IMAGING SYSTEM FOR ANALYZING A MULTIPHASE FLOW
20220349738 · 2022-11-03
Inventors
Cpc classification
H04N23/555
ELECTRICITY
G01F1/74
PHYSICS
G01F1/704
PHYSICS
H04N23/90
ELECTRICITY
International classification
G01F1/74
PHYSICS
G01F1/704
PHYSICS
Abstract
An imaging system for measuring flow rates of the individual phases of a multiphase flow and for providing images of the multiphase flow, wherein the imaging system is adapted to also measure the thickness of deposits on the internal wall of a pipe, and to a method for analyzing a multiphase flow flowing through a pipe using the imaging system.
Claims
1. Imaging system for measuring flow rates of the individual phases of a multiphase flow and for providing images of the multiphase flow, wherein the imaging system is adapted to also measure the thickness of deposits on the internal wall of a pipe.
2. The imaging system of claim 1, wherein the multiphase flow comprises at least a gaseous phase and a liquid phase, and wherein the liquid phase comprises water and/or oil.
3. The imaging system of claim 1, further comprising an online flow conditioner.
4. The imaging system of claim 3, wherein the online flow conditioner generates annular flow or stratified flow.
5. The imaging system of claim 3, wherein the online flow conditioner is a swirl separator or cyclone separator.
6. The imaging system of claim 3, wherein the online flow conditioner is positioned upstream of the imaging system.
7. The imaging system of any claim 1, comprising a THz imaging system, an ultrasonic array imaging system, an electrical capacitance tomography system, an electrical resistance tomography system and/or a magnetic inductance tomography system.
8. The imaging system of claim 1, comprising a THz imaging system and an ultrasonic array imaging system, wherein the THz imaging system is adapted to measure multiphase flows of gas void fractions above a predefined value, and wherein the ultrasonic array imaging system is adapted to measure multiphase flows of gas void fractions below the predefined value.
9. The imaging system of claim 1, further comprising one or more pairs of ultrasonic sensors which operate in transit time mode and/or Doppler-effect mode adapted to measure the flow rates of the multiphase flow, wherein the one or more pairs of ultrasonic sensors are adapted to be inserted into the multiphase flow.
10. The imaging system of claim 7, wherein the ultrasonic array imaging system is arranged as a circular array.
11. The imaging system of claim 9, wherein the at least one pair of ultrasonic sensors is arranged such that in operation, the ultrasonic waves propagate through the liquid.
12. The imaging system of claim 1, further comprising one or more pressure sensors adapted to measure the flow rates of the multiphase flow.
13. The imaging system of claim 7, wherein the THz imaging system comprises an THz source and a THz camera, which capture a THz image reflecting the permittivity of the multiphase flow within the vicinity of the THz camera.
14. The imaging system of claim 13, wherein the THz image is processed by performing block-based motion estimation or region-based motion estimation to provide an image of the multiphase flow, the GVF, the water-cut, the density, and/or the velocity of the liquid-gas interface, which is the average between the gas velocity and the liquid velocity.
15. The imaging system of claim 13, wherein the THz imaging system comprises two or more THz cameras and/or two or more THz sources adapted to perform three-dimensional reconstruction of the multiphase flow and/or to perform an accurate two-dimensional image reconstruction.
16. The imaging system of claim 13, wherein the at least one THz camera comprises one or more pixels.
17. The imaging system of claim 7, wherein the ultrasonic array imaging system comprises one or more rings of ultrasonic elements and wherein the ultrasonic array imaging system operates in transit and/or reflection mode adapted to determine the thickness of the gas phase and the water-cut value, and to perform image reconstruction using a tomography technique.
18. Use of the imaging system according to claim 1 for measuring flow rates of a multiphase flow and for visualizing the flow of the multiphase flow, and/or for measuring the thickness of deposits on the internal wall of a pipe.
19. Use of the imaging system according to claim 18, wherein the multiphase flow has a low gas-void-fraction and/or a high water-cut.
20. Method for analyzing a multiphase flow flowing through a pipe using the imaging system according to claim 1 comprising the steps of: determining the flow rates of the individual phases of the multiphase flow; acquiring a two-dimensional or three-dimensional image of the flow of the multiphase flow; and preferably, measuring the thickness of scale which is deposited at the internal wall of the pipe.
21. The method of claim 20, wherein the multiphase flow comprises at least a gaseous phase and a liquid phase, and wherein the liquid phase comprises water and/or oil.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] In the following preferred embodiments of the invention are described by reference to the drawings in which shows:
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DETAILED DESCRIPTION OF THE INVENTION
[0066] In the following, preferred embodiments of the invention are described in detail with respect to the accompanying figures. It is, however, understood, that these embodiments are not meant to limit the application and scope or configuration of the disclosure. On the other hand, the following description of the invention can provide to those skilled in the art other exemplary preferred embodiments. It is understood that various changes can be made without departing from the concept and scope as set in the appended claims.
[0067] The present invention relates to a compact imaging system for multiphase flow metering, which can be also used for the measurement of scale thickness, i.e. the thickness of scale which is deposited at the internal wall of the pipe. The imaging system may, for example, comprise a THz imaging system and/or an ultrasonic array system. It may also include other sets of additional sensors such as ultrasonic sensors to determine the flow rates of individual phases. Depending on the flow conditions, the imaging system may also comprise an upstream online flow conditioner to generate a suitable flow regime such as an annular flow (using a swirl separator) or a stratified flow which can be more easily processed by the imaging system. The imaging system can also work autonomously, without a flow conditioner, in case the overall dielectric value of the multiphase flow does not exceed a predefined value. For instance, in case of multiphase flow with very high gas void fraction (GVF) or a multiphase flow with relatively low water-cut, the usage of a THz imaging system to determine the individual flow rates is appropriate. Alternatively, in case of very low GVF the ultrasonic array imaging system can be used.
[0068] According to one embodiment, the invention relates to an imaging system which may comprise a THz imaging system which consists of a THz camera, a THz source, and associated electronics to measure individual flow rates of the multiphase flow and to visualize the flow. The THz camera can comprise a two-dimensional array of pixels, where each pixel is associated to a color value coded in a predefined number of bits (e.g. 8, 12, 16, or 24 bits) and represents the amplitude of the THz wave transmitted through the target under test (TUT) medium. The two-dimensional pixel array can be as small as 1×1 pixels and as large as thousands of pixels. The physical principal of the meter is based on the fact that THz waves propagation in a given medium depends on several physical parameters such as its dielectric value and size. In case of a multiphase flow comprising oil, water, and gas, water phase has a relative dielectric value which can exceed 80, while the one of the gas is usually around unity. Consequently, THz radiations are more absorbed in the water phase than in the gas phase. Depending on the design of the imaging system, a two-dimensional or three-dimensional image of the multiphase flow can then be achieved in real-time using a dedicated hardware machine.
[0069] The imaging system can also contain an additional ultrasonic array imaging system which can operate either in echo mode, transit time mode, or Doppler-effect mode. This device is complementary to the THz imaging system to handle for instance scenarios of multiphase flows of very low GVFs and high water-cut. The device may also comprise an online flow conditioner to generate either annular flow, using swirl cage, or stratified flow. While compact and efficient online separators are available, these two flows are easier to acquire and process by the two aforementioned imaging systems.
[0070] In addition to the two imaging systems and flow conditioners, the apparatus may also comprise other sensors. For instance, ultrasonic sensors can be used to determine the gas flow rate in case the multiphase flow fluid comprises only dry gas or relatively very small concentration of liquid or that the conditioned flow downstream the separator is relatively uniform and does not significantly change over time. Temperature sensors can also be included to compensate for eventual offsets caused by the temperature variations.
[0071] The advantage of the suggested imaging system is that in addition of being non-invasive and non-intrusive, the system can provide an image of the flow and can easily handle cases which are hardly tackled in today's multiphase flow meters such as high GVF (e.g. GVF>95%) and very high water-cut.
[0072] Moreover, the system according to the present invention does not use any statistical approach but relies on physical data captured from various imaging sensors that include THz camera(s) and ultrasonic array sensor(s) (and accompanying hardware). Moreover, an online flow conditioner is suggested in order to improve the signal to noise ratio of the image signal. In addition of providing the flow regime of the actual flow, the suggested system has the advantage to accurately estimate the amount of deposits which may build-up on the wall of the probe. Oilfield scale deposits is an issue which has been rarely considered in other multiphase flow meters but it is a real practical problem to conduct accurate measurements.
[0073] As illustrated in
[0074] The THz frequency range, named also sub-millimeter wave band, refers to frequencies above 0.1 THz and below 10 THz (which corresponds to wavelengths from 30 μm to 3 mm and energies from 0.41 to 41 meV), nevertheless other frequencies below and above this range can be also used according to the present invention. Selecting the operating frequency and the power of transmission depends on various factors such as the range of water-cut, the range of the gas void fraction (GVF), and the zone classification where the device will be deployed. Both the THz camera 8 and the THz source 5 (and eventually lenses which are either embedded into the camera and/or the source of light or used as separate components to set an adequate field view) are placed in front of each other to enclose the pipeline which carries the multiphase flow. Upstream to the THz imaging system, an online flow conditioner, consisting for instance of a swirl cage 11 comprising several slots 3 which are oriented according to a predefined orientation angle and through which the multiphase flow pass through. Downstream, a multiphase flow with a certain flow regime can be created (e.g. annular flow consisting of liquid phase as the outer layer and the gas phase as the inner layer). This design has the advantage to simplify the computation complexity of the imaging system, while it causes a relatively negligible pressure drop. A transmitter 9 performs image capture and processing at video frame rate in order to determine the flow rates of individual flows composing the flow, as well as to reproduce an image of the flow. A differential pressure sensor 30 can also be used to measure the static pressure at a given section of the probe but within the vicinity of the THz camera in order to estimate the gas flow rate and the liquid flow rates using for instance the simplified momentum equation, in addition to the one estimated by the THz imaging system:
where ε.sub.G is the void fraction, dp/dz the measured differential pressure along a given axial distance, z the axial distance, g the acceleration due to the gravity, ρ.sub.G the gas density, ρ.sub.L the liquid density, τ.sub.0 the wall shear stress, S the pipe cross sectional area, P the pipe periphery, α the angle of inclination of the pressure sensor to the horizontal (e.g. 90° in
ρ.sub.TP=(1−ε.sub.G)ρ.sub.L+ε.sub.Gρ.sub.G (Equation 2)
[0075] The three terms on the right-hand side of Equation 1 denote respectively the frictional, acceleration, and gravitational pressure gradient terms. Using Equation 1, the variable {dot over (m)} which represents the mass flux of the mixture can be determined and consequently a second relationship between the gas velocity and liquid velocity can be obtained.
[0076] In a preferred embodiment, the communication between the THz source light 5 and the drive circuit logic 22 is done using optical fiber 4 as the communication medium. This is convenient if the process to be measured is hazardous and can only host intrinsically safe instruments. The system according to
[0077] Even though
[0078] One of the main tasks of the image processing module 9 is to perform block-based or region-based motion estimation on the acquired images which can be either in a two-dimensional space by using a single THz camera or in three-dimensional space, if more than one camera are used. In addition, both the dielectric and densities of the liquid and gas phases can be determined from those images by running some pattern recognition algorithm in the image processing module 9. For instance, it is expected that the pixel value, which is typically coded in 8, 12, or 16 bits for THz cameras, is highly linearly dependent on the dielectric value of the corresponding medium. Also, the density of both gas and liquid phases has to some extent an effect on the pixel values (but not as much as the dielectric value). The motion fields of the liquid-gas interface which is created downstream the flow conditioner as well as the dielectric and density values of both the gas and liquid phases will be used to determine the individual flow rates of the liquid droplets and the gas.
[0079] A differential pressure sensor 30 can also contribute to the measurement of the gas and liquid velocities using the simplified momentum equation (Equation 1). This information may be transmitted to a remote computer or remote Programmable Logic controller (PLC) via a standard bus 10 (i.e. 4-20 mA bus or field bus network).
[0080] Prior to perform the motion estimation algorithm, the data acquisition module 9 may perform image binarization using dynamic thresholding technique, followed by image morphology (e.g. erosion and dilation of regions corresponding to liquid bubbles).
[0081] It shall be appreciated that the permittivity of the mixed medium, ε.sub.mix, affects both the attenuation and the mixed velocity, V.sub.mix, of the THz waves according to the following equation:
wherein c is the sound speed (equal to 3*10.sup.8 m/s). In case the fluid consists of three phases, α.sub.1 (water), α.sub.2 (oil), and α.sub.3 (gas), then the above equation can be rewritten as follows:
wherein ε.sub.1, ε.sub.2, and ε.sub.3 are the relative permittivity of the water, oil, and gas respectively, which are variables and range in the intervals [60, 80], [2, 5], and [1, 1.15] respectively. Assuming a realistic case that the permittivity of air is almost constant, and that the fluid consists of only water and gas (which is a typical case in wet gas fluid) would lead to determine the following air fraction:
ε.sub.mix can be determined using Equation 1 above, for which V.sub.mix is the average velocity of the THz waves over all the pixels of the image. This data can be used to correct the data extracted from the THz camera which may provide some uncertainties because of the two-dimensional nature of the acquired images.
[0082] It should be appreciated that most or some of the logic in the image processing unit 7 to measure the flow rate and gas/liquid fraction from the acquired THZ images may be performed either in software using one or several central processing units or in hardware using logic gates based ICs such as Field Programmable arrays.
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[0084] The fact that the boundary of the liquid-gas interface is not a straight line but rather wavy to some extent can be explored in the image processing part to estimate the motion vector of this interface, v.sub.interface, which can be estimated as the average velocity between the average liquid velocity v.sub.liquid 34 and the average gas velocity, v.sub.Gas 35.
v.sub.interface=(v.sub.interface+v.sub.interface)/2 (Equation 6)
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[0087] The liquid flow rate is determined using the two pairs of ultrasonic sensors 26 and 27 which emit an upstream ultrasonic wave and a downstream wave respectively, the time delays of which are given by the following expression:
T.sub.Upstream=2d/(v−v.sub.Liquid) (Equation 7)
T.sub.Downstream=2d/(v+v.sub.Liquid) (Equation 8)
where d is the distance between the two ultrasonic sensors of each pair, v the propagation speed of the ultrasonic wave into the liquid phase, and v.sub.Liquid is the unknown liquid velocity. The variable, v, which depends on the water-cut can be determined using the THz camera. Using the above equations (7) and (8), the liquid velocity can be determined as follows:
v.sub.Liquid=(T.sub.Upstream−T.sub.Downstream)*v.sup.2/(2d) (Equation 9)
[0088] The gas velocity, v.sub.Gas, can be determined using the other pair of ultrasonic sensors 28 and 29 which operate in Doppler mode:
v.sub.Gas=a(f.sub.t−f.sub.r)/(2f.sub.t cos θ) (Equation 10)
where f.sub.t is frequency of the transmitted ultrasonic wave, f.sub.r the frequency of the received ultrasonic waves, and θ the half angle between the two sensors.
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Stk=t.sub.0u.sub.0/l.sub.0 with: t.sub.0=ρ.sub.Pd.sup.2.sub.p/(18 μ.sub.g) (Equation 11)
where u.sub.0 and l.sub.0 are the characteristic velocity and length of the fluid while ρ.sub.p, d.sub.p and μ.sub.g are the density, particle size of transported phase, and the viscosity of the transporting fluid respectively.
[0094] Regarding the gas-liquid fraction, it can be determined by measuring the amount of absorption of THz waves in the THz image. In case of very low water-cut, the THz waves can penetrate more easily into the flow and depending on the gas-liquid fraction, either transit time ultrasonic sensor and/or a pressure sensor can be used.
[0095] Similarly,
WC=(L.sub.Water)/(L.sub.Total)=(2t−v.sub.OilL.sub.Total)/[(L.sub.Total)*(v.sub.Water−v.sub.Oil)] (Equation 12)
where t is the transit time of the ultrasonic wave, v.sub.Oil is the speed of ultrasonic waves in oil, and v.sub.Water the speed of ultrasonic waves in water.
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[0097] It should be appreciated that the absorption spectrum in NIR range exhibits much narrower frequency band of absorbance wavelength which requires a high resolution of the emitter and receiver alike, as compared to THz range. This constitutes a significant advantage of THz imaging.
[0098] From the suggested embodiments illustrated in
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[0100] A three-dimensional image capture of the fluid can be acquired by using two or more THz cameras, instead of one single THz camera and then proceeds by a 3D reconstruction of the fluid profile using stereovision or other 3D reconstruction techniques. This is shown in
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Y=K.Math.Z=K.Math.(R.sup.2−X.sup.2).sup.0.5 (Equation 14)
where K is a constant which depends on the power of the THz source, R the radius of the probe and Z the vertical coordinate. In case series of adjacent pixels, X, of a given row have a pixel value Y given in Equation 14 above for a given number of frames, then the corresponding zone may consist of a build-up substance.
[0102] The same principle can be used for the detection of build-up substances which may appear on the top or bottom side of the pipeline by providing a THz camera and THz source along the X axis of the frame represented in
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