ideas pipelines

8/18/2019 IDEAS Pipelines

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Optimization of Liquid Pipeline

Pressure Control Valve Systems

Roger Shirt, R.W. Shirt Consulting


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Outline

Pressure control valves in pipeline service

(Re-) Engineering of control valve installations

Role of IDEAS simulation

Benefits of control valve optimization


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Pressure Control Valves inPressure Control Valves in

Pipeline ServicePipeline Service

Large network – 300 mainline PCVs

PCVs are primary final control element

Disturbances propagated


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Pipeline Installations

Pumping stations every 40 miles

3 or 4 lines in parallel

Large SC! system

PLCs for station control

40 miles


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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


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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)


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Pipeline PCV Locations

3orthern Al*erta

An!es 4ountains,5olum*ia


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Operating C%aracteristics

6lo7 rates8 ### 9### m:hr

Pressure !rops8 ### psi

Densities8 9## ;%#


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Performance 5equirements

Set-point trac


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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


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ngineered pproac% to Control

Valve Performance

6iel! =ests


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Valve Performance

6iel! =ests

Data Anal+sis


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Valve Performance

6iel! =ests

Data Anal+sis

Simulation 4o!elling


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Valve Performance

6iel! =ests

Data Anal+sis


enerate ptimal Settings


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Valve Performance

6iel! =ests

Data Anal+sis



Implement Settings


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Valve Performance

6iel! =ests

Data Anal+sis



Implement Settings

erif+ Performance


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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#


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!ata nalysis

Installe! 5v !etermination• 5onfirm manufacturerHs information

• 4anufacturers tests !etermine! un!er i!eal

piping geometr+ con!itions


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Installed Cv Curves ."

Ineffective 5ontrol


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Installed Cv Curves .$


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!ata nalysis

Simulation mo!el cali*ration

Each mo!el cali*rate! against stea!+-stateprocess !ata (& points)

9 stan!ar! error t+pical


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&ypical Pipeline 6odel

• Stu!+, upstream an! !o7nstream stations

• Pipeline lengths, elevations

• Pro!uct properties (!ensit+, viscosit+, RP)

• Pressure an! pump minimum flo7 constraints


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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


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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


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9ain Curve nalysis

Installe! gain curves 'inearit+

Effective controlla*le range


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9ain Curve nalysis

5omparison of can!i!ate valves 'inearit+, size an! positioning of controlla*le range

Sizing (valve companies) versus performance assessment


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llo:a7le Operating 5ange

Evaluate gain over allo7a*le operating range$ ain (an! other performance parameters) var+

consi!era*l+


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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


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Output Linearization


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Linearized 9ain Curves

5onsistent gain consistent close!-loopresponse

'arger effective controlla*le range


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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


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Performance Confirmation &ests

Set-point step tests

Pump starts Stage! isolation valve operation

F+!raulic transients teste!


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Pressure !rop ;


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Pressure !rop ;

&orque 5equirements


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Cavitation

5avitation pre!iction over allo7a*le operatingrange Select valve 7ith lo7est cavitation potential

A!vise operations of potential cavitating operating regions


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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


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