See Part 1 Here.

Last month, we introduced the dilemma that, even as the oil and gas industry expands its use of produced water during extraction operations, it faces mounting constraints on its use and disposal. Thus, with a heightened importance of accurate and reliable measurement of produced water flow at every stage, more companies are turning to electromagnetic flowmeters, commonly known as magmeters. Now, we’ll walk through some of the details for and benefits of transitioning from mechanical flowmeters to magmeters. Not only do they offer higher accuracy, more reliability, and ease of maintenance, but they also open the door for smart meter capabilities, as we’ll see below.

TRANSITION FROM MECHANICAL FLOWMETERS

While mechanical flowmeters have traditionally been a common choice for measuring produced water, an increasingly rapid transition towards electromagnetic flowmeters is occurring in new installations and repair/replacement scenarios.

This transition is motivated by vastly improved accuracy, reliability, longevity, and ease-of-maintenance. Moreover, electromagnetic flowmeters offer additional capabilities such as online diagnostics, and data collection, making them a compelling choice. Due to their accuracy and reliability, they can also be used for leak detection.

ACCURACY, RELIABILITY, AND EASE-OF-MAINTENANCE

First and foremost, electromagnetic flowmeters are completely electronic, eliminating the need for any moving parts. This makes them far more robust and less prone to wear and tear, thereby reducing the need for frequent maintenance and replacement. As a result, they have an exceptionally long lifespan. Krohne has magmeters that have been in service for over twenty-five years, continuing to provide accurate flow measurement of produced water. 

Second, electromagnetic flowmeters offer better accuracy compared to their mechanical counterparts. Mechanical flowmeters can be affected by the viscosity of the fluids they measure, which can lead to inaccuracies. On the other hand, electromagnetic flowmeters are independent of fluid properties such as viscosity, temperature, and pressure, offering more reliable readings.

Third, magmeters offer significantly easier maintenance compared to mechanical flowmeters. The latter necessitate frequent maintenance, including an annual check and periodic removal from the line. Internal components require inspection, replacement, and often need to be sent for rebuilding. Available information within the magmeter can also be periodically monitored to alert the user of any potential issues, such as electrode wear or coating or even a degradation of the liner in extreme conditions, without having to take the meter out of service.

SMART METERS

Electronic and Smart Capabilities

The intrinsic electronic nature of magmeters enables the seamless integration of essential, groundbreaking smart functionalities that are beyond the capabilities of mechanical flowmeters. These intelligent devices can self-monitor and provide operational status updates, ensuring they are functioning correctly and alerting maintenance personnel to any irregularities.

Leak Detection

Advanced leak detection is a key smart feature of magmeters that adds significant value over mechanical meters. These sophisticated devices are capable of continuously monitoring the flow rate and identifying discrepancies, which can indicate a leak within the system. By doing so, magmeters can alert operators to even small leaks that might go unnoticed with less sensitive devices. Moreover, when combined with a relatively simple mass balance system, the magmeters can also provide information about the location, extent, and severity of the leak, allowing for prompt action to be taken when needed and avoiding false alarms that waste resources.

Online Diagnostics

The online diagnostics perform health checks on the meter, detecting issues such as electrode fouling, liner deformation, and ensuring accuracy within factory specifications. This proactiveness empowers operators to address issues before they escalate, avoiding costly downtime and enhancing overall system reliability. Mechanical meters offer no such visibility: if the reading appears inaccurate, the entire meter must be removed from the line for maintenance.

Magmeters not only provide continuous monitoring of the meter’s performance, but also continuously track variations in the qualities of the water passing through, including the water’s conductivity. 

Data Collection and Analytics

Mechanical meters typically only provide a flow rate reading, but electronic magmeters can record and store a wealth of data over time. This information can be used for detailed analysis, optimizing system performance, and improving resource management through trends and patterns identification. The integration of magmeters with industrial Internet of Things (IoT) platforms can also facilitate remote monitoring and advanced data analytics for strategic decision-making.

SELECTING A MAGMETER

When measuring produced water, it’s important to consider that magmeters are not the only type of meter required. While magmeters are well-suited for water lines, Coriolis meters are more ideal for oil lines, and Ultrasonic or Coriolis meters are commonly used for gas lines. To ensure efficiency and avoid redundancy, incompatibility, and training hassles, it is wise to take an integrated approach by leveraging the same electronics to manage all meters in your portfolio. With instrumentation and metering systems from a single vendor, operators can rely on seamless integration of all components.

Similarly, it is advisable to select a vendor who offers a full range of magmeters that can meet all your specific requirements. For instance, it is important to have a vendor whose product range includes high-pressure magmeters specifically designed for injection wells. By considering these factors, you can optimize the performance and effectiveness of your metering systems.

LOOKING FORWARD

In conclusion, the oil and gas industry is turning to magmeters as a vital solution to tackle the increasing challenges of managing produced water. With the surge in volume and mounting constraints on its use and disposal, accurate and reliable measurement of produced water flow is of utmost importance. 

This has led to a transition from conventional mechanical meters to intelligent electromagnetic flowmeters, empowering more efficient and effective management of produced water throughout its lifecycle. By embracing these advancements, the industry can navigate the financial and environmental pressures while ensuring sustainable practices in water management. 


Ron Garcia is strategic business director for Krohne, a world-leading manufacturer and supplier of solutions in industrial process instrumentation. Krohne offers supporting products and services for one-stop-shopping and in industries as widespread as oil and gas, water and wastewater, chemical and petrochemical, food and beverage, power, minerals, and mining and marine. For more information, visit www.krohne.com