Field of invention
[0001] The present invention relates to a method of operating a pipeline-riser system, in
particular to tuning of a PID and PI controllers for robust anti-slug control. Moreover,
the invention relates to a pipeline-riser system, in particular to a pipeline-riser
system comprsing an anti-slug valve. Furthermore, the invention relates to a program
element and to a computer readable medium.
Art Background
[0002] In the field of offshore oil production often pipeline-riser systems are used. In
particular, at offshore oilfields, subsea pipelines are used to transport the multiphase
mixture of oil, gas and water from producing wells to the processing facilities. Several
kilometers of pipeline run on the seabed ending with risers to top-side platforms.
Therefore, in new field developments, multiphase transport technology and flow assurance
become more important. Especially, depleted reservoirs have low pressures to push
the fluid along the pipeline, and they are prone to flow instabilities. Liquids tend
to accumulate at places with lower elevation, and can block the gas flow in the pipe.
In low flow rate conditions, this blockage leads to a slugging flow regime called
terrain slugging.
[0003] If the oscillating frequency or the lengths of slugs are comparable to the length
of the riser, the flow condition is called "severe slugging" or "riser-slugging".
The severe-slugging flow is also characterized by large oscillatory variations in
pressure and flow rates. The oscillatory flow condition in offshore multi-phase pipelines
is undesirable and an effective solution is needed to suppress it. One way to prevent
this behavior is reducing the opening of a choke valve arranged at the top-side of
the riser. However, this conventional solution increases the back pressure of the
valve, and it reduces the production rate from the oil wells. The recommended solution
to maintain a non-oscillatory flow regime together with the maximum possible production
rate is active control of the topside choke valve. Measurements such as pressure,
flow rate or fluid density are used as the controlled variables and the top-side choke
valve is the manipulated variable. However, existing anti-slug control systems are
not robust in practice and the closed-loop system becomes unstable after some time,
because of inflow disturbances or plant changes.
[0004] Thus, there may be a need for providing a method of operating a pipeline-riser system
and a pipeline-riser system showing a low probability of slugging.
Summary of the Invention
[0005] This need may be met by a method of operating a pipeline-riser system, a pipeline-riser
system, a program element to and a computer readable medium according to the independent
claims. Further embodiments are described in the dependent claims.
[0006] According to an exemplary aspect a method of operating a pipeline-riser system comprising
an anti-slug valve is provided, wherein the method comprises controlling the anti-slug
valve by a control signal generated based on a measured signal indicative for a flow
of a fluid through the pipeline-riser system, wherein the control signal comprises
a signal component relating to a linear time-invariant system G(s), wherein the linear-time
invariant system is modeled according to

[0007] In particular, b
0, b
1, a
0 and a
1 are parameters derivable from pressure measurements and respective point in times.
For example, for a closed-loop stable system the four parameters may be derived or
estimated from six measurement data of a closed-loop step response describing pressure
measured at respective points in the pipeline-riser system and respective point in
times for the measurement.
[0008] In particular, G(s) denotes a gain factor which may be time dependent. Thus, G(s)
may form a transfer function or at least a portion of a transfer function describing
the behavior of the gain.
[0009] In particular, the controlling may be performed by opening or closing the anti-slug
valve or an aperture of the anti-slug valve or more general by changing the through-flow
of a liquid through the anti-slug valve. The anti-slug valve may be formed by a choke
valve for example or any other valve which is suitable to control a through-flow of
a fluid (gas, liquid or mixture thereof).
[0010] According to another exemplary aspect a pipeline-riser system is provided, wherein
the pipeline-riser system comprises a pipeline portion, a riser portion, an anti-slug
valve, and a control unit, wherein the pipeline portion and the riser portion are
joined at a joining point, wherein the anti-slug valve is arranged in the pipeline-riser
system in such a way that a flow rate of fluid flowing through the pipeline-riser
system is controllable, and wherein the control unit is adapted to generate a control
signal for controlling the anti-slug valve according to a method according to an exemplary
aspect.
[0011] In particular, the pipeline-riser system may be an undersea pipeline-riser system,
e.g. for offshore oil production. For example, the pipeline section is arranged upstream
of the riser portion. In particular, the anti-slug valve may be arranged in the pipeline
portion, the riser portion, or the joining point. In particular, the anti-slug valve
may be arranged in proximity of a joining point of the pipeline portion and the riser
portion or at a top-side of the riser portion, for example.
[0012] According to an exemplary aspect a program element is provided, which, when being
executed by a processor, is adapted to control or carry out a method according to
an exemplary aspect.
[0013] According to an exemplary aspect a computer-readable medium is provided, in which
a computer program is stored which, when being executed by a processor, is adapted
to control or carry out a method according to an exemplary aspect.
[0014] The term "pipeline portion" may particularly denote a portion of a tube system adapted
to convey fluids, e.g. natural gas, crude oil or a multiphase fluid and which is arranged
substantially horizontal or following the contour of the terrain, e.g. a subsea floor.
A pipeline portion has to be distinguished from a riser portion of a pipeline-riser
system.
[0015] The term "riser portion" may particularly denote a portion of the tube system which
is arranged substantially vertical or at least does not follow a contour of the terrain.
In particular, the riser portions may be the portions of a subsea tube arrangement,
which are adapted to convey crude oil from the sea level to the surface, e.g. by pumping
up the crude oil or multiphase fluid.
[0016] The term "anti-slug valve" may particularly denote a valve which is adapted or suitable
to reduce or avoid slugging in a conveying pipeline-riser system. In particular, the
anti-slug valve may be controllable or may have a preset or predetermined throughput
of a fluid, e.g. crude oil. For example, the anti-slug valve may be a top-side valve
arranged on an oil platform.
[0017] Surprisingly the inventors have found out by experiments by using a test rig and
performing simulations that an anti-slug valve controlled by a control signal comprises
a signal component relating to a linear time-invariant system G(s) may allow for an
improved and in particular robust or stable anti-slug control. In particular, it may
be possible to reduce or even eliminate slugging during conveying of fluids through
the pipeline-riser system.
[0018] Experiments even have shown that the non-slugging flow may even be maintained for
a larger valve opening when using the specific algorithm for anti-slug control than
it can be maintained when using conventional solutions (e.g. manual choking) Thus,
it may be possible to provide a more robust anti-slug control and/or a more robust
slug control and therefore an increased rate of oil production
[0019] Next further embodiments of the method of operating a pipeline-riser system will
be described. However, these embodiments also apply to method the pipeline-riser system,
to the program element and to the computer readable medium.
[0020] According to an exemplary embodiment the control signal comprises a further signal
component relating to or representing a static nonlinearity.
[0021] In particular, the control signal may comprise or may be formed according to a Hammerstein
model structure, comprising a static nonlinearity (representing a static gain) component
and a linear time-invariant (representing unstable dynamics of the modeled pipeline-riser
system) component. For example, the static nonlinearity component may be described
and/or calculated by

wherein Δ
P represents a pressure difference generated by a respective element, e.g. a valve
or pump, or by the resistance in a pipeline,
a represents a constant parameter, and
f(
z) represents the valve characteristic function depending on the valve opening z.
[0022] According to an exemplary embodiment the method further comprises controlling a through-flow
through the anti-slug valve according to the control signal.
[0023] According to an exemplary embodiment of the method an internal model control function
is used for generating the control signal.
[0024] In particular, the internally model control function or internal model controller
may be described by a stabilizing controller

wherein
G(
s) is a model of a plant or the pipeline-riser system,
Q̃(
s) is the inverse of the minimum phase part of
G(
s) and
f(
s) is a low-pass filter which may ensure stability and robustness of a closed-loop
system.
[0025] According to an exemplary embodiment of the method the internal model control function
is given by

wherein
k' is the gain of the plant or pipeline-rides system
G(s), λ is an adjustable filter time constant, α
1 and α
2 represent coefficients and ϕ represents the zero dynamics of the pipeline-riser system.
[0026] In particular,
k' is the gain of the plant
G(s), as will be described later on in equation (9). In particular, the internal model
control function or internal model controller may be a second order transfer function
which may be written in form of a PID (proportional, integral, and derivative) controller.
Alternatively, the internal model control function may be written in form of a PI
(proportional, integral) controller.
[0027] According to an exemplary embodiment of the method the controlling of the anti-slug
valve is performed by a PID or PI controller.
[0028] According to an exemplary embodiment of the method a tunig rule for the PID controller
is given by

wherein

and
Kd =
Kiα2-KpTf, wherein
Kp<0 and
Kd<0.
[0029] In particular, λ may be chosen so that
Kc<0 and
Kd<0 is valid.
[0030] According to an exemplary embodiment of the method a tunig rule for the PI controller
is given by

wherein

and τ
1=α
2ϕ.
[0031] Summarizing, a gist of an exemplary embodiment may be seen in providing a control
regime for an anti-slug valve for an undersea pipeline-riser system, wherein the anti-slug
valve comprises a control interface and connected to a control unit. The control unit
is adapted to generate a control signal based on measured variables, e.g. flow rate,
pressure or fluid density in the pipeline-riser system.
[0032] It has been found out that when using a control signal generated according to a Hammerstein
model structure it may be possible to decrease the probability of riser slugging and/or
the amount of riser slugging. It should be noted that due to the specific control
of the anti-slug valve an increased robustness of the slug control and thus of the
flow rate and/or pressure may be provided.
[0033] In particular, the anti-slug valve may be a choke valve. The term "anti-slug valve"
may particularly denote a valve, e.g. a choke valve, which is adapted to control a
flow through a pipeline, in particular, to prevent or at least reduce the probability
of an oscillatory flow regime. In particular, the anti-slug valve may be adapted to
be controlled by a control signal, wherein the control may be provided by increasing
or decreasing a flow rate through the anti-slug valve, e.g. by opening or closing
an aperture of the anti-slug valve.
[0034] The aspects defined above and further aspects of the present invention are apparent
from the examples of embodiment to be described hereinafter and are explained with
reference to the examples of embodiment. The invention will be described in more detail
hereinafter with reference to examples of embodiment, but to which the invention is
not limited.
Brief Description of the Drawings
[0035]
- Fig. 1
- shows a simplified experimental set-up.
- Fig. 2
- shows bifurcation diagrams.
- Fig. 3
- shows a schematic block diagram for a Hammerstein
- Fig. 4
- shows a closed-loop step response diagram.
- Fig. 5
- shows a schematic block diagram of an internal model control system.
- Fig. 6
- shows some simulation results.
Detailed Description
[0036] The illustration in the drawing is schematically. It is noted that in different figures,
similar or identical elements are provided with the same reference signs or with reference
signs, which are different from the corresponding reference signs only within the
first digit.
[0037] Fig. 1 shows a simplified experimental set-up. In particular, Fig. 1A shows a simplified
pipeline-riser system 100 comprising a fluid reservoir 101 for simulating an oilfield,
for example. The fluid reservoir is connected via a pump 102 (simulating the pressure
the crude oil in the oil field is exposed to) and a water flow meter 103 to a mixing
point 104. Furthermore, an air flow meter 105 is connected to an air buffer tank 106
having a pressure of P
1 or P
in. The air buffer tank 106 is connected to the mixing point 104 via a safety valve
107 and is used in the experiment to simulate gas expansion of a very long pipeline
(corresponding to a real pipeline-riser system). The mixing point 104 corresponds
in principle to the well head of a real offshore pipeline-riser system. At the mixing
point the water/air fluid has a pressure of P
3 and is pumped through a pipeline portion or section 108 which is arranged substantially
horizontal. At the bottom of the riser the multiphase (water/air) fluid has a pressure
of P
rb (pressure at riser bottom) or P
4.
[0038] In the experimental set-up of Fig. 1A a riser of the pipeline-riser system 100 is
formed by a framework structure to which the riser portion 110 is attached for simulating
the riser portion of a real pipeline-riser system. The riser portion 110 and the pipeline
portion 108 are joined at a joining point 113. At top of the framework structure a
top-side valve 111 is connected to the riser 110 simulating a common top-side valve
which is typically used for slugging control. At the top-side the multiphase fluid
has a pressure of P
rt (pressure at riser top) or P
2. After the top-side valve the multiphase fluid is conveyed to a separator 112 in
which the air phase is separated from the water phase which is recycled and conveyed
back to the water reservoir 101.
[0039] Additionally in Fig. 1B a schematic sketch of a set-up for performing simulations
of a pipeline-riser system is depicted. In addition to the simplified pipeline portion
108, the riser portion 110, and the top-side valve 111, parameters are defined which
can be used in the calculation. These are the mass flow rate of liquid w
l,in, the mass flow rate of gas w
g,in, and the corresponding pressure P
in at the input point, e.g. in the case of a real pipeline-riser system the wellhead
position. Furthermore, the corresponding values for the pressure at the riser bottom
P
rb and at the riser top P
rt are indicated in Fig. 1B. Moreover, the pressure after a separation P
s is indicated in Fig. 1B after the top-side valve 111. Additionally, some geometric
parameter like an angle θ indicating an inclination of the pipeline portion before
the riser basis and a length L
r of the riser indicating a height difference between the riser bottom and the riser
top are indicated in Fig. 1B as well.
[0040] Fig. 2 shows bifurcation diagrams. In particular, Fig. 2A shows a bifurcation diagram
200 for the input pressure P
in simulated by the known OLGA simulation tool at the input point of Fig. 1B vs. the
opening Z of the anti-slug valve, e.g. the top-side valve. More specifically, solid
lines 201 and 202 indicate the maximum and minimum of the oscillations, respectively,
while dashed line 203 indicate the steady-state of the input pressure. Fig. 2B shows
a bifurcation diagram 204 for the pressure P
rt at the top of the riser simulated by the known OLGA simulation tool at the top-side
valve of Fig. 1B vs. the opening Z of the anti-slug valve, e.g. the top-side valve.
More specifically, solid lines 205 and 206 indicate the maximum and minimum of the
oscillation, respectively, while dashed line 207 indicate the steady-state of the
topside pressure.
[0041] Fig. 3 shows a schematic block diagram for a Hammerstein model which may be used
for describing a desired unstable flow regime. The block diagram of the Hammerstein
model 300 is a structure consisting of series connection of a static nonlinearity
301 followed by a linear time-invariant dynamic system 302. The static nonlinearity
may represent the static gain of the process and G'(s) may account for the unstable
dynamics. For identification of the unstable dynamics a model structure may be assumed.
A simple model which may be used for unstable systems is an unstable first order plus
dead-time model:

[0042] If this system is controlled by a proportional controller
Kc0, the closed-loop transfer function from the set-point (
ys) to the output (
y) becomes

[0043] To get a stable closed-loop system, one needs
Kc0be-θs>a and
Kc0b>a. The steady-state gain of the closed-loop transfer function is

[0045] This model contains two unstable poles, two stable poles and two zeros. Seven parameters
have to be estimated to identify this model. However, if one look at the Hankel Singular
Values of the fourth order model one may find out that the stable part of the system
may have little dynamical contribution. This suggests that a model with two unstable
poles is enough for control design. Thus, balanced model truncation via square root
may be used as a method to get a reduced order model. It is in the following form:

[0046] Four parameters,
b1,
b0, a1 and a0, need to be estimated. If one controls the unstable system in (5) by
a proportional controller with gain
Kc0, the closed-loop transfer function from the set-point to the output will be

[0047] For the closed-loop stable system one may consider a transfer function.

[0048] Six data (Δ
yp, Δ
yu, Δ
y∞, Δ
ys,
tp, and Δ
t) may be observed from the closed-loop response (see Fig. 4) to estimate the four
parameters (
K2, τ
z, τ and ζ) in (7). Then, one may back-calculate to parameters of the open-loop unstable
model in (5). Details of the respective calculations will be given later on.
[0049] Fig. 4 shows a closed-loop step response diagram. In particular, Fig. 4 shows a pressure
behaviour 400 in response to a change in a set-point. At a point in time 401 the set-point
for the pressure is increased by Δ
ys leading to a peak rise of the pressure of Δ
yp in the time interval
tp. After a further time interval Δ
t the pressure decreases to a minimum pressure Δ
yu representing an undershoot of the pressure. From that point in time the pressure
is approaching a steady state value represented by Δ
y∞.
[0051] Fig. 5 shows a schematic block diagram of an internal model control system 500 comprising
a low-pass filter 501 (
f(
s)) (for robustness of the closed-loop system), a model 502 (
G(
s)) describing the behaviour of a plant (e.g. an oil platform). The model typically
will have a mismatch with the real plant 503 (plant,
GP(
s)). Furthermore, the IMC system 500 comprises an element 504 (
Q̃(
s)) which denotes an inverse of the minimum phase part of
G(
s). In general, the shown IMC configuration cannot be used directly for unstable systems;
instead the stabilizing controller may be given as the following:

wherein
G(
s)is a model of a plant or the pipeline-riser system,
Q̃(
s) is the inverse of the minimum phase part of
G(
s) and
f(
s) is a low-pass filter which may ensure stability and robustness of a closed-loop
system. For internal stability,
Q̃(
s)
f and 1-
GQ̃f have to be stable. In particular, one may use the above identified model as the plant
model:

and one gets

[0052] The filter
f(
s) may be defined using:
k = number of RHP poles + 1 = 3
m = max (number of zeros of Q̃(s) - number of pol e of Q̃(s), 1) =
l (this is for making Q=Q̃f proper) ;
n = m + k -1 = 3; filter order.
[0053] The filter is in the following form:

[0054] Where λ is an adjustable filter time-constant. One may choose α
0=1 to get an integral action in the controller, and the coefficient α
1 and α
2 are calculated by solving the following system of linear equations:

[0055] The feedback version of the IMC controller is as the following:

[0056] In the following some PID tuning rules and their determination will be explained.
[0058] It is required to get
Kc < 0 and
Kd < 0, in order that the controller works in practice. Thus, λ may be chosen accordingly
in order that these two conditions may be satisfies.
[0059] In the following some PI tuning rules and their determining will be explained. For
a PI controller in the following form

the tuning rules may be derived from the controller (13) as follows

[0060] This means that the PI-controller approximates high-frequency and low-frequency asymptotes
of C(s) in (13).
[0061] In the following some explanations concerning a model for the static nonlinearity
(cf. Fig. 3) will be given. In particular, a simple model for the static nonlinearity
in Fig. 3 instead of using a full dynamical 4-state model may be used. The slope of
the steady-state line of a bifurcation diagram of Fig. 2 may represent the static
gain of the system which is related to valve properties. The valve equation is assumed
as the following:

where w[kg/s] is the outlet mass flow and ΔP[N/m
2] is the pressure drop. From the valve equation (22), the pressure drop over the valve
for different valve openings may be written as

[0062] Where
a may be assumed to be a constant parameter the calculation of which is described in
more detail afterwards. A simple model for the inlet pressure may then as the following

[0063] Where
Pfo is another constant parameter that is the inlet pressure when the valve is fully
open. By differentiating (24) with respect to
z, one get static gain of the system as function of valve opening

which reduces for a linear valve (i.e.
f(
z) =
z) to

where 0≤z≤1.
[0064] The PID and PI tuning rules given above are based on a linear model identified at
a certain operating point. However, the gain of the system may change drastically
with the valve opening. Hence, a controller working at one operating point may not
work at other operating points.
[0065] One solution may be gain-scheduling with multiple controllers based on multiple identified
modes. In this case simple PI tuning rules based on single step test, but with gain
correction to counteract nonlinearity of the system may be used. For this, the static
model given in equation (25) may be used. In the following a closed-loop step test
using the data in Fig. 4 may be used to calculate

[0066] Where
z0 is the average valve opening in test and
Kc0 is the proportional gain used for the test. The PI tuning values as functions of
valve opening are given as the following:

where
Tosc is the period of slugging oscillations when the system is open-loop and z* is the
critical valve opening of the system (at the bifurcation point).
[0067] Fig. 6 shows some experimental results. In particular, Fig. 6A shows a closed-loop
step test for an experimental set-up similar to the one shown in Fig. 4. In particular,
the responses of a set-point increase for P
in of 2kPa is shown, wherein line 600 represents the data, line 601 represents the set-point,
line 602 represents the filtered response to reduce the noise effect, while line 603
represents the identified closed-loop transfer function.
[0068] The parameters for the experimental set-up are chosen to correspond to the case that
the system switches to slugging flow at 15% of valve opening. Hence, the system is
unstable at 20% valve opening. The control loop is closed by a proportional controller
K
c0=-10, and the set-point is changed by 2kPa. Additionally a low-pass filter was used
to reduce noisy effects. With the above described methods a closed-loop stable system
(equation (7)) was determined to be:

[0069] In a next step from the corresponding identified closed-loop transfer function (see
Fig. 6A) the open-loop unstable system G(s) (see equation (9)) is calculated to be:

[0070] Afterwards λ is selected to be 10 for the IMC design to get the controller C(s) (see
equations (8) and (13)) to be

[0071] The related PID tuning values (see equations (15) to (18)) are then K
p=-4.44, K
i=-0.24, K
d=-60.49, and T
f=2.81.
[0072] Figs. 6B and Fig. 6C shows the result for an anti-slug control for this experimental
set-up. While the described controller for the experimental set-up was tuned for 20%
valve opening it can stabilize the system up to 32% valve opening which shows good
margin of the controller. The system was also stable for up to an additionally added
delay time of 3 seconds. A corresponding PI controller having tunig values K
c=-25.95 and τ
I=107.38 (see equations (20), (21)) did show similar results up to an additional added
time delay of 2 seconds.
[0073] In particular, Fig. 6B shows the time dependence of the inlet pressure for a valve
opening Z of 20%. At 4 minutes the above described PID controller was switched on
while at 16 minutes it was switched off again. One can clearly see that the oscillation
of the input pressure substantially vanishes after the PID controller is switched
on, while it increases again when the PID controller is switched off again.
[0074] Fig. 6C shows the corresponding valve opening Z. Starting at 20% valve opening (which
was the limit for avoiding unstable condition as described in the experimental set-up)
the valve opening slowly increases during the time the PID controller is switched
on while it decreases again to 20% when the PID controller is switched off again at
16 minutes.
[0075] Thus, the experimental results clearly show that an oscillatory slug flow can be
avoided even by an increased opening of the top-side valve used as the anti-slug valve.
Therefore, the PID controller may be an efficient controller to reduce the risk of
slugging while possibly increasing the flow rate due to an increased opening of the
top-side valve.
[0076] In the following some details concerning the model identification calculations are
given.
[0078] By differentiating (A.2) with respect to time and setting the derivative equation
to zero, one gets time of the first peak:

and the time between the first peak (overshoot) and the undershoot becomes:

[0079] The corresponding damping ratio

can be estimated as

where

[0080] Then using equation (A.7) one get

[0081] The steady-state gain of the closed-loop system can be estimated to be:

[0082] From the time of the peak
tp and (A.6) an estimate of Φ can be derived:

[0083] From (A.4) one can get

while the overshoot is defined by:

[0084] By evaluating (A.2) at time of peak
tp one gets

[0085] Combining equation (A.11), (A.14) and (A.15) gives

[0086] The last parameter can be estimated by solving (A.3):

[0088] It should be noted that one has to have
â1>0 to have an unstable system.
[0089] In the following some details concerning calculations of static nonlinearity parameters
are given.
[0090] In particular, the value of the constant
a of equation (23) can be calculated by

where C
v is the known valve constant,
w is the average outlet flow rate and ρ is the average mixture density. The average
outlet mass flow is approximated by constant inflow rates:

[0091] In order to estimate the average mixture density ρ, one can perform the following
calculations:
[0092] Average gas mass fraction:

[0093] Average gas density at top of the riser from ideal gas law:

where P
s is the constant separator pressure, and
Pv,min is the minimum pressure drop across the valve that exists even with fully open valve.
In the numerical simulations
Pv,min is zero but in the experimental set-up 2 kPa was chosen.
[0094] The liquid volume fraction:

[0095] Average mixture density:

[0096] In order to calculate the constant parameters
Pfo in the static model, one can use the fact that if the inlet pressure is large enough
to overcome a riser full of liquid, slugging will not happen. The corresponding pressure
can be defined as

[0097] This pressure is associated with the critical valve opening at the bifurcation point
z*. As a result, one gets
Pfo as the following:

[0098] It should be noted that the term "comprising" does not exclude other elements or
steps and "a" or "an" does not exclude a plurality. Also elements described in association
with different embodiments may be combined. It should also be noted that reference
signs in the claims should not be construed as limiting the scope of the claims.