | Not applicable |
ELECTRICAL SPECIFICATIONS | |
Hazardous Area classification | Ex ia protection from Sensor Unit to Safe Area Analyzer Interface cabinet Profiler Rod (Sensor Unit): ATEX/IECEx II 1/(1)G Ex ia/[Ex ia] IIB T4-T2 Ga Controller Unit enclosure: ATEX/IECEx Ex ia IIB T4 Ga -40°C ≤ Ta ≤ +60°C Analyzer Interface cabinet: Must be placed in Safe Area IS barriers: Located in Safe Area within the Analyzer Interface cabinet. If required, they can be installed in Zone 2 |
ATEX certificate | Presafe 16 ATEX 8593X |
IECEx certificate | PRE 14.0004X |
Ambient temperature | -40°C ≤ Ta ≤ +60°C |
Outputs | RS485 Modbus RTU, 4–20 mA (e.g., for oil/water interface level & alarm) |
External power supply | 120/230VAC, 24VDC to Safe Area Analyzer Interface cabinet |
Power consumption | < 10 W |
Cable entry | Profiler Rod terminals housing: Factory connected instrument cable Controller Unit enclosure: Factory connected instrument cable + M20 |
Maximum cable length | Profiler Rod to Controller Unit: 5 m Controller Unit to Safe Area barrier modules: 500 m |
PERFORMANCE SPECIFICATIONS | |
Primary measurement | Water, emulsion, oil, foam & gas profile (Modbus RTU serial output) Water level (% or mm) (4–20 mA output) |
Measurement principle | Single Electrode Capacitance (SeCaP) |
Measurement range | Defined by profiler rod Active Measurement Section length |
Number of sensors | Selected by customer based on separator height and required resolution |
Profile resolution | Defined by Active Measurement Section length / Number of sensors |
Sensitivity | Each sensor can distinguish between water, emulsion (incl. varying water content across emulsion layer), oil, foam and gas |
Applications Fields
The Stolway Level Profiler employs a series of SeCaP sensors allowing operators to “see through the walls” of the separator:
- Accurate location of water, emulsion, oil, foam and free gas layers relative to top of weir plate
- Seamless gradient color for varying water cut across emulsion layer
- Customization of vertical resolution to customer requirements (1 cm resolution possible)
- Optimization of resolution at critical levels in separator (e.g. just below top of weir plate)
- Optional flushing capability for effective cleaning of sensors without affecting production