Abstract
Abstract This research presents a thorough description of a novel method for mitigating the consequences of incoming slug flow using dynamic simulation software. Additionally, it paves the way for future improvements in the model's deployment for real-time level controller tuning parameter adjustment. In the facilities that receive multiphase wet crude from numerous distant manifolds with a number of trunk lines of expansive terrain, slug flows are quite typical. Operational challenges are brought on by the slug flow. Slug flows alter high-pressure production trap (HPPT) levels and separation efficiency, which will negatively affect the quality of the produced water and the crude oil, making handling slug flows in gas-oil separation plant (GOSP) facilities particularly difficult. The objective of this study was to employ the dynamic simulation model to investigate the behavior of incoming slug flow to the inlet 3-Phase Separators and its ramifications on downstream equipment. The findings of the dynamic simulation are to be utilized to reduce the flow variability in downstream equipment by developing an appropriate level control scheme. This measure is aimed at enhancing the separation efficiency and conserving energy by minimizing the recycling operation of injection pumps. By utilizing HYSYS dynamic simulation model results, a novel control strategy was devised, involving the modification of the split range controller into two independent controllers. The larger valve controller was tuned for a slower response, whereas the smaller valve controller was set to be more aggressive. These adjustments improved level management and reduced the flow variations to Water Oil Separation (WOSEP) and downstream equipment. The newly developed control scheme was implemented in one of the HPPT’s and was further fine-tuned to minimize the level variations. The HPPT levels were able to be controlled automatically, as compared to the past practice of manual mode of operation. Additionally, the dynamic simulation results were employed to modify HPPT level settings to accommodate higher slug volumes, with the slug volume handling capacity increasing almost three-fold. The produced water quality from the WOSEP was enhanced, and the recycling operation of produced water pumps was reduced, resulting in energy conservation. The new logic reduced the flow variability and controllers could be operated in Auto mode. This resulted in the pumps operating at their BEP and improving energy efficiency.
Published Version
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