Rheotherm Application Focus: Offshore Oil Platforms

When it comes to offshore oil production in the Gulf of Mexico, “extreme” is the standard operating environment. The isolated environment demands extreme reliability and the work requires very high levels of safety. In 2011, our team was tasked with a unique engineering challenge: developing a chemical feed measurement system that could handle incredibly low flow rates under immense pressure, all while meeting rigorous hazardous area safety standards.

Here is how we engineered a custom solution for one of the most demanding environments on Earth.

The Challenge: Precision at the Extreme

A leading pump manufacturer approached us with a specific need for a chemical feed system. Designed to inject chemical additives to the deep well environment, the requirements were precise and unforgiving:

• Ultra-Low Flow Rates: Measuring chemical additives at rates as low as 0.11 gallons per hour (GPH).
• High-Pressure Durability: The system had to maintain integrity and accuracy under the high-pressure conditions, 10,000 psi operating, typical of offshore platforms.
• Fluid Versatility: The sensors required calibration

  

  for multiple distinct fluids. (e.g. Corrosion, Scale and Vapor inhibitors)

• Hazardous Area Compliance: The entire solution needed to be rated for Class I, Div. I environments, ensuring safety in the presence of flammable gases or vapors.

The Engineering Solution: Material Strength & Safety

To meet these requirements, our engineers took our proven Rheotherm technology and evolved it for the deepwater sector.

1. Advanced Metallurgy with Super Duplex 2507

   

Rheotherm inline transducers make their measurements from outside the tube wall. This requires a relatively thin wall to sense through. However, 10,000 psi operating pressures demand a thick and robust tube to meet safety regulations. To meet these conflicting requirements, standard materials weren’t enough. We selected a special alloy, Super Duplex 2507, for all wetted parts. Known for its exceptional yield strength and incredible resistance to chloride stress corrosion cracking, this material ensured the sensor could withstand the harsh chemicals and high pressures of the Gulf.

2. Intrinsically Safe Design

Safety is paramount in offshore operations. By integrating our Rheotherm’s custom designed intrinsically safe barrier, we ensured the sensor was approved for hazardous areas. This limited the electrical and thermal energy to levels below what would be required to ignite a hazardous atmospheric mixture.

3. Streamlined Electronics Integration

The client required multiple flow sensors for their system. To maximize space and maintain safety, we engineered a custom configuration:

• Remote Electronics: We housed up to four sets of remote electronics within a single NEMA 7 enclosure.
• Explosion-Proof Protection: This enclosure is specifically designed to contain an internal explosion without igniting the surrounding atmosphere, making the electronics fully compliant for hazardous duty.

Proven Reliability in the Field

The result was a robust, custom-designed inline Rheotherm flow metering system that proved we could scale our low-flow expertise into the most challenging industrial sectors. By combining specialized metallurgy with innovative safety packaging, we provided the pump manufacturer with the accuracy they needed and the peace of mind the offshore industry demands. This system has been successfully operating for 15 years, and new iterations have been installed by other companies operating deepwater wells.

Need a custom flow solution for a hazardous environment?  Our engineering team specializes in solving complex measurement challenges. Contact us today to discuss your project requirements.