From the process control point of view, any reliable and online Oil-in-Water (OiW) measurement could provoke a brand new control paradigm for produced water treatment. However, the real-time OiW monitoring is still an open and ad-hoc situation in recent decades. The fundamental issue, ie, the OiW measurement is methodology dependent, leads to numerous challenges, such as (i) how to verify the reliability and accuracy of a specific methodology/instrument; (ii) how to handle and interpret the measured data in a most objective manner; and (iii) how to keep a cost-effective on-site calibration and maintenance under the harsh offshore conditions etc. The paper reports our latest achievements and observations in usage of fluorescence- and microscopybased OiW monitoring technologies for advanced Produced Water Treatment (PWT) control and evaluation, particularly by focusing on the de-oiling hydrocyclone installations.
Multi-phase flow meters are of huge importance to the offshore oil and gas industry. Unreliable measurements can lead to many disadvantages and even wrong decision-making. It is especially important for mature reservoirs as the gas volume fraction and water cut is increasing during the lifetime of a well. Hence, it is essential to accurately monitor the multi-phase flow of oil, water and gas inside the transportation pipelines. The objective of this review paper is to present the current trends and technologies within multi-phase flow measurements and to introduce the most promising methods based on parameters such as accuracy, footprint, safety, maintenance and calibration. Typical meters, such as tomography, gamma densitometry and virtual flow meters are described and compared based on their performance with respect to multi-phase flow measurements. Both experimental prototypes and commercial solutions are presented and evaluated. For a non-intrusive, non-invasive and inexpensive meter solution, this review paper predicts a progress for virtual flow meters in the near future. The application of multi-phase flows meters are expected to further expand in the future as fields are maturing, thus, efficient utilization of existing fields are in focus, to decide if a field is still financially profitable.
This paper presents the design and development of a conceptual prototype of an autonomous self-driven inline inspection robot, called Smart-Spider. The primary objective is to use this type of robot for offshore oil and gas pipeline inspection, especially for those pipelines where the conventional intelligent pigging systems could not or be difficult to be deployed. The Smart-Spider, which is real-time controlled by its own on-board MCU core and power supplied by a hugged-up battery, is expected to execute pipeline inspection in an autonomous manner. A flexible mechanism structure is applied to realize the spider's flexibility to adapt to different diameters of pipelines as well as to handle some irregular situations, such as to pass through an obstructed areas or to maneuver at a corner or junction. This adaptation is automatically controlled by the MCU controller based on pressure sensors' feedback. The equipped devices, such as the selected motors and battery package, as well as the human-and-machine interface are also discussed in detail. Some preliminary laboratory testing results illustrated the feasibility and cost-effectiveness of this design and development in a very promising manner.
The offshore de-oiling process is a vital part of current oil recovery, as it separates the profitable oil from water and ensures that the discharged water contains as little of the polluting oil as possible. With the passage of time, there is an increase in the water fraction in reservoirs that adds to the strain put on these facilities, and thus larger quantities of oil are being discharged into the oceans, which has in many studies been linked to negative effects on marine life. In many cases, such installations are controlled using non-cooperative single objective controllers which are inefficient in handling fluctuating inflows or complicated operating conditions. This work introduces a model-based robust H ∞ control solution that handles the entire de-oiling system and improves the system’s robustness towards fluctuating flow thereby improving the oil recovery and reducing the environmental impacts of the discharge. The robust H ∞ control solution was compared to a benchmark Proportional-Integral-Derivative (PID) control solution and evaluated through simulation and experiments performed on a pilot plant. This study found that the robust H ∞ control solution greatly improved the performance of the de-oiling process.
The upstream offshore multi-phase well-pipeline-riser installations are facing huge challenges related to slugging flow: An unstable flow regime where the flow rates, pressures and temperatures oscillate in the multi-phase pipelines. One typical severe slug is induced by vertical wells or risers causing the pressure to build up and hence originates the oscillating pressure and flow. There exist many negative consequences related to the severe slugging flow and thus lots of investments and effort have been put into reducing or completely eliminating the severe slug. This paper reviews in detail the state-of-the-art related to analysis, detection, dynamical modeling and elimination of the slug within the offshore oil & gas Exploration and Production (E&P) processes. Modeling of slugging flow has been used to investigate the slug characteristics and for design of anti-slug control as well, however most models require specific facility and operating data which, unfortunately, often is not available from most offshore installations. Anti-slug control has been investigated for several decades in the oil & gas industry, but many of these existing methods suffer the consequent risk of simultaneously reducing the oil & gas production. This paper concludes that slug is a well defined phenomenon, but even though it has been investigated for several decades the current anti-slug control methods still have problems related to robustness. It is predicted that slug-induced challenges will be even more severe as a consequence of the longer vertical risers caused by deep-water E&P in the future.
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.
The current offshore oil & gas multi-phase production and transportation installations have big challenges related to the slugging flow: An unstable multi-phase flow regime where the flow rates, pressures and temperatures oscillate in the considered processes. Slug can be caused by different operating conditions and installation structures. The most severe slugs are often induced in long vertical risers or production wells, where liquid blocks gas at the riser/well base and correspondingly it causes the pressure to accumulate and hence originates the oscillating performance. There are many severe consequences to the production processes because of the slugging flow. This paper reviews some observed latest status and key challenges about slug detection, dynamical modeling and elimination of slugging flows. Mathematical modeling of slug has been used to investigate the slug mechanism and anti-slug control. Most of available models are based on mass-balance formulations, which often require sufficient data for reliable parameter tuning/identification. Slug elimination and control have been investigated for many years and there exist many solutions to eliminate the slug, but some of these methods can simultaneously reduce the oil & gas production, which is a very big concern as the production rate is the key evaluation parameter for offshore production. We conclude that the slugging flow is a well-defined phenomenon, even though this subject has been extensively investigated in the past decades, the cost-effective and optimal slug modeling and control are still open topics with many related challenges.