The present invention relates generally to oil recovery using steam and, more particularly to the noninvasive, real-time measurement of steam quality and flow.
Heavy oil represents a substantial fraction of world petroleum reserves. Conventional production practices cannot recover a large percentage of this oil partly because high viscosity at reservoir conditions inhibits flow to production wells. Therefore, ultimate recovery by conventional production is frequently below 10%. Steam injection is the most widely utilized method for stimulating the production of heavy oil, currently accounting for approximately 80%. A benefit of using steam as a heat transfer medium is the large quantity of heat released when it condenses into water. With a latent heat of vaporization (or condensation) as high as 1,000 BTU per pound, very little steam carries a large quantity of energy. Other advantages include the safe, nontoxic and nonflammable characteristics of steam, in addition to its ability to deliver heat at a constant, controlled temperature.
Steam-flooding involves injection of two-phase steam having sufficient quality at effective rates into a reservoir. However, the cost for generating steam is high, accounting for about one-half of all steam-flooding operating costs. Because of the high steam cost and the difficulty in obtaining generator permits, optimization of the use of injected steam is necessary. However, the quality or steam delivered to the reservoir is largely unknown, which makes steam quality measurements important for both oil extraction and reservoir management. Such determinations are also important in other industries where steam is used.
Water can exist as either a gas or a liquid under saturated conditions. Wet steam can contain both gas and liquid components, known to those of ordinary skill in the art as two-phase flow. A common method of expressing the quantities of each phase, known as steam quality, is the ratio of the mass flow rate of the gas phase to the total mass flow rate, and is given as a number less than one, or as a percentage. Steam quality measurements, which are determinative of the efficiency of the steam delivery system in surface distribution lines, have been made using various methods. One technique is based on pressure drop measurements as the steam passes through an area constriction, and requires the accurate measurement of pressures with pressure measurement devices within the pipeline. Another method bleeds steam to the outside of a pipe through an orifice, for generating acoustic energy, which is detected. The amplitude of the detected signal is related to steam quality. However, this method produces unnecessary noise and releases steam into the environment. Capacitance measurements for determining steam quality, where the measurement apparatus is inserted into a steam carrying pipe, also requires an additional temperature or pressure measurement device. Measurements of differential pressure fluctuations on both sides of a metal plate containing an orifice inserted into a steam carrying pipe to determine steam quality also require pressure measurement devices connected through holes in the pipe.
Optical on-line measurement systems have been used as well for determining steam quality. Multiple wavelengths of radiant energy are passed through the steam from an emitter to a detector through optical windows in a pipe. By comparing the amount of radiant energy absorbed by the flow of steam for each wavelength, an accurate measurement of the steam quality can be determined on a continuous basis in real-time.
Since these approaches require either penetration of the steam-carrying pipes or insertion of devices into the pipe, none provides a simple and noninvasive method for monitoring steam quality that can be installed at one location and then readily moved to another location without significant plumbing changes, often rendering these methods unsuitable for field use. Additionally, steam conduits are operated in excess of 400° F., and measurement devices must withstand high temperatures.
Approximate measurements of steam flow rate or steam quality parameters, are often sufficient for field steam injection operations, and the ability to make noninvasive measurements at multiple locations using inexpensive, easily maintained and easily automated devices is of value.
Embodiments of the present invention overcome the disadvantages and limitations of the prior art by providing an apparatus and method for monitoring steam quality in real time.
Another object of embodiments of the present invention is to provide an apparatus and method for noninvasively monitoring steam quality in real time.
Yet another object of embodiments of the invention is to provide an apparatus and method for noninvasively monitoring steam quality at a chosen location along a steam pipe, and at other chosen locations along the pipe.
Still another object of embodiments of the present invention is to provide an apparatus and method for noninvasively monitoring steam flow in real time.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, the method for monitoring steam quality at a chosen location in a pipe in which steam is flowing, hereof, includes the steps of: detecting sound generated in the pipe by the steam flowing through the pipe at the chosen location; determining at least one acoustic frequency from the natural resonance vibration frequency spectrum of the pipe; and monitoring a peak amplitude at the at least one acoustic vibration frequency; whereby changes in the steam quality are obtained from changes in the peak amplitude at the at least one acoustic vibration frequency.
In another aspect of the present invention and in accordance with its objects and purposes, the apparatus for monitoring steam quality at a chosen location in a pipe in which steam is flowing, hereof, includes: a piezoelectric transducer for detecting sound generated in the pipe by the steam flowing through the pipe at the chosen location; a signal processor for receiving the signal from the piezoelectric transducer and determining at least one acoustic frequency from the natural resonance vibration frequency spectrum of the pipe; and a microprocessor for monitoring a peak amplitude at the at least one acoustic vibration frequency from the signal processor; whereby changes in the steam quality are obtained from changes in the peak amplitude at the at least one acoustic vibration frequency.
In still another aspect of the present invention and in accordance with its objects and purposes, the apparatus for monitoring steam quality at a chosen location in a pipe in which steam is flowing, hereof, includes: a detector spaced-apart from the pipe for detecting sound generated in the pipe by the steam flowing through the pipe at the chosen location; a signal processor for receiving the signal from the detector and determining at least one acoustic frequency from the natural resonance vibration frequency spectrum of the pipe; and a microprocessor for monitoring a peak amplitude at the at least one acoustic vibration frequency from the signal processor; whereby changes in the steam quality are obtained from changes in the peak amplitude at the at least one acoustic vibration frequency.
In another aspect of the present invention and in accordance with its objects and purposes, the method for monitoring steam quality at a chosen location in a pipe in which steam is flowing, hereof, includes the steps of: detecting sound generated in the pipe by the steam flowing through the pipe at the chosen location; determining at least one acoustic frequency from the natural resonance vibration frequency spectrum of the pipe; and monitoring the frequency of a peak at the at least one acoustic vibration frequency; whereby changes in the steam quality are obtained from changes in the frequency of the peak at the at least one acoustic vibration frequency.
In another aspect of the present invention and in accordance with its objects and purposes, the apparatus for monitoring steam quality at a chosen location in a pipe in which steam is flowing, hereof, includes: a piezoelectric transducer for detecting sound generated in the pipe by the steam flowing through the pipe at the chosen location; a signal processor for receiving the signal from the piezoelectric transducer and determining at least one acoustic frequency from the natural resonance vibration frequency spectrum of the pipe; and a microprocessor for monitoring the frequency of a peak at the at least one acoustic vibration frequency from the signal processor; whereby changes in the steam quality are obtained from changes in the frequency of the peak at the at least one acoustic vibration frequency.
In yet another aspect of the present invention and in accordance with its objects and purposes, the apparatus for monitoring steam quality at a chosen location in a pipe in which steam is flowing, hereof, includes: a detector spaced-apart from said pipe for detecting sound generated in the pipe by the steam flowing through the pipe at the chosen location; a signal processor for receiving the signal from the detector and determining at least one acoustic frequency from the natural resonance vibration frequency spectrum of the pipe; and a microprocessor for monitoring the frequency of a peak at the at least one acoustic vibration frequency from the signal processor; whereby changes in the steam quality are obtained from changes in the frequency of the peak at the at least one acoustic vibration frequency.
Benefits and advantages of embodiments of the present invention include, but are not limited to, providing an apparatus and method for noninvasively monitoring steam quality and flow rate of steam flowing in a pipe from acoustic measurements made in direct contact with the pipe or remotely thereto. At certain frequencies, such acoustic measurements may be made through pipe insulation.
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
When steam and, in particular wet steam, flows through a pipe, flow-induced vibrations are generated in the pipe at frequencies which range between the low audible to above normal hearing. As the steam quality changes, the generated frequency spectrum in the pipe varies with it. Embodiments of the present invention include an apparatus and method for noninvasively monitoring steam quality and flow in pipes and conduits bearing flowing steam. Measuring acoustic vibrations generated in steam-carrying conduits by the flowing steam either by direct contact with the pipe or remotely thereto, converting the measured acoustic vibrations into a frequency spectrum characteristic of the natural resonance vibrations of the pipe, and monitoring the amplitude and/or the resonance frequency of one or more chosen resonance peaks, permits changes in the flow rate of the steam in the pipe to be determined.
The steam quality and the steam flow rate are inversely related, as will be discussed in more detail hereinbelow, and as is set forth in Equation (9) of U.S. Pat. No. 5,421,209, which issued to Redus et al. on Jun. 6, 1995. Therefore, if either the steam quality or the steam flow rate is measured or otherwise known, the other is also known.
Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. In the FIGURES, similar structure will be identified using identical reference characters. It will be understood that the FIGURES are for the purpose of describing particular embodiments of the invention and are not intended to limit the invention thereto. Turning now to
Other suitable commercially available stand-off vibration detectors include fiber optic systems, laser Doppler vibrometers, and capacitance and electromagnetic sensors.
Direct contact vibration detection measurements were used to verify the stand-off detector measurements. Since the surface of pipe 12 is hot (>400° F.), disc-shaped, lithium niobate piezoelectric crystal (1 MHz center frequency, 5 mm diameter), 20, was coupled directly to pipe surface, 22, as a vibration detector. Lithium niobate has a long lifetime at such temperatures, while bismuth titanate piezoelectric ceramics may be used for direct-contact measurements at operating temperatures up to 800° F. As an alternative, piezoelectric transducer (lead zirconate-lead titanate) disc (500 kHz center frequency), 24, having cylindrical quartz buffer rod (5 mm diameter and 1 cm long), 26, was inserted between transducer 24 and pipe surface 22. Quartz has a low thermal conductivity and thus provides good temperature insulation for protecting the piezoelectric crystals. However, even with the use of buffer rod 26, the piezoelectric vibration detector is not suitable for long-term usage at temperatures above 400° F. because of deterioration of piezoelectric properties. A circulating fluid heat sink (not shown in
As stated, it may not be necessary to make measurements where thermal insulation on the steam-carrying pipe is removed in order to provide access to the vibration measurement sensors, since frequencies less than 10 kHz transmit well through such insulation without much attenuation.
Direct contact vibration measurements are especially useful when there are too many pipes carrying steam, the valves or pipe sections are very close to each other, thereby preventing installation of stand-off measurement devices, or vibration measurements from a particular region of interest. Since there is no requirement for coupling gels or epoxies, transducers can be easily removed and moved to another location.
Signals from either the microphone or the contact measurement transducers are first amplified using amplifiers, 28, 30, and 32, respectively, and then directed to multi-channel, 12-bit, 100 kHz bandwidth A/D converter, 34. If measurements from multiple locations are required, the present system can easily be expanded to 32 or more separate channels. Microprocessor, 36, having an integral or separate DSP (digital signal processor), analyzes the signal from each channel and provides an output, such as USB or Ethernet, 38. The DSP system is sufficiently fast to process the signal from a phased-array microphone system. A FFT (Fast Fourier Transform) of the digitized vibration data is performed by the DSP in less than 100 μs, and determines the vibration frequency spectrum. These vibration frequencies are related to the various natural resonance frequencies of pipe (conduit) 12 that are excited by the flow of steam through the pipe. The steam interacts with the pipe surface as it flows, transferring molecular energy possessed by steam to the pipe surface which in turn excites and amplifies the natural frequencies of the pipe that are detected in accordance with embodiments of the present invention. At high flow rates, the turbulent nature of the flow also enhances this energy coupling to the pipe due to vortex shedding, and other coupling phenomena. The mechanisms giving rise to such flow-induced vibrations have been extensively studied and are well understood. The amplitudes and also the resonance peak frequencies of various resonance frequencies are therefore related to the steam flow rate and to the steam quality. The amplitude of the peak may be a better indicator since it is more easily measured. The output can be in a variety of forms such as graphs, numbers displayed on an LCD screen, an alarm signal when identified ranges of steam quality are exceeded, or input to an appropriate feedback control, whereby a choke valve may be adjusted to control steam flow.
A spectrum analyzer may be employed for directly providing a frequency spectrum that can be used to track resonance peaks and their amplitudes on a microprocessor.
The foregoing description of the invention has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
The present application claims the benefit of U.S. Provisional Patent Application No. 61/449,791 for “Method And Apparatus For Acoustic Steam Quality Monitoring” which was filed on Mar. 7, 2011, the entire contents of which is hereby specifically incorporated by reference herein for all that it discloses and teaches.
This invention was made with government support under Contract No. DE-AC52-06NA25396 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
Number | Date | Country | |
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61449791 | Mar 2011 | US |