This paper investigates the optimal control solution using MPC for a typical offshore topside de-oiling process. By considering the combination of the upstream three-phase gravity separator and the downstream de-oiling hydrocyclone set-up as one integrated plant, the plant-wide control problem is formulated and handled using MPC technology. The de-oiling dynamics of the hydrocyclone are estimated via system identification while the key dynamics of the considered gravity separator are modeled based on mass balance and experimental parameter estimation. The developed MPC solution is simulated and experimentally validated via a lab-scaled pilot plant. The comparison of performances of the MPC controlled system with those of a PID controlled system, which emulates the commonly deployed control solution in most current installations, shows the promising results in optimally balancing the gravity separator's (level) control and hydrocyclone's (PDR) control.
There has been a continued increase in the load on the current offshore oil and gas de-oiling systems that generally consist of three-phase gravity separators and de-oiling hydrocyclones. Current feedback control of the de-oiling systems is not done based on de-oiling efficiency, mainly due to lack of real-time monitoring of oil-in-water concentration, and instead relies on an indirect method using pressure drop ratio control. This study utilizes a direct method where a real-time fluorescence-based instrument was used to measure the transient efficiency of a hydrocyclone combined with an upstream gravity separator. Two control strategies, a conventional PID control structure and an H ∞ robust control structure, both using conventional feedback signals were implemented, and their efficiency was tested during severely fluctuating flow rates. The results show that the direct method can measure the system's efficiency in real time. It was found that the efficiency of the system can be misleading, as fluctuations in the feed flow affect the inlet concentration more than the outlet oil concentration, which can lead to a discharge of large oil quantities into the ocean.
An increasing water to oil ration in the North Sea oil and gas production motivates for an optimization of the current deoiling facilities. Current facilities are operated on matured methodologies, which in most cases fulfill the government regulations. However, it has also observed that these solutions could be further improved. In order to more precisely monitor the deoiling operations, this study investigated the real-time monitoring of the deoiling efficiency of the hydrocyclone facilities which are commonly used in offshore oil and gas production. Fluorescence based monitors were applied to measure hydrocyclone inlet's and underflow's Oil-in-Water (OiW) concentrations in real-time. Image-based microscopy was used to analyze the oil droplet size distribution at inlet and underflow to investigate the droplets' influence on hydrocyclone's efficiency. Performance experiments were carried out to identify how pressure difference ratio (PDR) and the droplet's sizes affect the deoiling efficiency. The performance of the deoiling hydrocyclone was significantly influenced by the inlet flow rate, while less or marginally dependent on the PDR. The droplet size distribution experiment proved that large droplets have a high probability to be separated by the hydrocyclone. The findings suggest that the coupled separator tank and hydrocyclone system can be further improved upon by deploying coordinated control as the two systems are strongly interdependent.
Offshore de-oiling installations are facing an increasing challenge with regards to removing oil residuals from produced water prior to discharge into the ocean. The de-oiling of produced water is initially achieved in the primary separation processes using gravity-based multi-phase separators, which can effectively handle large amounts of oil-well fluids but may struggle with the efficient separation of small dispersed oil particles. Thereby hydrocyclone systems are commonly employed in the downstream Produced Water Treatment (PWT) process for further reducing the oil concentration in the produced water before it can be discharged into the ocean. The popularity of hydrocyclone technology in the offshore oil and gas industry is mainly due to its rugged design and low maintenance requirements. However, to operate and control this type of system in an efficient way is far less simple, and alternatively this task imposes a number of key control challenges. Specifically, there is much research to be performed in the direction of dynamic modeling and control of de-oiling hydrocyclone systems. The current solutions rely heavily on empirical trial-and-error approaches. This paper gives a brief review of current hydrocyclone control solutions and the remaining challenges and includes some of our recent work in this topic and ends with a motivation for future work.
This article is a feasibility study on using fluorescence-based oil-in-water (OiW) monitors for on-line dynamic efficiency measurement of a deoiling hydrocyclone. Dynamic measurements are crucial in the design and validation of dynamic models of the hydrocyclones, and to our knowledge, no dynamic OiW analysis of hydrocyclones has been carried out. Previous studies have extensively studied the steady state efficiency perspective of hydrocyclones, and have related them to different key parameters, such as the pressure drop ratio (PDR), inlet flow rate, and the flow spill. Through our study, we were able to measure the dynamics of the hydrocyclone's efficiency (ϵ) response to step changes in the inlet flow rate with high accuracy. This is a breakthrough in the modelling, control, and monitoring of hydrocyclones.
The goal of this paper is to introduce and design a cost-effective Oil-in-Water (OiW) measuring instrument, which will be investigated for its value in increasing the efficiency of a deoiling hydrocyclone. The technique investigated is based on Electrical Resistivity Tomography (ERT), whose basic principle is to measure the resistivity of substances from multiple electrodes and from these measurements create a 2-D image of the oil and gas component in the water. This technique requires the measured components to have different electrical resistances, such as seawater which has a lower electrical resistance than hydrocarbon oil and gas. This work involves construction of a pilot plant, for testing the feasibility of ERT for OiW measurements, and further exploring if this measured signal can be applied as a reliable feedback signal in optimization of the hydrocyclone's efficiency. Different algorithms for creating 2-D images and the feasibility of estimating OiW concentrations are studied and evaluated. From both steady state and continuous laminate flow perspectives, with respect to the objective which is to use this measurement for feedback control purposes.