EP4396557A1 - System for monitoring solid particles in fluid flow - Google Patents

Abstract

The present invention provides a system for monitoring solid particles in a fluid or hydrocarbon flow and a method for monitoring the same. The system comprises a camera (101) for capturing images of the flow; a conditioning device (102); a filtering means for capturing solids; and a separator (108) for separating phases of the flow. The conditioning device is located upstream of the camera for isolating phases and solids in the flow before passing the flow through the camera. The camera communicates with a computer system that provides algorithms to interpret images captured by the camera for data on particle size distribution, concentration, and shape of the solids; and the filtering means provides solids for sampling.

Description

SYSTEM FOR MONITORING SOLID PARTICLES IN FLUID FLOW FIELD OF THE INVENTION The present invention relates to a system for monitoring solids in a fluid flow. More particularly, the present invention relates to a system and method for monitoring solid particles in a fluid or hydrocarbon flow. BACKGROUND OF THE INVENTION Managing produced solids such as sand and other particles in a fluid or hydrocarbon production system is essential in estimating the performance and risk of individual wells and optimizing well and reservoir productivity. In processing hydrocarbon or fluid containing solids, solids such as sand and other solid particles suspended in the fluid or hydrocarbon flow need to be filtered and removed by the production system. The presence of solids in the flow can disrupt production due to deposition and erosion at many points along the production system. In managing solids such as sand and other solid particles in a fluid or hydrocarbon flow, the solids in the flow need to be monitored and sampled for analysis. The results from the analysis can be used to determine the optimal operating condition of the system. The analysis will ensure that the equipment used during the production operates accordingly with the results and ensures that removing solids such as sand and other solid particles from the fluid or hydrocarbon flow can be carried out effectively. Depending on the flow conditions of the fluid or hydrocarbon and solids production from the well, the sampling process may need to be carried out at specific and frequent intervals. The process is labour-intensive and time-consuming. At times, results from the sample analysis may take up to 2 weeks to obtain. This method is not desirable when the work area is exposed to hazardous and toxic substances released from the production fluid. A detection device may also be used to detect solid particles such as sand in the fluid flow. The device is placed at a flow line and works based on the conversion of sound energy from the impingement of solid particles on pipe wall to raw data. This method is not desirable as detection may limited to solids with 20 microns and above and could not provide information such as particle size distribution and concentration, and no provision for sampling. The existing systems and methods currently being used to monitor solid particles in a fluid or hydrocarbon flow have several limitations. Some of the systems do not provide instant information about the solids and depend on manual sampling. Some of the methods rely on a single filter in which when the filter is clogged, the operation needs to be stopped for changing or cleaning the filter and no facility for backwashing the filter. Some of the systems are configured without adequate control and indicator for regulating flow and pressure. A camera may also be used for monitoring solids in a fluid or hydrocarbon flow. JP2004117005A discloses measurements of the particle size distribution of solids with a laser diffraction light scattering method by sampling the powder directly from a pipe during transportation. A dispersing member is provided in front of a nozzle tip to be sampled, and between the nozzle and the dispersing member. The system does not include a process assembly for the physical collection of solids and control according to the present invention; and a method for conditioning the flow upstream. WO2007088842A1 discloses a particle measuring apparatus comprising a particle removing part for removing particles contained in a fluid at a predetermined proportion and a sensor part for measuring particles passed through the particle removing part. Means for correcting data on the number of particles comprising a property data memory and DSP for correcting data on the number of particles measured with a sensor part using inherent removing properties of the particle removing part in relation to particle diameters is provided, whereby the number of particles contained in a fluid having a high particle number concentration can be measured with high accuracy. The difference with the present invention system is that the filter is upstream of the imaging element that removes a portion of solids for a reduced particle concentration, and the imaging element captures the same. JP2005114664A discloses a particle detector for measuring the particle concentration of suspended particles. A classifier takes out particles in a particular size range and guides them to the particle detection region. A particle detection apparatus comprises a particle detection unit that simultaneously irradiates a plurality of particles with light and detects scattered light emitted by the particles, and an arithmetic processing unit obtains a particle concentration from an output signal of the particle detection unit. The system does not include a process assembly for the physical collection of solids and control according to the present invention; and a method for conditioning the flow upstream. US8812236B1 discloses a method for optimizing drilling fluids by creating a proper particle size analysis and distribution curve of particle sizing within drilling fluid. The particle size distribution curve is maintained with a maximum particle sizing of 6 microns to not allow for coarser drilled solids to degrade beyond the point of mechanical separation to prevent a build- up of low gravity solids that can no longer be removed from the drilling fluid during the drilling operation due to their size. An optimal drilling system requires that drilling fluids be modified through the following process to attain the appropriate particle sizing distribution to make the most efficient use of the drilling operation, reduce the amount of drilling fluids utilized, and reduce formation damage. The method generates corrective actions to modify the drilling fluids or adjust solids control equipment parameters, to obtain a unique particle size distribution throughout the drilling process. The system does not include a process assembly for the physical collection of solids and control according to the present invention; and a method for conditioning the flow upstream. CN106368675A discloses an oil and gas well sand production monitoring data processing method. The data collecting and processing system is used to synchronously collect output signals after smoothing the sand production monitoring channel. The difference with the present invention is that the method utilizes acoustic detection, which is not desirable, and the system does not include a process assembly for the physical collection of solids and control according to the present invention; and a method for conditioning the flow upstream. WO2000046586A1 discloses an apparatus for monitoring particulate material in a fluid comprising a passageway, through which fluid to be monitored is passed wherein at least a portion of the boundary of the passageway being translucent to enable radiation to pass through that portion. A camera is arranged to receive such radiation and is constructed to generate electrical signals representative of the images it receives. Image analysis means are connected to receive those electrical signals and to provide data from them relating to the particulate material contained within the fluid. The system does not include a process assembly for the physical collection of solids and control according to the present invention; and a method for conditioning the flow upstream. WO2012053898A1 discloses a technical system for online measuring and monitoring of the particle content in an injection water flow (6') in an underwater line, wherein the technical system comprises a data gathering means, a data communication link and a data receiving means, and wherein the data gathering means comprises an image analysis apparatus. The system does not include a process assembly for the physical collection of solids and control according to the present invention; and a method for conditioning the flow upstream. NL2010538C2 discloses the use of a camera for application in water. The difference with the proposed system is that this system is only applicable to water and not suitable for monitoring solids in hydrocarbon flow. The system does not include a process assembly for the physical collection of solids and control according to the present invention; and a method for conditioning the flow upstream. In light of the above shortcomings and limitations, it is an object of the present invention to provide a system and method that can effectively monitor solids in a fluid or hydrocarbon flow, where the information about the solids or solid particles that flow with the fluid or hydrocarbon can be directly and instantly measured. It is a further object of the present invention to provide a system and method for online measurement of solid partciles with facility of solids sampling and an improved flow and pressure control in the system.

SUMMARY OF THE INVENTION Embodiments of the present invention provides a system, apparatus and method for monitoring solid particles in a fluid or hydrocarbon flow. The monitoring of solid particles by the system, apparatus and method involve an online measurement of particle size distribution and concentration of solid particles. According to the first aspect of the invention, the system includes an apparatus for monitoring solids in a fluid or hydrocarbon flow. The apparatus provides online measurement of particle size distribution and concertation of solid particles during the fluid or hydrocarbon flow in a conduit e.g piping or pipelines of a production system. The apparatus can be configured to provide instant information on the particle size distribution and concentration of solid particles in the flow. The information or data relating to the solid particles is directly and instantly measured via a camera system connected to a computer system. The communication between the camera and the computer system may be via a wired or wireless connection. The apparatus can be configured to be portable and can be installed as a temporary or permanent unit on the existing flow lines. An installation of the apparatus in the area that is hazardous to the operators is an advantage where the information about the solid particles can be remotely measured and monitored. Portable or permanent unit can be installed on a skid with trolley to ease mobilisation. The apparatus can be configured to allow manual sampling for further analysis, such as sand particle size composition, concentration and compositional or mineralogy analysis. An effective sampling can contribute to flow assurance allowing increased production optimization, and the analysis can provide valuable data to enhance and prolong the reservoirs' life cycle and asset life. In an embodiment, the system comprises a camera for capturing images of solid particles suspended in a fluid or hydrocarbon flow, a filtering means for capturing solid particles in the flow, and a separator for separating phases flow and individual flowmeter for liquid and gas flowrate measurements. The fluid or hydrocarbon flow may include a single-phase flow of gas or liquid or a multiphase flow. A flow conditioning device may be provided upstream of the camera to condition the flow. For example, a hydro cyclone unit may be disposed to prepare the flow to suit the camera's operating requirement to capture images. The camera communicates with a computer system that includes algorithms to interpret the image data for desirable properties relating to the solid particles, such as particle size distribution, concentration, and shape. Visualisation of data could be by means of using computer tablet, or screen that ca be installed together with apparatus, or both. The flow and downstream pressure are controlled via a regulator disposed at the inlet of the separator. The regulator is in the form of a valve for controlling fluid flow and pressure. The operators may manipulate the regulator to achieve the required downstream parameters for isokinetic sampling. The regulator can be automated by means of actuation using pneumatic, hydraulic, motor operated etc. In such option, a local control panel can be provided to ease control, or in separate example, it can also be controlled remotely from control room. A pressure differential indicator to gauge and indicate the pressure at the inlet and outlet of the filter is provided. The reading of the pressure differential by the indicator (202) may indicate potential clogging of the filter or range of pressure differential for a filter change or switching between filters. Connections are also provided at inlet and outlet of the filter for filter backwashing when the limit of pressure differential is met. In one example, nitrogen gas is used to backwash the filter to unclog. A drain line is also provided at the bottom of the filter housing to allow discharge of medium for collection, or to evacuate the trapped medium during flushing, or for general draining, which connection could be fixed with hard tubing or flexible hose with quick connect. Accordingly, a system for monitoring solid particles in a fluid or hydrocarbon flow according to the present invention comprises a camera (101) for capturing images of the flow; a conditioning device (102); a filtering means for capturing solid particles; and a separator (108) for separating phases of the flow; wherein the conditioning device is located upstream of the camera for isolating phases and solid particles in the flow before passing the flow through the camera that communicates with a computer system that provides algorithms to interpret images captured by the camera for data on particle size distribution, concentration, and shape of the solid particles; and the filtering means provides solid particles for sampling. In another example, where the physical sample is not required to be captured hence the filter can be bypassed, the camera can be relocated to downstream of separator, either connected to gas outlet of the separator, or liquid outlet of the separator, to obtain measurement on either liquid outlet, or gas outlet, respectively. According to the second aspect of the invention, the system provides a method for monitoring solids in a fluid or hydrocarbon flow. The method provides online measurement of particle size distributions and concentration of solid particles during the hydrocarbon flow. The method includes steps that allow information or data relating to solid particles, such as particle size distribution and concentration of solid particles during the flow be directly and instantly measured and monitored. In operation, a fluid or hydrocarbon that flows in a pipe run or a flow line is tapped into the apparatus. An integral double block and bleed valve may be used to tap in the fluid or hydrocarbon flow from the flow line. This type of valve may provide better isolation of the flow when it enters the apparatus. Preferably, the flow is conditioned to prepare the flow for the camera to capture images. The flow may be conditioned via a hydrocyclone unit before the flow passes through the camera. The flow will then enter a filtering means where solid particles such as sand and other particles are trapped therein and continue to flow through a separator or a standpipe where the flow phases are separated for individual phase flow measurement. Accordingly, a method for monitoring solid particles in a fluid or hydrocarbon flow according to the present invention comprises the steps of ● tapping the flow from a pipe and channeling the flow into a conditioning device (108), a first and a second filters (104, 106), and a separator (108); ● conditioning the flow via a conditioning device at an upstream of a camera for isolating phases and solid particles in the flow before passing the flow through the camera for image capture; ● interpreting images captured by the camera via a computer system for data on particle size distribution, concentration, and shape of the solid particles; ● regulating pressure and flow of the fluid or hydrocarbon flow to achieve the optimal downstream parameters or for isokinetic sampling via a connection of a valve to an inlet of the separator (108) and providing solid particles for sampling. The method further comprises the step of indicating pressure differential via a gauge connection to an inlet and outlet of the filters (104, 106) for potential clogging of the filter (104, 106) and for a filter change or switching between filters. The combination of online measurement and a facility to obtain physical samples of solid particles in the present invention allows the solid particles to be directly measured, monitored, and sampled in a fluid or hydrocarbon flow. Operators can obtain the sample of the solid particles under different operating conditions from a pipeline or tubing at a take-off point or a sampling point. The present invention can be used to monitor the performance of the production system equipment. For example, the system can be connected to the inlet and outlet of separation equipment such as hydrocyclone desander or filter to determine solid separation efficiency. It can be connected to the inlet and outlet of a separator to determine the trapped solid particles such as sand. Cumulative sand production properties in a particular flowing event, for example, during a normal condition, slugging condition, water breakthrough, or during drilling for drilling particle monitoring as well as pigging condition, can also be monitored.

BRIEF DESCRIPTION OF DRAWINGS The present invention will be described further by way of example, with reference to the accompanying drawings, in which: Fig.1 shows a diagram of an exampla of a system for monitoring solid particles in a fluid or hydrocarbon flow according to an embodiment of the present invention;and Fig.2 shows a diagram of an example of a system for monitoring solid particles in a fluid or hydrocarbon flow according to another embodiment of the present invention.

DETAILED DESCRIPTION The system will now be described with reference to the examplary embodiments shown in the accompanying drawings. Fig.1 shows a schematic diagram of an example of a system (10) for monitoring solid particles in a fluid or hydrocarbon flow according to an embodiment of the present invention. The system (10) comprises a high speed camera (101) for capturing images of solid particles suspended in the flow, a conditioning device (102) for conditioning the flow, a filtering means (104, 106) for capturing solid particles in the flow, and a separator (108) for separating phases of the flow. The above components are interlinked via piping or tubing and valves. For example, a duplex stainless steel tubing with ½ inch outer diameter and ½ inch isolation valves with double compression fitting may be used. In this example, the tubing may be provided until the inlet flange of the filtering means. A fluid or hydrocarbon flowing in a pipe run (200) or flow line is tapped into the system (10) via sampling connection, that maybe equipped with an integral double block and bleed valve. For example, the valve is provided with a sampling probe protruded into the pipe run at 1/3 of the pipe’s internal diameter. A plurality of valves are provided in the piping of the system. The conditioning device (102) is connected to the camera (101) via tubing and is located upstream of the camera for isolating phases and solid particles in the flow. The phases of the flow may include gas, hydrocarbon liquid, and water. A hydrocyclone unit or other suitable flow conditioning device may be used to meet the camera’s operating requirement. The camera (101) is in communication with a computer system that provides algorithms to interpret the captured images for data on particle size distribution, concentration, and shape of the solid particles. The connection between the computer and the camera may be via wired or wireless connection and configured to provide particle data at specific intervals. The solid particles captured by the filtering means can be taken for sampling analysis. The filtering means may be a redundant filtering system. The redundant filtering system may include a first filter (104) and a second filter (106). Stainless steel filters with 2 x 100% configuration may be used where the collecting volume is large enough to accommodate a long monitoring and sampling process. For example, a minimum of 4 hours is required for the sampling process. The filtering elements of the filters are changeable according to specific location requirements. A cartridge-type filter may be used to collect a large volume of solid particles such as sand. The second filter (106) allows a quick interchange when the pressure differential is detected. A dual-range interchangeable pressure gauge is provided to measure low and high pressure range accurately. For example, a 10 bar pressure gauge (204) is equipped with a 10-70 bar pressure gauge (205) for measuring operating pressure below 10 bar and 10-70 bar, respectively. A pressure differential indicator (202) is connected to an inlet and outlet of the filters to gauge and indicate the pressure differential. The reading of the pressure differential by the indicator (202) may indicate potential clogging of the filter or range of pressure differential for a filter change or switching between filters. A bypass line may be provided for maintaining purpose. A regulator (201) is connected to an inlet of the separator (108) for controlling the pressure and flow of the fluid or hydrocarbon flow in the system to achieve the optimal downstream parameters or for isokinetic sampling. Isokinetic sampling may be required especially for the gas dominant flow to reduce disturbance to flow velocity profile. Downstream parameter e.g pressure could be monitored via pressure indicator that can be installed either separately or as part of the system. A check valve may be installed at the outlet of the system to prevent reverse flow in the system when the downstream pressure is higher than the upstream pressure. The separator (108) is provided with sight glass and level gauge or level instrument to indicate separation of gas and liquid in the separator and channel a gas-dominated flow through the gas outlet located at the top and channel a liquid-dominated flow through the outlet located at the bottom. In this example, liquid level within the separator (108) is manually controlled by throttling the gas and liquid outlet valve. Liquid level control could also be achieve via automated level control. The outlets are connected to individual flow meters (302, 304) to measure the fluid or hydrocarbon phase flow rate in the system. A variable area or coriolis flowmeter may be used to provide a volumetric or mass flow rate measurement with total volume flowing through. The flow meter (106) includes a totalizer function to obtain total flow throughout sampling duration. In Fig.1, a first line (401) can be connected to the outlet of the filters (104,106) for flushing the filters when the filters are clogged, or when a cleaning or purging process on the filters is required. Fig.2 shows a schematic diagram of an example of a system (20) for monitoring solid particles in a fluid or hydrocarbon flow according to another embodiment of the present invention. In another embodiment, the camera can be relocated to downstream of the separator (108) when physical sample capture is not required. To relocate the camera, the filtering means is bypassed. As shown in Fig.2, the first line (401) is now acting as a bypass for the filters. A second line (402) can be provided to connect to the filters (204, 206) for quick flushing if the filters are clogged, and when a cleaning or purging process is required. Pressurized water can be channeled from a backwash system (501) to flush the filters. In this example, the camera (101) can be provided downstream of the separator (108) for monitoring solid particles in the gas- dominated flow and/or liquid-dominated flow from the separator (108). The camera can be placed at the outlets of the separator. While the foregoing describes various embodiments of the present invention, other and further embodiments of the present invention may be devised without departing from the working concept of the invention. The present invention is not limited to the described embodiments, versions or examples.

Claims

CLAIMS 1. A system for monitoring solid particles in a fluid or hydrocarbon flow comprising a camera (101) for capturing images of the flow; a conditioning device (102); a filtering means for capturing solid particles; and a separator (108) for separating phases of the flow; wherein the conditioning device is located upstream of the camera for isolating phases and solid particles in the flow before passing the flow through the camera that communicates with a computer system that provides algorithms to interpret images captured by the camera for data on particle size distribution, concentration, and shape of the solid particles; and the filtering means provides solid particles for sampling.

2. The system as claimed in claim 1 wherein the filtering means includes a first filter (104) and a second filter (106).

3. The system as claimed in claim 1 wherein the system includes a regulator (201) connected to the inlet of the separator for controlling pressure and flow.

4. The system as claimed in claim 1 and 2 wherein the system includes a pressure differential indicator (202) connected to an inlet and outlet of the filtering means to gauge and indicate potential clogging of the filter (104, 106)

5. The system as claimed in claim 1 and claim 2 wherein the system includes a pressure differential indicator (202) connected to an inlet and outlet of the filters (104, 106) to indicate a range of pressure differential for a filter change or switching between filters.

6. The system as claimed in claim 1 wherein a regulator (201) is connected to an inlet of the separator (108) for controlling pressure and flow of the fluid or hydrocarbon flow in the system to achieve the optimal downstream parameters for isokinetic sampling.

7. The system as claimed in claim 1 wherein the separator is connected to individual flow meters (302, 304) to measure a flow rate of gas and liquid.

8. The system as claimed in claim 1 wherein the individual flow meters (302, 304) includes a totalizer function to obtain total flow throughout sampling duration.

9. The system as claimed in claim 1 wherein the conditioning device is a hydro cyclone unit.

10. The system as claimed in claim 1 wherein a first line (401) is provided for quick flushing in the event the filtering means is clogged, and a cleaning or purging process is required.

11. The system as claimed in claim 1 wherein a first line is provided to bypass the filtering means.

12. The system as claimed in claim 1 wherein the camera (101) is relocated downstream of the separator for monitoring solids particles in a gas-dominated flow from the separator (108).

13. The system as claimed in claim 1 wherein the camera (101) is relocated downstream of the separator for monitoring solids particles in a liquid-dominated flow from the separator (108).

14. The system as claim in claim 11 wherein a second line (402) is connected to the filtering means for quick flushing in the event the filter is clogged, and a cleaning or purging process is required 15. A method for monitoring solid particles in a fluid or hydrocarbon flow comprising the steps of tapping the flow from a pipe (200) and channeling the flow into a conditioning device (108), a first and a second filters (104, 106), and a separator (108); conditioning the flow via a conditioning device at an upstream of a camera for isolating phases and solid particles in the flow before passing the flow through the camera for image capturing; interpreting images captured by the camera via a computer system for data on particle size distribution, concentration, and shape of the solid particles; regulating pressure and flow of the fluid or hydrocarbon flow to achieve the optimal downstream parameters for isokinetic sampling via a connection of a valve to an inlet of the separator (108); and providing solid particles for sampling. 16. The method for monitoring solid particles in a fluid or hydrocarbon flow as claimed in claim 15 wherein the method further comprising the step of indicating pressure differential via a gauge connection to an inlet and outlet of the filters (104, 106) for potential clogging of the filter (104, 106) 17. The method for monitoring solid particles in a fluid or hydrocarbon flow as claimed in claim 15 wherein the method further comprising the step of indicating pressure differential via a gauge connection to an inlet and outlet of the filters (104, 106) for a filter change or switching between filters. 18. The method for monitoring solid particles in a fluid or hydrocarbon flow as claimed in claim 15 wherein the method further comprising flushing the filter via a flushing line (401)