Multi-Phase Flow Metering in Offshore Oil and Gas Transportation Pipelines: Trends and Perspectives

Measuring volume fractions of a three-phase flow without separation utilizing an approach based on artificial intelligence and capacitive sensors

Many different kind of fluids in a wide variety of industries exist, such as two-phase and three-phase. Various combinations of them can be expected and gas-oil-water is one of the most common flows. Measuring the volume fraction of phases without separation is vital in many aspects, one of which is financial issues. Many methods are utilized to ascertain the volumetric proportion of each phase. Sensors based on measuring capacity are so popular because this kind of sensor operates seamlessly and autonomously without necessitating any form of segregation or disruption for measuring in the process. Besides, at the present moment, Artificial intelligence (AI) can be nominated as the most useful tool in several fields, and metering is no exception. Also, three main type of regimes can be found which are annular, stratified, and homogeneous. In this paper, volume fractions in a gas-oil-water three-phase homogeneous regime are measured. To accomplish this objective, an Artificial Neural Network (ANN) and a capacitance-based sensor are utilized. To train the presented network, an optimized sensor was implemented in the COMSOL Multiphysics software and after doing a lot of simulations, 231 different data are produced. Among all obtained results, 70 percent of them (161 data) are awarded to the train data, and the rest of them (70 data) are considered for the test data. This investigation proposes a new intelligent metering system based on the Multilayer Perceptron network (MLP) that can estimate a three-phase water-oil-gas fluid's water volume fraction precisely with a very low error. The obtained Mean Absolute Error (MAE) is equal to 1.66. This dedicates the presented predicting method's considerable accuracy. Moreover, this study was confined to homogeneous regime and cannot measure void fractions of other fluid types and this can be considered for future works. Besides, temperature and pressure changes which highly temper relative permittivity and density of the liquid inside the pipe can be considered for another future idea.

A Pressure-Based Multiphase Flowmeter: Proof of Concept

Multiphase flowmeters (MPFMs) measure the flow rates of oil, gas, and brine in a pipeline. MPFMs provide remote access to real-time well production data that are essential for efficient oil field operations. Most MPFMs are complex systems requiring frequent maintenance. An MPFM that is operationally simple and accurate is highly sought after in the energy industry. This paper describes an MPFM that uses only pressure sensors to measure gas and liquid flow rates. The design is an integration of a previously developed densitometer with an innovative Venturi-type flowmeter. New computing models with strong analytical foundations were developed, aided by empirical correlations and machine-learning-based flow-regime identification. A prototype was experimentally validated in a multiphase flow loop over a wide range of field-like conditions. The accuracy of the MPFM was compared to that of other multiphase metering techniques from similar studies. The results point to a robust, practical MPFM.

Dual-Modal Electrical Imaging of Two-Phase Flow-Experimental Evaluation of the State Estimation Approach

Accurate measurement of two-phase flow quantities is essential for managing production in many industries. However, the inherent complexity of two-phase flow often makes estimating these quantities difficult, necessitating the development of reliable techniques for quantifying two-phase flow. In this paper, we investigated the feasibility of using state estimation for dynamic image reconstruction in dual-modal tomography of two-phase oil-water flow. We utilized electromagnetic flow tomography (EMFT) to estimate velocity fields and electrical tomography (ET) to determine phase fraction distributions. In state estimation, the contribution of the velocity field to the temporal evolution of the phase fraction distribution was accounted for by approximating the process with a convection-diffusion model. The extended Kalman filter (EKF) and fixed-interval Kalman smoother (FIKS) were used to reconstruct the temporally evolving velocity and phase fraction distributions, which were further used to estimate the volumetric flow rates of the phases. Experimental results on a laboratory setup showed that the FIKS approach outperformed the conventional stationary reconstructions, with the average relative errors of the volumetric flow rates of oil and water being less than 4%. The FIKS approach also provided feasible uncertainty estimates for the velocity, phase fraction, and volumetric flow rate of the phases, enhancing the reliability of the state estimation approach.

Towards Real-Time Analysis of Gas-Liquid Pipe Flow: A Wire-Mesh Sensor for Industrial Applications

Real-time monitoring of gas-liquid pipe flow is highly demanded in industrial processes in the chemical and power engineering sectors. Therefore, the present contribution describes the novel design of a robust wire-mesh sensor with an integrated data processing unit. The developed device features a sensor body for industrial conditions of up to 400 °C and 135 bar as well as real-time processing of measured data, including phase fraction calculation, temperature compensation and flow pattern identification. Furthermore, user interfaces are included via a display and 4…20 mA connectivity for the integration into industrial process control systems. In the second part of the contribution, we describe the experimental verification of the main functionalities of the developed system. Firstly, the calculation of cross-sectionally averaged phase fractions along with temperature compensation was tested. Considering temperature drifts of up to 55 K, an average deviation of 3.9% across the full range of the phase fraction was found by comparison against image references from camera recordings. Secondly, the automatic flow pattern identification was tested in an air-water two-phase flow loop. The results reveal reasonable agreement with well-established flow pattern maps for both horizontal and vertical pipe orientations. The present results indicate that all prerequisites for an application in industrial environments in the near future are fulfilled.

Application of Microwave Transmission Sensors for Water Cut Metering under Varying Salinity Conditions: Device, Algorithm and Uncertainty Analysis

The measurement of water cut in crude oil is an essential procedure in petroleum production and it is desirable to obtain these data through an automatic and real-time method. Microwave sensors can be used for the task, and they are safe, robust and can cover the whole water cut range. However, they are relatively susceptible to the water conductivity and temperature, and the algorithms for addressing these problems are still rare in the literature. In this paper, a microwave transmission sensor that can measure the water cut under varying salinity conditions is proposed, and the algorithm for solving the water cut and salinity simultaneously with the measured amplitude and phase is described in detail. Experiments under different water cut and salinity conditions are conducted, and the results are used to verify the model and algorithm. Finally, a simplified and fast method for uncertainty analysis is proposed and applied to the iteration algorithm under test conditions. It can be concluded that accuracy higher than 95% in the water cut measurements can be expected under the 0~100% water cut range, and an error of about 10% in the water conductivity is achievable under water-continuous flow conditions. The uncertainty analysis shows that the calculated water cut and salinity results are negatively correlated, and the water salinity uncertainty tends to be larger than the water cut uncertainty. When the water salinity is high, the water cut uncertainty tends to be high whereas the water salinity uncertainty tends to be low.

The Nuclear Magnetic Flowmeter for Monitoring the Consumption and Composition of Oil and Its Complex Mixtures in Real-Time

The necessity of increasing the efficiency of primary oil purification in a drilling station or an offshore platform has been substantiated. We consider the problems that arise during the primary processing of oil mixtures. Important conditions for increasing the efficiency of primary purification (separation) of oil mixtures include measuring the consumption and determining the content of various impurities (water, undissolved particles) and air in them, with an error of no more than 2%. We analyzed the possibilities of using various designs of flowmeters to measure the consumption of the oil mixture coming from a well. It is also necessary to use other measuring instruments to control the state of this mixture, which creates additional problems (searching for an appropriate locations to place them, providing the required operating conditions). Various designs of nuclear magnetic flowmeters–relaxometers were considered, making it possible to measure the consumption of a liquid medium and its times of longitudinal T1 and transverse T2 relaxation with one device. The measured values of T1 and T2 determine the state of the medium. The design of the industrial nuclear magnetic flowmeter–relaxometer M-Phase 5000, which is used to control the flow and quality of oil and oil products, was considered in more detail. Problems were identified that did not allow using this design of a nuclear magnetic flowmeter–relaxometer in a drilling rig or offshore platform. A new design of a nuclear magnetic flowmeter–relaxometer was developed, implementing the methods for measuring q, T1, and T2. These methods and various technical solutions make it possible to use this device at a drilling station or offshore platform. The measurement errors of the consumption q, T1, and T2 were determined. The results of various media studies are presented and compared with q, T1, and T2 measurements on other devices and measured volume (to confirm the adequacy of q measurements). The application scopes of the developed nuclear magnetic flowmeter–relaxometer were determined, in addition to the systems of primary oil processing.

Reinforcement Learning Based Relay Selection for Underwater Acoustic Cooperative Networks

In the complex and dynamically varying underwater acoustic (UWA) channel, cooperative communication can improve throughput for UWA sensor networks. In this paper, we design a reasonable relay selection strategy for efficient cooperation with reinforcement learning (RL), considering the characteristics of UWA channel variation and long transmission delay. The proposed scheme establishes effective state and reward expression to better reveal the relationship between RL and UWA environment. Meanwhile, simulated annealing (SA) algorithm is integrated with RL to improve the performance of relay selection, where exploration rate of RL is dynamically adapted by SA optimization through the temperature decline rate. Furthermore, the fast reinforcement learning (FRL) strategy with pre-training process is proposed for practical UWA network implementation. The whole proposed SA-FRL scheme has been evaluated by both simulation and experimental data. The simulation and experimental results show that the proposed relay selection scheme can converge more quickly than classical RL and random selection with the increase of the number of iterations. The reward, access delay and data rate of SA-FRL can converge at the highest value and are close to the ideal optimum value. All in all, the proposed SA-FRL relay selection scheme can improve the communication efficiency through the selection of the relay nodes with high link quality and low access delay.

An Ultrasonic-Capacitive System for Online Characterization of Fuel Oils in Thermal Power Plants

This paper presents a ultrasonic-capacitive system for online analysis of the quality of fuel oils (FO), which are widely used to produce electric energy in Thermal Power Plants (TPP) due to their elevated heating value. The heating value, in turn, is linked to the quality of the fuel (i.e., the density and the amount of contaminants, such as water). Therefore, the analysis of the quality is of great importance for TPPs, either in order to avoid a decrease in generated power or in order to avoid damage to the TPP equipment. The proposed system is composed of two main strategies: a capacitive system (in order to estimate the water content in the fuel) and an ultrasonic system (in order to estimate the density). The conjunction of the two strategies is used in order to estimate the heating value of the fuel, online, as it passes through the pipeline and is an important tool for the TPP in order to detect counterfeit fuel. In addition, the ultrasonic system allows the estimation of the flow rate through the pipeline, hence estimating the amount of oil transferred and obtaining the total mass transferred as a feature of the system. Experimental results are provided for both sensors installed in a TPP in Brazil.

Uncertainty Estimation for Machine Learning Models in Multiphase Flow Applications

In oil and gas production, it is essential to monitor some performance indicators that are related to the composition of the extracted mixture, such as the liquid and gas content of the flow. These indicators cannot be directly measured and must be inferred with other measurements by using soft sensor approaches that model the target quantity. For the purpose of production monitoring, point estimation alone is not enough, and a confidence interval is required in order to assess the uncertainty in the provided measure. Decisions based on these estimations can have a large impact on production costs; therefore, providing a quantification of uncertainty can help operators make the most correct choices. This paper focuses on the estimation of the performance indicator called the water-in-liquid ratio by using data-driven tools: firstly, anomaly detection techniques are employed to find data that can alter the performance of the subsequent model; then, different machine learning models, such as Gaussian processes, random forests, linear local forests, and neural networks, are tested and employed to perform uncertainty-aware predictions on data coming from an industrial tool, the multiphase flow meter, which collects multiple signals from the flow mixture. The reported results show the differences between the discussed approaches and the advantages of the uncertainty estimation; in particular, they show that methods such as the Gaussian process and linear local forest are capable of reaching competitive performance in terms of both RMSE (1.9–2.1) and estimated uncertainty (1.6–2.6).

Multiphase Flow Regime Characterization and Liquid Flow Measurement Using Low-Field Magnetic Resonance Imaging

Multiphase flow metering with operationally robust, low-cost real-time systems that provide accuracy across a broad range of produced volumes and fluid properties, is a requirement across a range of process industries, particularly those concerning petroleum. Especially the wide variety of multiphase flow profiles that can be encountered in the field provides challenges in terms of metering accuracy. Recently, low-field magnetic resonance (MR) measurement technology has been introduced as a feasible solution for the petroleum industry. In this work, we study two phase air-water horizontal flows using MR technology. We show that low-field MR technology applied to multiphase flow has the capability to measure the instantaneous liquid holdup and liquid flow velocity using a constant gradient low flip angle CPMG (LFA-CPMG) pulse sequence. LFA-CPMG allows representative sampling of the correlations between liquid holdup and liquid flow velocity, which allows multiphase flow profiles to be characterized. Flow measurements based on this method allow liquid flow rate determination with an accuracy that is independent of the multiphase flow profile observed in horizontal pipe flow for a wide dynamic range in terms of the average gas and liquid flow rates.

A Survey on Distributed Fibre Optic Sensor Data Modelling Techniques and Machine Learning Algorithms for Multiphase Fluid Flow Estimation

Real-time monitoring of multiphase fluid flows with distributed fibre optic sensing has the potential to play a major role in industrial flow measurement applications. One such application is the optimization of hydrocarbon production to maximize short-term income, and prolong the operational lifetime of production wells and the reservoir. While the measurement technology itself is well understood and developed, a key remaining challenge is the establishment of robust data analysis tools that are capable of providing real-time conversion of enormous data quantities into actionable process indicators. This paper provides a comprehensive technical review of the data analysis techniques for distributed fibre optic technologies, with a particular focus on characterizing fluid flow in pipes. The review encompasses classical methods, such as the speed of sound estimation and Joule-Thomson coefficient, as well as their data-driven machine learning counterparts, such as Convolutional Neural Network (CNN), Support Vector Machine (SVM), and Ensemble Kalman Filter (EnKF) algorithms. The study aims to help end-users establish reliable, robust, and accurate solutions that can be deployed in a timely and effective way, and pave the wave for future developments in the field.

A Novel Multi-Sensor Fusion Algorithm Based on Uncertainty Analysis

During the research and development of multiphase flowmeters, errors are often used to evaluate the advantages and disadvantages of different devices and algorithms, whilst an in-depth uncertainty analysis is seldom carried out. However, limited information is sometimes revealed from the errors, especially when the test data are scant, and this makes an in-depth comparison of different algorithms impossible. In response to this problem, three combinations of sensing methods are implemented, which are the “capacitance and cross-correlation”, the “cross-correlation and differential pressure” and the “differential pressure and capacitance” respectively. The analytical expressions of the gas/liquid flowrate and the associated standard uncertainty have been derived, and Monte Carlo simulations are carried out to determine the desired probability density function. The results obtained through these two approaches are basically the same. Thereafter, the sources of uncertainty for each combination are traced and their respective variations with flowrates are analyzed. Further, the relationship between errors and uncertainty is studied, which demonstrates that the two uncertainty analysis approaches can be a powerful tool for error prediction. Finally, a novel multi-sensor fusion algorithm based on the uncertainty analysis is proposed. This algorithm can minimize the standard uncertainty over the whole flowrate range and thus reduces the measurement error.

Restoration of Missing Pressures in a Gas Well Using Recurrent Neural Networks with Long Short-Term Memory Cells

This study proposes a data-driven method based on recurrent neural networks (RNNs) with long short-term memory (LSTM) cells for restoring missing pressure data from a gas production well. Pressure data recorded by gauges installed at the bottom hole and wellhead of a production well often contain abnormal or missing values as a result of gauge malfunctions, noise, outliers, and operational instability. RNNs employing LSTM cells to prevent long-term memory loss have been widely used to predict time series data. In this study, an RNN with the LSTM method was used to restore abnormal or missing wellhead and bottom-hole pressures in three intervals within a production sequence of more than eight years in duration. The pressure restoration was performed using various input features for RNNs with LSTM models based on the characteristics of the available data. It was carried out through three sequential processes and the results were acceptable with a mean absolute percentage error no more than 5.18%. The reliability of the proposed method was verified through a comparison with the results of a physical model.

Electrical Tomography: A Review of Configurations, and Application to Fibre Flow Suspensions Characterisation

Understanding the behaviour of suspension flows continues to be a subject of great interest considering its industrial relevance, regardless of the long time and effort dedicated to it by the scientific and industrial communities. Information about several flow characteristics, such as flow regimen, relative velocity between phases, and spatial distribution of the phases, are essential for the development of exact models for description of processes involving pulp suspension. Among the diverse non-invasive techniques for flow characterisation that have been reported in the literature for obtaining experimental data about suspension flow in different processes, Electrical Tomography is one of the most interesting, since it presents perhaps the best compromise among cost, portability, and, above all, safety of handling (indeed there is no need to use radiation, which requires special care when using it). In this paper, a brief review and comparison between existing technologies for pulp suspension flow monitoring will be presented, together with their strengths and weaknesses. Emphasis is given to Electrical Tomography, because it offers the above-mentioned compromise and thus was the strategy adopted by the authors to characterise different flow processes (solid–liquid, liquid–liquid, fibres, etc.). The produced portable EIT system is described, and examples of results of its use for pulp suspension flow characterisation are reported and discussed.

Particle Image Velocimetry of Oil-Water Two-Phase Flow with High Water Cut and Low Flow Velocity in a Horizontal Small-Diameter Pipe

Velocity and flow field are both parameters to measure flow characteristics, which can help determine the logging location and response time of logging instruments. Particle image velocimetry (PIV) is an intuitive velocity measurement method. However, due to the limitations of image acquisition equipment and the flow pipe environment, the velocity of a horizontal small-diameter pipe with high water cut and low flow velocity based on PIV has measurement errors in excess of 20%. To solve this problem, this paper expands one-dimensional displacement sub-pixel fitting to two dimensions and improves the PIV algorithm by Kriging interpolation. The improved algorithm is used to correct the blank and error vectors. The simulation shows that the number of blank and error vectors is reduced, and the flow field curves are smooth and closer to the actual flow field. The experiment shows that the improved algorithm has a maximum measurement error of 5.9%, which is much lower than that of PIV, and that it also has high stability and a repeatability of 3.14%. The improved algorithm can compensate for the local missing flow field and reduce the requirements related to the measurement equipment and environment. The findings of this study can be helpful for the interpretation of well logging data and the design of well logging instruments.