Desalter Measurement Challenges
Desalter Measurement Challenges
Desalter Measurement Challenges
Bob Irvin, Ametek STC Business Unit, USA, evaluates the benefits of capacitance level and interface measurement
in desalter applications.
All crude oil goes through a desalter before any Desalters use a transformer to generate a high
processing begins, if the desalter does not work voltage electrostatic field, typically 20000 V, for the
properly, the refinery will be short on feedstock and grid. This field (combined with heat, pressure, and
may have to cut back operations or even shut down. chemical additives) forces the water and sediment to
coalesce into larger drops, becoming heavier and
These units can run continuously without shutdowns
falling to the bottom of the vessel.
for a few years, hence why long-term reliability is
essential. Desalters typically operate at 300-400 psi(20-26 bar)
and 150-200C (300-400F). The processed crude oil
leaving the desalter is usually limited to a maximum
PROVEN SYSTEMS of 0.5% water, and the discharged water to 100 ppm
of oil.
pg. 1
the “rag” layer) in the middle. The sediment collects major consideration in desalter operation. For
on the bottom of the vessel. maximum production, the top of the emulsion layer
should be kept as high as possible without overloading
the grids. Capacitance /RF admittance technology
offers a major advantage in this application, because
MEASUREMENT CHALLENGES
it measures the actual electrical interface. Keeping
this interface close to the grids helps coalesce the
water and solids more quickly and completely.
The overall challenge of the desalter is to separate
water from crude, to knock out sediment, to minimize SEDIMENT
the number of chemical additives, and to maximise
This accumulates at the bottom of the vessel in excel
throughput of “dry-clean” crude oil. This must be done
of what is removed with the water. Desalters are
without discharging any oil in the wastewater. To
regularly “blown down” through a series of openings
accomplish this, operators must understand the
to remove the sediment, sometimes with the help of
process. They need to balance the use of chemicals
built-in water jets. However, the sediment is not
(both quantities and types) with product residence
always fully removed and excess sediment build-up
time (throughput and velocity), thickness of the
will change the flow rate and reduce the desalter
emulsion layer, and water content or the output oil.
efficiency. If sediment backs up into the measuring
Specific measurement challenges are as follows:
range, the desalter may require and early shutdown
BUILT-UP for cleaning. If the desalter has an internal stilling well
extending below the grids(required for internal
The feedstock to the desalter may be heavy, medium, displacers), sediment tends to build up inside the
or light crude oil, and may contain varying quantities stilling well at a faster rate.
of wax and sulfides. Heavy oils and wax may coat
everything installed in the vessel, which can affect the HIGH WATER
measuring instruments. However, high-quality
The electrostatic rid must be protected form and
capacitive level instruments are not affected by this
overload. Grids are designed to provide high voltage,
build-up.
not current (hence the term electrostatic). Only water
DENSITY (present in the emulsion layer) will create a high
current in the grids, causing the transformer to
Variations in the crude, plus the contaminants in both overload and trip the circuit breakers. Drexelbrooks
crude and water, will cause wide density variations in Grid Guard is designed to protect against this
both the oil and water phases. happening.
The emulsion layer is a bound mixture of oil and water The continuous interface sensor must be installed at a
that’s is between the water and “dry” crude oil. This representative location.
emulsion can vary from a couple of inches to several
feet thick, depending on the characteristics of the This location is not always obvious as it depends on
crude oil and how the desalter is operated and the type of crude, flow rates, and how the desalter is
controlled. Emulsion containing medium of heavy operated. The ideal sensor location is where the
crude oils and high percentages of wax and sulfur can samples are withdrawn. Sample taps are located on
be very difficult to break up. Emulsion control is a the discharge side of the desalter. Operators draw
pg. 2
samples from these taps to determine the location of allows the operator the flexibility to raise or lower the
and percentage of water in the different liquid phases interface a few inches when conditions change. The
in the desalter. heavier the oil and the thicker the emulsion, the
greater the advantages of a continuous transmitter.
LOW OIL
pg. 3
CUT MONITOR the cost of chemicals as much as 50% or more. This
instrument is also called a basic sediment and water
(BS&W) monitor. Capacitive based cut monitors are
an excellent instrument for this measurement.
The purpose of the desalter is to furnish dry, salt-free
crude oil to the refinery. Oil containing too much
water cannot be processed efficiently by the refinery.
Water content should be continuously measured in- GUARDING THE GRID
line to ensure it is on-specification.
pg. 4
WATER DUMP GUARD.
SUMMARY
pg. 5