OMC 2013 – 21 March – Riccardo Martini

Advanced Process Control applications
to improve industrial productivity and
operational effectiveness in the Oil &
Gas industry
© ABB Group
April 8, 2013 | Slide 1

Presentation Agenda

Brief Introduction to Advanced Process Control
Sample applications
APC on Oil & Gas Separators & Stabilizer
APC on Acid Gas Removal unit

© ABB Group
April 8, 2013 | Slide 2

Advanced Process Control .Positioning .

2013 | Slide 4 .How APC Improves Performance (1) Time domain view Reduce Variance Shift Target actual constraint before MPC © ABB Group April 8.

How APC Improves Performance (2) Statistical view Reduces Variance And Pushes To Limit 6 % Samples/ Degree F 5 4 3 2 1 0 330° 350° 370° 390° 410° 430° Degree F © ABB Group April 8. 2013 | Slide 5 .

How APC Improves Performance (3) Handling simultaneous constraints and variables Steam Condenser Constraint Flooding Constraint Economic Optimum MPC Operator’s Initital Preferred MPC Operating Region Reboiler Temperature Constraint Reflux © ABB Group April 8. 2013 | Slide 6 .

Manipulated Process Inputs (Base Controller SPs) CVs = Dependent. Controlled (Constraint) Process Outputs FFs = Independent. Process Inputs (Disturbances) © ABB Group April 8.How APC Improves Performance (4) CVs CV Limits PVs MVs CV Targets MV Targets MV Limits MPC Base Loop Setpoints BASE LOOPS COs Inputs PROCESS Outputs FFs MVs = Independent. 2013 | Slide 7 .

2013 | Slide 8 .APC & Optimization Suite Deliver state of the art technology Create a suite of products that have consistent look and feel that work together seamlessly Reduce service and maintenance efforts Loop Scan/Track Predict & Control Inferential Modeling Platform © ABB Group April 8.

2013 | Slide 9 .Gas & Oil Separation – Typical configuration © ABB Group April 8.

2013 | Slide 10 .Gas & Oil separators – basic diagram & objectives From wells MP Gas LP Gas HP Sep Process control Main Objectives : Oil Stabilizer MP Sep Keep column temperature (composition) at target LP Sep Keep separators pressure at target Keep levels in range Manage composition changes Manage flow variations in inlet (HP separator) Steam reboiler Oil Preserve stable operation © ABB Group April 8.

Gas & Oil separation – process control From wells Oil & gas separation by means of sequence of separators and stabilizer column HP Sep Hi pressure separator affected by large disturbances that get cascaded to lower pressure separators and column Oil Stabilizer MP Sep LP Sep Advanced process control strategies provide better results than standard DCS control schemes Steam reboiler Oil © ABB Group April 8. 2013 | Slide 11 Moving from multiple local objectives to coordinated overall objectives .

Gas & Oil separation – disturbance path From wells Hi pressure separator affected by large disturbances HP Sep Disturbances get cascaded to lower pressure separators and stabilizer Oil Stabilizer MP Sep If level control is tight disturbance is fully propagated or even amplified LP Sep Steam reboiler Oil © ABB Group April 8. 2013 | Slide 12 .

2013 | Slide 13 .Separator trends – prior to implementation Flow Flow Temperature Temperature From wells HPS Oil Stabilizer MPS LPS Steam reboiler Oil © ABB Group April 8.

Separator trends – consistent pattern Flow Flow Flow Temperature Temperature From wells HPS Pattern: consistent over time Oil Stabilizer MPS LPS Steam reboiler Oil © ABB Group April 8. 2013 | Slide 14 .

Disturbance source: oil wells HP separator btm flow HP separator level Line pressure: feed forward information © ABB Group April 8. 2013 | Slide 15 .

A. MP to LP. LP levels Stabilizer temperatures Main MVs Level flows (HP to MP.APC Solution DCS control scheme modifications and re-tune Advanced Process Control implementation Keep level in range. FFs Line pressure © ABB Group April 8. use level buffer to smooth disturbance transfer Coordinate column feed with steam to improve temperature control Use existing well pressure to anticipate level/temperature changes Main CVs HP. 2013 | Slide 16 . LP to column) Steam P. MP.

APC Results Results: Improvement in temperature control (std. dev. 2013 | Slide 17 . Decrease >60%) Consistent composition control Process stabilization Reduction in operations workload © ABB Group April 8.

2013 | Slide 18 Steam .Acid Gas Removal unit SRU Chemical separation Ammine injection to separate H2S from sour gas Sweet Gas Rich ammine sent to regenerator for H2S stripping Different ammine types or solvents could improve efficiency but overall still large LP consumer Lean Ammine Sour Gas © ABB Group April 8.

2013 | Slide 19 .Preliminary evaluation Residual H2S not consistently at specification – large fluctuations Multiple trains with inconsistent residual H2S Ammine circulations typically kept at constant value Steam/ammine ratio typically kept at constant value Potential improvement also in the area of gas inlet temperature control (refrigerant) Large potential savings with APC implementation © ABB Group April 8.

64 9902 9902 9902 9902 .38 260.78 5. 2013 | Slide 20 V330FIC412_MV 19897.5 37.38 V330AT401_VALUE -0.Addolcimento Gas – Unità 330 L4 Steam Ammine flow H2S.05 0.48 159.06 21354.5 -1 © ABB Group April 8.5 20768.93 4.58 V330FIC402_OUT 37.4 0.95 172. day/night cycling Name Min Avg Max Std Dev Samples V330FIC402_MV 151.5 37.

2013 | Slide 21 .Acid Gas Removal unit SRU Main CVs Residual H2S Sweet Gas Regen top temp Sour gas inlet temp Main MVs Lean Ammine Ammine injection Steam/ammine ratio Refrigerant Sour Gas Objectives Steam Maintain specs. minimize steam usage © ABB Group April 8.

SRU APC 100% ON APC ∆= 15 % APC OFF © ABB Group April 8. 2013 | Slide 22 Maint APC ON Maint APC ON .Results Consistent control of H2S Large energy savings (steam savings ~ 15%) Unit stabilization Reduction of disturbances to downstream units .

other operational benefits can be achieved Stabilization of operations Reduction of operators workload © ABB Group April 8. tangible benefits to the O&G industry APC Software and technology in the mature stage In addition to financial benefits. 2013 | Slide 23 .Conclusions APC can provides large.