Apr-2025

How radiometric level measurement enhances sustainability

In today’s highly competitive oil and gas industry, process optimisation, equipment reliability, and sustainability are more critical than ever to maintaining profitability.

Berthold Technologies

Article Summary

One of the most complex yet essential challenges refiners face is effectively monitoring separation processes. Advanced multiphase level measurement technologies, particularly radiometric solutions like Berthold’s EmulsionSENS, offer unmatched reliability, operational performance, and significant environmental benefits, making them a smart investment for both ROI and long-term sustainability.

The separation challenge
Separation processes are vital across oil and gas operations, from separators and storage tanks to desalters and alkylation units. In desalters, for example, ensuring a clear distinction between the oil, water, and emulsion layers is critical to prevent salt, mineral, and metal carryover, which can cause corrosion and fouling in downstream equipment. Additionally, the occurrence of rag layers, stubborn, semi-stable emulsions that resist separation, can further complicate the process. Without proper monitoring, these rag layers can lead to inefficiencies, increased chemical consumption, and potential process upsets.

Measurement technologies fall into two categories: direct and indirect methods. Direct methods like differential pressure and RF absorption physically contact process fluids but struggle with emulsion height changes and buildup interference. Indirect methods, such as nuclear density profiling systems, offer more reliable monitoring under challenging conditions.

Nuclear density profiling: How it works
Radiometric measurements employ a simple yet sophisticated principle – radiation attenuation. A typical system consists of a radioactive source and detector positioned on opposite sides of the vessel. As gamma radiation from the source penetrates the vessel and its contents, the radiation intensity decreases based on the density of the materials it passes through. This attenuation allows for accurate density determination of the vessel contents through appropriate calibration.

Different configurations exist in the market, but many utilise one or more internal sources inside dip tubes, with detectors positioned either on the vessel exterior or within internal dip tubes. Berthold Technologies’ EmulsionSENS exemplifies an effective implementation of this technology, featuring internal sources in a curved dip tube and externally mounted detectors. This design ensures that the electronics are always accessible, while providing multiple density measurements at different heights to create a comprehensive density profile of vessel contents.

Practical advantages for operators
The EmulsionSENS system offers several practical benefits that translate to operational advantages:
· Extended measurement range: By using multiple sources in a single dip tube, EmulsionSENS offers an almost unlimited measurement range, whereas some competing systems are limited to 1-1.5m ranges per dip tube.
· Advanced algorithms: Sophisticated algorithms not only output density values but determine individual layer filling levels, providing redundant measured values through independent outputs.
· Compact, permanent shielding: A permanently mounted, small shield enhances safety, especially during maintenance.
· Simplified source exchange: All sources can be pulled into the shield and replaced together, reducing radiation exposure.
· Fault tolerance: Even with detector failures, EmulsionSENS continues providing level readings, unlike competitors that fail with a single malfunction.
· Buildup resistance: The configuration with detectors outside the vessel and sources inside a dip tube creates longer, more consistent measurement paths that are neglectable influenced by process buildup.

Sustainability impact in desalter operations
Beyond operational improvements, EmulsionSENS technology delivers significant sustainability benefits, particularly in desalter applications:
· Reduced energy consumption: Traditionally, desalters require substantial energy to achieve necessary separation temperatures. With the improved level control provided by EmulsionSENS, operational temperatures can be significantly reduced, directly lowering energy requirements. Industry reports suggest a 10% reduction can save approximately $500,000 annually in a medium-sized refinery, based on typical energy costs and consumption rates.
· Minimised equipment fouling: Better separation reduces salt, mineral, and metal carryover, preventing heat exchanger fouling. Studies on refinery maintenance costs estimate potential savings of up to $200,000 per year.
· Extended equipment life: By limiting salt carryover and corrosion, refineries can extend equipment lifespan by 20%, with material replacement costs reduced by an estimated $300,000 annually.
· Catalyst protection: Reducing iron (Fe) and other contaminants extends catalyst life, cutting replacement costs by approximately $150,000 per year, according to operational case studies.
· Improved heat recovery efficiency: Less fouling means better heat exchanger efficiency, contributing to estimated energy savings of $100,000 annually, based on performance benchmarks in similar refineries.

Real-world impact: Customer success stories
The business impact of these systems extends far beyond technical specifications. Refineries implementing nuclear density profiling systems report remarkable operational improvements:
· Eliminated desalter upsets: One refinery experienced a decrease from 2-6 desalter upsets annually to zero in two years after implementation.
· Automated process control: Continuous adjustment of water outlet valves maintains proper control and minimise oil or mineral carryover
· Optimised chemical usage: Precise monitoring enables significant cost savings in chemical dosing

A refinery using EmulsionSENS reported transformative results, exclaiming ‘Bye-bye Iron! Thanks to make it happen!’ Prior to installation, operators had little visibility into vessel conditions. The new insights allowed them to adjust operational parameters to improve efficiency regarding iron carryover. By maintaining lower interface levels in the vessel, they leveraged turbulence from the mud washing system to agitate the emulsion layer, assisting with iron dropout. The operator praised the implementation: ‘Perfect design and great result. It’s performing like a dream!’

Conclusion
As refiners continue seeking ways to maximise efficiency, minimise downtime, and improve sustainability, radiometric multiphase level measurement system is a game-changer. The ability to ‘see’ inside vessels with precision transforms operational decision-making, enabling proactive adjustments that prevent upsets, optimise chemical usage, and extend equipment life.