Documente Academic
Documente Profesional
Documente Cultură
Abstract: This paper presents a nonlinear predictive controller with a feed-forward action
applied to a three-phase separator used in the petroleum industry. Two tools are used in order
to include the feed-forward action in the NMPC, a disturbance estimator and a disturbance
predictor. Moreover, a supervisory control changes the objective function characteristics of the
NMPC depending on the type of disturbances acting on the process. The separator advanced
controller, which is capable to maintain all process variables in pre-defined zones, uses a practical
nonlinear model predictive controller (PNMPC) developed in the Department of Automation
and Systems (Federal University of Santa Catarina). The performance of the proposed strategy
is compared to a traditional PI Zone controller used in industry and to a different NMPC
based on a Hammerstein model. All the case study simulations are developed with a complete
phenomenological nonlinear model of the separator. The obtained comparative results show that
the proposed strategy gives the best results, allowing good oscillation attenuation under slug
perturbations.
Keywords: Three Phase Separators, Predictive Controllers, Zone control, Process Control
1. INTRODUCTION
Most of the oil wells produce fluid consisting of a mixture
of gas, oil and water, Triggia et al. (2001). In a conventional
system of oil separation there is usually a group of gravity
separators connected in series starting with a three-phase
separator. The three-phase separator is basically designed
to separate the multiphase fluid and also to damp the
load oscillation that comes from well. A proper control
scheme of this process allow to maximize oil production
and to minimize the quantity of residual oil in water,
therefore, improving energy production and minimizing
ambient impact.
Horizontal gravity separators, as the one considered in
this work, are normally used in oil industry at the first
stage of the fluid treatment with two principal objectives:
separation of the different phases and absorbing load fluctuations. According to Nunes (1994) oil wells and risers
may produce with different flow regimes. In certain conditions a regime known as slug flow is established which
is characterized by a flow-rate alternating between high
and low values. This flowing regime is detrimental to the
three phase separation process because of the pressure and
flow variation into the separator. Thus separator control
should be designed to allow good efficiency of separation
and still manage to filter out disturbances caused by slug
flow, sending a more stable flow for downstream processes.
Several control strategies have been used to control this
process. For example, Filgueiras (2005) presents a separation vessel controller that has three SISO PI compensators,
one on each fluid phase. This classical control scheme, although quite common in industry, is not able to adequately
IFAC, 2012. All rights reserved.
101
Win
Sg
Gin
Lin
Win
Zone
SUPERVISORY
PNMPC
Wout_sp
Lout_sp
Gout_sp
PI
sw
sl
sg
Lin
Gin
SEPARATOR
Vwflcs
Lweir
hT
Vlfwcs
Vwflcl
hW
hl
DETECTOR
Sw
Wout h
w
Lout h
l
Gout p
Disturbance
rejection
Win_est
Lin_est
Gin_est
ht
DISTURBANCE
ESTIMATOR
Sl
Lout
N
X
y (t + j|t) y b (t + j|t)
2 +
R
(2)
j=1
Nu
X
ku (t + j 1)kQ
j=1
(4)
(5)
dp
(Gin + Win + Lin Gout Wout Lout ) p
=
. (6)
dt
Vt Vcl Vcs
As can be seen, this model needs the values of the disturbances Gin , Win , Lin that are not measurable. Therefore,
to compute the output predictions, an estimated value of
these variables is needed. Thus, using equations (3), (4),
(5) and (6) it is possible to compute the estimated values
as follows:
i
h
p
cin = Ccs 2 (D hw ) hw dhw + Wout
(7)
W
dt
i
b weir + Ccs 2 (D ht ) ht dht
=L
dt
i dh
h
p
w
Ccs 2 (D hw ) hw
dt
hw
0.6
0.4
0.2
time (seconds)
(9)
7
4
x 10
1
0.8
0.6
0.4
0.2
time (seconds)
7
4
x 10
13
12.5
dp c
Vt Vcs Vcl
b in
Win L
(10)
p
dt
+Wout + Lout + Gout
In the controller implementation, discrete equivalent equations are used, where the derivatives are computed using
Euler approximation.
b in =
G
1
0.8
b in
L
(8)
hl
h
i
p
b weir = Ccl 2 (D hl ) hl dhl + Lout
L
dt
12
11.5
time (seconds)
7
4
x 10
Inside Zone
Kc
Ti
0, 001
125
0, 01
125
0, 03
50
Out of Zone
Kc
Ti
0, 1
50
0, 02
50
0, 03
50
Win e Wout
tests the input and output gas flow rate are the same,
because the control objective was to maintain a constant
pressure inside the separator. On the other hand, for the
oil and water flow rates different results were obtained with
each controller.
0.014
0.0135
0.013
0.0125
Win
Wout
0.012
0.0115
0
time (seconds)
7
4
x 10
Lin e Lout
0.022
0.02
0.018
0.016
Lin
Lout
0.014
0.012
0
time (seconds)
7
4
x 10
Controller
Gin e Gout
0.14
0.13
Flow Rate
Oscillation (%)
Variance
Win
Lin
Gin
Wout
Lout
Gout
Wout
Lout
Gout
Wout
Lout
Gout
20, 45
14, 97
26, 29
6, 06
63, 69
26, 29
3, 03
27, 97
26, 29
3, 03
29, 17
26, 29
2, 3366 108
1, 5443 106
1, 5589 104
3, 0692 109
2, 4813 106
1, 3945 104
1, 7054 108
1, 5958 106
0, 0019
0.12
0.11
Gin
Gout
0.1
0.09
time (seconds)
7
4
x 10
PI Zone
Proposed
hw
0.8
0.6
0.4
0.2
0.8
0.9
1.1
1.2
1.3
time (seconds)
Zone PNMPC
1.4
5
x 10
Hammerstein
hl
0.8
0.6
0.4
0.2
0.8
0.9
1.1
1.2
1.3
time (seconds)
1.4
5
x 10
12.04
12.02
Controller
12
Flow Rate
Variance
Wout
Lout
Gout
Wout
Lout
Gout
6, 6002 108
1, 7689 107
2, 4220 105
2, 1663 108
2, 3255 108
2, 4138 105
11.98
11.96
0.8
0.9
1.1
1.2
1.3
time (seconds)
1.4
5
x 10
PI Zone
Zone PNMPC
0.014
0.0135
0.013
0.0125
0.012
Win
Wout
0.0115
0.8
0.9
1.1
1.2
1.3
time (seconds)
1.4
5
x 10
Lin e Lout
0.022
0.02
0.018
0.016
0.014
0.012
Lin
Lout
0.8
0.9
1.1
1.2
1.3
time (seconds)
1.4
5
x 10
Gin e Gout
0.14
0.13
0.12
0.11
0.1
0.09
Gin
Gout
0.8
0.9
1.1
1.2
time (seconds)
1.3
1.4
5
x 10
Value
[20; 20; 20]
[5; 5; 5]
[20; 3; 20]
[10000; 1000; 1]
[0; 0; 0]
de um Processo de Separaca
o Oleo/
agua. Dissertacao de
Mestrado, COPPE/UFRJ, Rio de Janeiro.
Hovland, S. (2004). Soft Constraints in Explicit Model Predictive Control. Msc. Thesis - The Norwegian University
of Science and Technology.
Kim, M., Domanski, S.H.Y.P.A., and Payne, W.V. (2008).
Design of a steady-state detector for fault detection and
diagnosis of a residential air conditioner. International
Journal of Refrigeration, 31, 790799.
106
Maciejowski, J. (2002). Predictive Control with Constraints. Prentice Hall, New Jersey.
Mendes, P.R.C., Carvalho, R.L., and Normey-Rico, J.E.
(2011). Nonlinear predictive control applied to load
oscillations damping in a three phese separator. Rio
Pipeline 2011, Rio de Janeiro: Brasil.
Nunes, G.C. (1994). Modelagem e Simulaca
o Din
amica do
Separador Agua/
Oleo/
G
as. Dissertacao de Mestrado Universidade Federal do Rio de Janeiro.
Nunes, G.C., Medeiros, J.L., and Ara
ujo, O.Q.F. (2010).
Modelagem e Controle na Produca
o de Petr
oleo.
Blucher, Sao Paulo: Brasil.
Nunes, G. (2001). Design and analysis of multivariable
predictive control applied to an oil-water-gas separator:
A polynomial approach. PhD Thesis, University of
Florida.
Nunes, G. (2004). Controle por bandas: Conceitos basicos
e aplicacao no amortecimento de oscilacoes de carga em
unidades de producao de petr
oleo. Technical report,
Comunicacao Tecnica - PETROBRAS.
Paoli, C., Voyant, C., Muselli, M., and Nivet, M.L. (2009).
Solar radiation forecasting using ad-hoc time series
preprocessing and neural networks. In D.S. Huang,
K.H. Jo, H.H. Lee, H.J. Kang, and V. Bevilacqua
(eds.), Emerging Intelligent Computing Technology and
Applications, volume 5754, 898907. Springer Berlin /
Heidelberg.
Pawlowski, A., Guzman, J.L., Rodrguez, F., Berenguel,
M., and Normey-Rico, J.E. (2011). Predictive control
with disturbance forecasting for greenhouse diurnal temperature control. 18th IFAC World Congress, Milano:
Italy, 17791784.
Pawlowski, A., Guzman, J.L., Rodrguez, F., Berenguel,
M., and Sanchez, J. (2010). Application of time-series
methods to disturbance estimation in predictive control.
IEEE Symposium on Industrial Electronics, Bari: Italy,
409414.
Plucenio, A. (2010). Desenvolvimento de Tecnicas de
Controle N
ao Linear para Elevaca
o de Fluidos Multif
asicos. Ph.D. thesis, PhD thesis PPGEAS - Universidade
Federal de Santa Catarina, Florianopolis-SC-Brasil.
Plucenio, A., Pagano, D.J., Bruciapaglia, A.H., and
Normey-Rico, J.E. (2007). A practical approach to predictive control for nonlinear processes. NOLCOS 2007
- 7th IFAC Symposium on Nonlinear Control Systems.
Prasath, G. and Jrgensen, J.B. (2009). Soft constraints
for robust mpc of uncertain systems. International
Symposium on Advanced Control of Chemical Processes.
Reikard, G. (2009). Predicting solar radiation at high
resolutions: A comparison of time series forecasts. Solar
Energy, 83, 342349.
Scandpower (2003). Users Manual OLGA 2000. Kjeller:
Norway.
Silveira, M.A.C.R. (2006). Controle de um Processo
de Tratamento Prim
ario de Petr
oleo. Dissertacao de
Mestrado - Universidade Federal do Rio de Janeiro.
Sotomayor, O.A.Z., Odloak, D., and Moro, L.F.L. (2009).
Closed-loop model re-identification of processes under
mpc with zone control. Control Engineering Practice,
17, 551U563.
Triggia, A.A., Correia, C.A., and Filho, C.V. (2001).
Fundamentos de Engenharia de Petr
oleo. Interciencia,
Rio de janeiro.