Post on 23-Feb-2016
description
DAS-UFSC R&D Efforts for the oil industry
Brazil-Norway R&D workshop
Agustinho PlucenioLaboratory for Smart Fields Automation
Department of Automation and Systems EngineeringFederal University of Santa Catarina
Rio de Janeiro, May 26, 2011
Topics Who we are PRH-ANP Program –
PRH34 Research Projects LACI INPetro Ongoing R&D Project NTNU Cooperation
DAS-UFSC R&D Efforts for the oil industry
Who we are
Who we are
The Federal University ofSanta Catarina
• Located in Florianopolis(pop. 600,000)• 25,000 undergraduates• 3,500 graduates• ≃ 2,000 faculty members
Who we are
Department of Automation and Systems Engineeringhttp://www.das.ufsc.br/das/index.php
24 faculty members 360 undergraduates (1st of its kind in Brazil) 40 M.Eng. students 50 Ph.D. students
Research areas at DAS-UFSC
Control theory and applications
Linear and nonlinear control Discrete event systems Predictive control Robotics
Industrial informatics Real-time embedded systems Industrial networks
General computing Fault tolerance Secure network systems Algorithms
Optimization
Oil &Gas R&D EvolutionProgram PRH-ANP34
2001
2006
20092010
1 R&D Project with Petrobras-CENPES
Construction Distilation column
Multiphase Flow Lab Construction (CNPQ)
2004
2 R&D Project with Petrobras-CENPES3 R&D Project
with Petrobras-CENPES
LACI Project with Petrobras-CENPES
2008
NW Control Lab(CNPQ)
The Program PRH34Program financed by the National Agency of Petroleum, Gas and Bio fuels for Human Resources Development
with the themeAutomation and Control for the Oil and Gas Industry.
PRH-34 is formed by members of the Department of Automation and Systems, Chemical and Mechanical Engineering.
Main objective:To complement the education of engineers at the under-graduate and graduate levels in the area of automation, control and instrumentation to work in the petroleum industry.
Chem. Eng.
C&A Eng.
Mech. Eng.
Ex PRH34 students
Some of PRH34 researches Automation and Control of wells with elevation by gas-lift, Optimization of gas-lift operations, Drilling bit wear prediction using neural networks,Oscillation control using switched systems applied to severe slug control, Variable Structure Control for the suppression of oscillations in oil well drilling systems, ARMAX and NARMAX model identification of oil wells operating by gas-lift, Model Predictive Control for nonlinear systems, Low cost water fraction meter based on micro-wave, Multiphase flow meter based on online partial separators, Development of New Drilling control techniques based on the theory ofnon-smooth dynamical systems, Nonlinear Model Predictive Control applied to a water injection developmentproject, Gas-lift optimization with constraints on transportation and handlingfacilities of produced fluids,
Research projects Development of control algorithms for artificial lift
methods (Petrobras-CENPES) (2006-2009) Multiphase Flow meter for heavy oil phase 1 (CNPQ-CTPetro) (2008-2010) LACI – Laboratory for the Automation of Intelligent
oilfields (Petrobras-CENPES) (2008-2011) Advanced control systems and production real
time optimization (Petrobras-CENPES) (2010-2013) Intelligent agents for distributed control of
complex system (Petrobras-CENPES) (2009-2010)
Development of Control Algorithms for artificial lift methods-Petrobras CENPES-(2006-2009)
One feature of the project is the utilization of Programmable Logic Computers connected with the well simulators and running the control algorithms (HIL concept).
Objective: To develop solutions for the automation of oil wells that optimize production using online surface and down hole measurements.
Some developments:For continuous gas lift:
Use of different WPC models pwf steady state detection via MPA Automatic procedure via MPA for model parameter update Automatic procedure for gas re-allocation due to:• gas flow rate availability• well model changes• well put in forced operation• separation capacity constraints
Introduction of control and optimization algorithms in LAPLACE and MPA Automatic procedures to re-start gas lift wells Study of a a solution based on NMPC
WPC - Well Production Curve
** ,wf
wf
g
g
pp
yqq
u
2431
2 ueymu
*~wfwf ypp
Pwf steady state detection
Optimization algorithms
Control strategies and algorithms
GLoptimMain Laplace screen
Screen for variables configuration
Automatic GL Well restarting
During the project 3 approaches were studied for automatically re-starting gas lift wells with:
Classical control algorithms Switching Control Fuzzy Logic
GL Control with NMPCControl of gas lift wells with NMPC optimize gas allocation stabilize GLM pressure minimizes wellhead flow rate oscillations during gas lift flow rate changesGLM Setup
GL Hammerstein dynamic model
Sucker rod pump with down hole pressure measurements
Sucker rod pump well
Developments: Development of a dynamic simulator Development of control strategies using down hole pressure measurements Fault detection techniques using down hole measurements
Controller strategyConventional fluid pound level detection used to update Down hole pressure set-point
Fault detection
Fault patterns
a) Normal operationb) Leak in the standing valvec )Leak on the traveling valved) Fluid pound
PCA approach
Multiphase Flow Laboratory LEEM (CTPetro-CNPQ) (2008-2010)
Main objective: To initiate research onlow cost measurement techniques formultiphase flow for heavy oil.
LEEMOther objectives:
installation of a multiphase flow laboratory for teaching purpose, to study sensors for water in oil content, flow-rate measurements of gas flow, gas-liquid flow, to test techniques for the control of severe slug flow, to study new separationtechniques.
Water cut meter using MW cavity ressonator
Prototype being developed in the LEEM
Inline liquid-gas separator
Low volume 3 Phase partial separation multiphase flowmeter
Gas
Oil-water
Control system
In line gas-liquid separator
Water cut meterLiquid flow-rate measurement
Gas flow-rate measurement
Second stage separator
Gas treatment (scrubber-compression, etc.)
Output values of oil, water and gas flow-rates
Level measurement
LACI-Laboratory for intelligent oilfield automation-Petrobras CENPES – (2008-2011)
Motivation:What is needed to develop and test reliable, catastrophic failure proof automation systems to control remote offshore production facilities like unmanned platforms?Is simulation enough?To build a laboratory to test automation and control of production facilities including oil wells is similar to what was done in the airplane industry with the construction of Wind Tunnels.
LACI objectivesThe facility should be designed for testing optimization algorithms, fault detection and control algorithms conceived to a remote operation scenario.It should allow: To test new down hole instruments To test fault detection (real induced fault) To test new control and automation surface instruments To test constraint handling like gas injection flow rate, leaks, etc.
)( wfs
ws
PPPIqghP
LACI Well design
)( wfs
ws
PPPIqghP
wfsg
ws
PPHkAq
ghP
Formation static pressure controlled
Fluid level controlled to simulate different depletion levels
)( . wfest PPLAkq
)( . wfest PPPIq
Gravel pack permeability tests
Gravel with 4 grain sizes were investigated:• Gravel 1: 0,59mm a 1,00mm• Gravel 2: 0,71mm a 1,41mm• Gravel 3: 1,00mm a 2,00mm• Gravel 4: 2,00mm a 3,36mm.
Dynamic behavior of LACI simulated with OLGA™
Simulations with OLGA™ confirm expected dynamic behavior
LACI wells setup
The wellheads are installed inside a pit
INPetro – UFSC Petroleum, Gas and Energy InstituteCreated by Research groups from Mechanical , Automation and Systems and Chemical Engineering with financing of Petrobras.
Main characteristics: 8800 m2 >35 MR$Main building (light Labs)
Heavy Labs
20 Laboratoriesinstrumentation, Computational visionOptical sensorsCorrosion,Combustion.Multiphase flow,Automation,Inteligent sensors,Robotics,Etc.
LACI Pipeline tests,Robotic weldingLaser welding soldagem a laser , Multidisciplinary projectsA pool for development and testing technology for underwater welding with robots.
INPetro – UFSC Petroleum, Gas and Energy Institute
Localization in Florianopolis Island
INPetro in the Sapiens Park – art. view
INPetro – art. view
Inpetro - Construction status May 06,2011
Main building outside view
Main building inside view
Advanced control systems and production real time optimization (Petrobras-CENPES)(2010-2013)
Research Goals:Develop systems for real-time optimization, control andautomation of production units and oil fields.
Areas to develop
Modeling Control strategies Optimization Fault detection
Simplified dynamic models
GL - density wave behavior
GL - heading behavior
Local controllers
Local controller
Without control
With control applied
Local controller-Density wave control
Optimization modeling and algorithms
Research goals
Models for mathematical optimization of equipment and production processes Efficient algorithms for real-time optimal operation Frameworks for system-wide optimization
Optimization modeling and algorithms
Current research topics Piecewise-linear models foroptimal lift-gas allocationand separator alignment Piecewise-linear models ofmultidimensional functionsfor pressure constraints Models for compressor allocation and scheduling
Reservoir recovery enhacement with NMPC
Using simulators SENSOR ™ and ECLIPSE™Our initial strategy is to use the knowledge existent in the simulator to build the dynamic representation of the process variables as function of the manipulated variables.Challenge: Is the solution the global optimum?
UFSC-NTNU cooperation
Prof. Dr. Ricardo Rabelo, Chief of the Automation and Systems Engineering Department-DAS UFSC talks minutes before signing an academic cooperation term with NTNU .
Since 2007 researchers of DAS-UFSC, NTNU and Petrobras-CENPES have had academic meetings in congress and workshops.
COPPE-UFRJ - February 18/2011.
Brazilian Congress of R&D in Oil and Gas Florianópolis, October 9-13, 2011
Takk Thank you Obrigado