ideas pipelines
TRANSCRIPT
-
8/18/2019 IDEAS Pipelines
1/38
Optimization of Liquid Pipeline
Pressure Control Valve Systems
Roger Shirt, R.W. Shirt Consulting
-
8/18/2019 IDEAS Pipelines
2/38
Outline
Pressure control valves in pipeline service
(Re-) Engineering of control valve installations
Role of IDEAS simulation
Benefits of control valve optimization
-
8/18/2019 IDEAS Pipelines
3/38
Pressure Control Valves inPressure Control Valves in
Pipeline ServicePipeline Service
Large network – 300 mainline PCVs
PCVs are primary final control element
Disturbances propagated
-
8/18/2019 IDEAS Pipelines
4/38
Pipeline Installations
Pumping stations every 40 miles
3 or 4 lines in parallel
Large SC! system
PLCs for station control
40 miles
-
8/18/2019 IDEAS Pipelines
5/38
Pump Station Pressure Control
"# $ or 3 pumps in service
!isc%arge pressure to prevent line overpressure
Suction pressure override to prevent pump cavitation
P&
PICPIC
P&
<
PTuctionPressure
Case
Pressure
Dis c!arge
Pressure
-
8/18/2019 IDEAS Pipelines
6/38
Pipeline C%aracteristics
Pipeline !iameters from "#$ - %&$
'arge valves ("$ "#$)
Ball an! glo*e
Electro-h+!raulic actuators
alveactuators costl+ (. /##0 for capital)
Remote locations
Servicing costl+ (e1g1 fre2uent fiel! tuning not practical)
-
8/18/2019 IDEAS Pipelines
7/38
Pipeline PCV Locations
3orthern Al*erta
An!es 4ountains,5olum*ia
-
8/18/2019 IDEAS Pipelines
8/38
Operating C%aracteristics
6lo7 rates8 ### 9### m:hr
Pressure !rops8 ### psi
Densities8 9## ;%#
-
8/18/2019 IDEAS Pipelines
9/38
-
8/18/2019 IDEAS Pipelines
10/38
Performance 5equirements
Set-point trac
-
8/18/2019 IDEAS Pipelines
11/38
Value of Simulation
3e7 or replacement installations8
Select *est performing valve from severalcompetitive *i!s
Provi!e optimal control valve s+stem settings
At e@isting sites 7here pressure control valve
s+stem performance capa*ilities un
-
8/18/2019 IDEAS Pipelines
12/38
ngineered pproac% to Control
Valve Performance
6iel! =ests
-
8/18/2019 IDEAS Pipelines
13/38
ngineered pproac% to Control
Valve Performance
6iel! =ests
Data Anal+sis
-
8/18/2019 IDEAS Pipelines
14/38
ngineered pproac% to Control
Valve Performance
6iel! =ests
Data Anal+sis
Simulation 4o!elling
-
8/18/2019 IDEAS Pipelines
15/38
ngineered pproac% to Control
Valve Performance
6iel! =ests
Data Anal+sis
Simulation 4o!elling
enerate ptimal Settings
-
8/18/2019 IDEAS Pipelines
16/38
ngineered pproac% to Control
Valve Performance
6iel! =ests
Data Anal+sis
Simulation 4o!elling
enerate ptimal Settings
Implement Settings
-
8/18/2019 IDEAS Pipelines
17/38
ngineered pproac% to Control
Valve Performance
6iel! =ests
Data Anal+sis
Simulation 4o!elling
enerate ptimal Settings
Implement Settings
erif+ Performance
-
8/18/2019 IDEAS Pipelines
18/38
1ield &ests
alve performance testing at site
• A3SIISA-?91"91#-"###
•
' an! 5' *ump tests
D+namic Data 5ollection
•#19 sec sampling rate
(S5ADA at "# sec sampling rate)
• -" 7ee< operating 7in!o7
Perf1 5riterion Spec1 Cnit
=ravel ;# !eg
Stro "1# sec
Resolution #19
F+stGDea!*an! 1#
-
8/18/2019 IDEAS Pipelines
19/38
!ata nalysis
Installe! 5v !etermination• 5onfirm manufacturerHs information
• 4anufacturers tests !etermine! un!er i!eal
piping geometr+ con!itions
-
8/18/2019 IDEAS Pipelines
20/38
Installed Cv Curves ."
Ineffective 5ontrol
-
8/18/2019 IDEAS Pipelines
21/38
Installed Cv Curves .$
-
8/18/2019 IDEAS Pipelines
22/38
!ata nalysis
Simulation mo!el cali*ration
Each mo!el cali*rate! against stea!+-stateprocess !ata (& points)
9 stan!ar! error t+pical
-
8/18/2019 IDEAS Pipelines
23/38
&ypical Pipeline 6odel
• Stu!+, upstream an! !o7nstream stations
• Pipeline lengths, elevations
• Pro!uct properties (!ensit+, viscosit+, RP)
• Pressure an! pump minimum flo7 constraints
-
8/18/2019 IDEAS Pipelines
24/38
I!S Control Valve O78ect
ISA Stan!ar! calculations
in ne@t IDEAS release for *oth li2ui!s an! gas
A3SIISA-?91#1#-"##" IE5 >#9:%-"-6lo7 E2uations for Sizing 5ontrol alves$
6eatures8
5ho
-
8/18/2019 IDEAS Pipelines
25/38
Control Valve System !etails
Set-point ramping (psisec)
Fi-select
alve cali*ration (at valve)
alve travel limiting (in P'5) =ransmitter !+namics
5ontroller output linearization
Actuator stro
-
8/18/2019 IDEAS Pipelines
26/38
9ain Curve nalysis
Installe! gain curves 'inearit+
Effective controlla*le range
-
8/18/2019 IDEAS Pipelines
27/38
9ain Curve nalysis
5omparison of can!i!ate valves 'inearit+, size an! positioning of controlla*le range
Sizing (valve companies) versus performance assessment
-
8/18/2019 IDEAS Pipelines
28/38
llo:a7le Operating 5ange
Evaluate gain over allo7a*le operating range$ ain (an! other performance parameters) var+
consi!era*l+
-
8/18/2019 IDEAS Pipelines
29/38
Output Linearization
5ounteract process nonlinearities in controller
Simulator gives complete picture of nonlinearities
6it function to (normalize!) pressure responses
6in! a function that gives mirror image$ ofnonlinearities
5ontroller 'inearization Process
Process 'inearization
-
8/18/2019 IDEAS Pipelines
30/38
Output Linearization
-
8/18/2019 IDEAS Pipelines
31/38
Linearized 9ain Curves
5onsistent gain consistent close!-loopresponse
'arger effective controlla*le range
-
8/18/2019 IDEAS Pipelines
32/38
Controller &unings
4a@imum process gain (P) from gain curves
Simulate! *ump test8 =ime constant (=5)
Dea! time (D=) D+namics of valve
an! transmitters
Appl+ 'am*!a tuning
rules
Open(Loop ump &est
$40
$4$
$44
$4*
$4,
0 ) "0 ") $0 $) 30
&ime .sec
40
4)
)0
))
*0
IDEAS Simulation
st r!er 4o!el
5ontroller utput
-
8/18/2019 IDEAS Pipelines
33/38
Performance Confirmation &ests
Set-point step tests
Pump starts Stage! isolation valve operation
F+!raulic transients teste!
-
8/18/2019 IDEAS Pipelines
34/38
Pressure !rop ;
-
8/18/2019 IDEAS Pipelines
35/38
Pressure !rop ;
&orque 5equirements
-
8/18/2019 IDEAS Pipelines
36/38
Cavitation
5avitation pre!iction over allo7a*le operatingrange Select valve 7ith lo7est cavitation potential
A!vise operations of potential cavitating operating regions
-
8/18/2019 IDEAS Pipelines
37/38
conomics
5equired ctuator Speed
#
9
#
9
"#
"9
:#
:9
%#
%9
9#
# "9 9# ?9 ## "9 9# ?9 "## ""9
Pre(Start Suction Pressure .psig
E@isting
Re-Engineere!
?isting ctuator Stro=e Spe ed
Preferred Stro=e Speed
6aster control J closer operation to constraints
Allo7s pipelines to operate at lo7er pressures
'arge potential pumping energ+ cost savings
/"#-:#0+r (5!n) for each pump station
-
8/18/2019 IDEAS Pipelines
38/38