Low Cost and Pipe Conformable Microwave-Based Water-Cut Sensor

Efficient oil production and refining processes require the precise measurement of water content in oil. This paper presents a novel planar microwave sensor for entirely non-intrusive in situ water cut (WC) sensing over the full range of operation, i.e., 0%-100%. A planar configuration has enabled the direct implementation of WC sensor on the pipe surface using low cost method, i.e., screen printing using 3D printed mask. Modified ground plane-based T-resonator design makes this WC sensor usable for the wide range of pipe sizes present in the oil industry. The viability of this sensor has been confirmed through electromagnetic simulations as well as through a prototype characterization. Two cases of oil and water mixtures, namely, separate phases and homogeneous mix, have been studied. Measurements performed over two independently built prototypes show the root mean square variation in results of only 0.1%.