11/22/2010

Welcome and Introduction

Your worldwide partner

Established: 1971 now including

Headquarter: Oslo, Norway
Employees: 200+
Ownership: Altor, Cubera, Pipeflow Invest and employees

Software, consulting services, training and solutions

2

1
 11/22/2010

Dynamic software solutions, consulting services, and training

Flow Assurance (OLGA)

Drilling Hydraulics (DRILLBENCH)

Reservoir Optimizer and Assisted History Matching tool (MEPO)

eField Solutions (OLGA ONLINE)

Steady state software solutions, consulting services, and training

Well Production & UBD/MPD Analysis (WELLFLO)

Single Pipelines & Complex Networks (PIPEFLO)

Integrated Gas & Oil Field Planning (FORGAS)

OLGA For Process

OLGA components
Slug-catcher

Multi-train separators

Compressor

Multiphase pump

Controllers

Valves

Heat-exchangers Advanced course

General Networks Multi-train separators

Simplified multiphase pump

Controllers

General Networks
4

2
 11/22/2010

Flow Assurance with OLGA

Pipeline sizingf

Insulation requirement

Hydrates formation
Shut-down Cool-down
risk assessment

Slugging

Hydrodynamic Terrain

Maximum liquid surge volumes in the separator

Parametric studies

PVTsim - Fluid property file

Pigging

Advanced Flow Assurance with OLGA

Slug Catcher/Separator sizing

Controllers

Amplification factor for level controller

CV value for drain valve

Blow-down controllers

Heavy Oil option

Viscosity/GOR tuning

Compositional Tracking

Water salt adding

Water hammer

3
 11/22/2010

OLGA - Annual Maintenance and Support (AMS)

Why AMS?
Latest updated version

Verification improvement of OLGA by OVIP

Support

Bug fixing

OVIP
OLGA Verification and Improvement Project

Collect data and identify areas where more data is needed

Compare OLGA to laboratory and field data

7

OLGA 7

4
 11/22/2010

(Next generation)

OLGA Online Architecture

10

5
 11/22/2010

OLGA 6 (OLGA & PETRA)

New C++ software Engine

Consolidation of OLGA and PETRA

Launched
OLGA 5 with new GUI 2006

OLGA 6 2008

OLGA 6 is the platform for the future

11

In this course we use

12

6
 11/22/2010

be dynamic

13

Fluids in OLGA

7
 11/22/2010

FLUIDS

1. OLGA Properties Tables

2. Water Options

15

Standard Properties Fluid Tables

Physical properties required by OLGA

Phase envelope and tables

Gas/Liquid mass transfer

Gas and water fractions in fluid table

Gas and water fractions in OLGA input

Limitations

16

8
 11/22/2010

Non-existing Phase

OLGA requires properties for the non-existing phase i.e. gas or

liquid (artificial properties)

Two methods of extrapolation to single- phase area

Derivatives

Compositional

17

Derivative Extrapolation
calculated at
d (p g 2- ) bubble-P for each T
p g s- p g 2- P for all properties
200 dP
Liquid
150 Regio Liquid
Pressure (bara)

n property is
100 copied from
dew point
line to gas
50 No
area
extrapolation
254 C in T
0
-100 0 100 200 300 400

Temperature (C)

18

9
 11/22/2010

Compositional Extrapolation

p g s- p g 2-
gas is added to elevate the
bubble-pressures to fit the
Extrapolated pressure for each point in
the liquid region. Gas
200 properties for the liquid
region are calculated at
each artificial bubble-point
150 liquid is added to
Pressure (bara)

elevate the dew-

100 temperatures to fit
the temperature for
each point in the
50 gas region. Liquid
properties for the
0 gas region are
calculated at each
-100 0 100 200 300 artificial
400dew-point

Temperature (C)

19

Mass Fractions

Definition in fluid table Definition in OLGA input

Gas mass fraction Gas mass fraction

mgas mgas
mgas always includes
mgas moil water vapour - if any mgas moil

Water vapour mass

fraction Water mass fraction
mwater( vapour) mwater( liquid)
mgas mgas mwater( liquid) moil

Total water mass fraction Total water mass fraction

mwater( liquidvapour) mwater( liquidvapour)
mgas mwater( liquid) moil mgas mwater( liquid) moil

20

10
 11/22/2010

How Gas Mass Fraction Is Integrated

Integrating along the pipeline

Boundary Pipeline
Conditions Section 1

Rsg Rsg
1 0
Rsg
P P
p 1 0
Rsg

T T
T 1 0

Integrating over time

Time n Time n+1

Rsg n 1 Rsg n 1
Rsgn 1 Rsgn P P n T T n
p T

21

How Gas Mass Fraction Is Calculated

Integrating along the pipeline

Taken from fluid table

P1 P0 T1 T0
Rsg Rsg
Rsg1 Rsg 0
P T

Integrating over time

Taken from fluid table

Rsg
n 1
Rsg
n

Rsg

P
n 1 n Rsg
P

P
T
T
n 1
T
n

22

11
 11/22/2010

FLUIDS

1. OLGA Properties Tables

2. Water Option

23

Justification

Slip between water and oil

water accumulation

Oil V1
Water V2

Oil/water dispersions
high viscosity / high pressure drop

Water in Oil Emulsion

24

12
 11/22/2010

OLGA Water Option

Separate mass balance equations for water film and droplets are solved

Velocity difference between oil and water is allowed through a steady

state force balance

Water properties are needed. They can be

Predefined in PVT tables

Calculated by OLGA

25

WATEROPTIONS Waterslip

WATERSLIP = OFF

Homogeneous liquid phase. no velocity

difference between oil and water
Water enthalpies are accounted for
temperature calculations

WATERSLIP = ON

OLGA calculates the slip velocity between

layers or droplets
Recommended when liquid accumulation
could be a problem

26

13
 11/22/2010

WATEROPTIONS Flashmodel
FLASHMODEL = HYDROCARBON
Mass transfer between gas and oil only

Assumes no water vaporization/condensation

FLASHMODEL = WATER
Assumes water vaporization/condensation

No separate mass balance for water vapor

Uses the rate of change of vapor mass

fraction (from the fluid table) to estimate

mass transfer

FLASHMODEL = WATER is disregarded if

water properties are calculated by OLGA

itself or compositional tracking is used 27

Remember
Total water flow in e.g. a mass source
=

Water fraction defined by user at

source (free water)
+
Water in gas phase given by the fluid
table

28

14
 11/22/2010

Oil-Water Dispersion Viscosity

Pal & Rhodes (default)

Ronningsen
BARNEA
WOELFLIN
Experimental
Dispersed phase volume fraction when
relative viscosity = 100
INPUTVSC
Viscosity tuning factors corresponding
to given WATERCUT values

Viscosity Cannot be adjusted for the

Ronningsen, Barnea and Woelflin
methods
29

Oil-Water Dispersion Viscosity

The mixture viscosity for oil continuous dispersions (mhw) and water
continuous dispersions (mwh) are expressed as

hw = h rel.h

wh = w rel.w

Where: h is oil viscosity

w is water viscosity
Dispersion viscosity
rel is relative viscosity =
Viscosity of continuous phase

Relative viscosity calculation method differs according to the

selected model
30

15
 11/22/2010

Tips on Oil-Water Dispersion Viscosity

In case of stable oil-water emulsion

Use a two-phase flow table with water and tune the emulsion
(liquid) viscosity with PVTsim

In case of potential for oil/water separation

Use three-phase flow with dispersion viscosity in OLGA

31

be dynamic

32

16
 11/22/2010

Component Tracking in OLGA

Tracking Modules in OLGA

Compositional Tracking
Tracks all components in three phases

Inhibitor-Tracking tracks a variety of inhibitors

MEG-Tracking (MEG, Methanol)

Tracer Tracking (KHI, CI etc)

Black Oil tracks oil, gas and liquid water

Oil systems (not recommended for GC)

34

17
 11/22/2010

Limitations of OLGA Fluid Table Approach

Any fluid property is a function of P, T and phase composition

Y f f ( P, T , x1, f , x2, f ,... xNC, f )

Total composition is fixed when generating table

Phase composition assumed constant at a given P and T

Amount of phase flowing or in pipeline, may differ from table

35

Compositional Tracking

Why use it ?
Reduce uncertainty and time spent on fluid table mixing and discussions

useful even if results may coincide with standard OLGA

Reduce inaccuracies due to compositional effects

e.g. shut-in and blow-down

Keep track of local composition and components e.g. CO2, H2S,

water and hydrate inhibitors

more general than inhibitor tracking but with longer computing times

36

18
 11/22/2010

Compositional Tracking for Merging Different

Fluids
Compositional Tracking should
be used when fluids of
significantly different
compositions merge

Production from different

reservoirs
is one example of this
scenario

37

Mixing Different Fluids (Tabulated)

Fluid of Fluid of
composition A composition B
Source-1 Source-2

C Fluid A I Fluid A+B P

Example 1
3 kg/s Fluid A
Fluid A+B = 75% Fluid A + 25% Fluid B
1 kg/s Fluid B

Example 2
3 kg/s Fluid A Fluid A+B = 50% Fluid A + 50% Fluid B
3 kg/s Fluid B

38

19
 11/22/2010

Mixing Different Fluids (Compositional)

Fluid of Fluid of
Source-1: composition A Source-2: composition B

C P

No need to specify fluid for a branch, and therefore no need for

making new fluids for new fluid inlet ratios

39

Compositional Tracking for Local Composition

Changes

Slippage

Compositional Tracking is generally required in practical applications

when local composition changes due to gas-liquid redistribution

40

20
 11/22/2010

The Fundamental limitation of The Table Approach

41

Compositional Tracking is Required For...

Gas Lift operations

Sea level Composition in the tubing can change

depending on gas injection (can be
intermittent)

For better book- keeping of gas - use

CompTrack
Mud line

42

21
 11/22/2010

Compositional Tracking is Required For....

shut-in and Blowdown operations

Blowdown Data, Measured vs OLGA With and Without Compositional Tracking

60000

50000

Blowdown test in the Gulf of Mexico

Accumulated Gas Flow, kg

40000

Measured
30000 OLGA with Comp. Track
Standard OLGA

20000

10000

0
0 10 20 30 40 50 60 70 80 90
Time, minutes

43

Profile Shut-down/Cool-down Case - Oil

44

22
 11/22/2010

Shut-down Inlet Pressure Over a 25 Hour

Shut in Period

Comp Track

standard OLGA 5

45

Inverted Profile- Shut-in

46

23
 11/22/2010

Inlet Pressure (Inverted Profile)

standard OLGA 5
Comp Track

47

Apply Compositional Tracking

OPTIONS
COMPOSITIONAL = ON

FILES
Specify the .ctm file
(made with PVTsim)
The .ctm file is ALWAYS needed to
specify individual component properties

COMPOPTIONS
Viscosity option of LBC or CSP

Thermal conductivity SIMPLE or CSP

48
Defaults are CSP

24
 11/22/2010

Applying Compositional Tracking cont.

FEED
You may specify additional compositions (FEEDs) via the OLGA GUI

The components specified must be available in the component list in the .ctm file

Assign FEEDs for SOURCE, WELL, MASS/PRESSURE-BOUNDARY

49

Component Output variables

TREND and PROFILE

Mole fractions
XG, XH, XW, Z

Specific masses
CMG, CMHL, CMHD, CMWL, CMWD

Total component mass in branch

CMTOT

Various flash and equilibrium rate variables

50

25
 11/22/2010

Computing Speed

Special speed-up algorithms

are implemented

You may limit number of components

Limit number of pseudo components when characterizing fluid in PVTsim (Char
Options - default is 12)

Use Same Pseudo when working with multiple feeds.

Use Char Options - Defined to lump light ends

51

Inhibitor Tracking
Consists of MEG-Tracking and Tracer Tracking
MEG-Tracking
Simplified and more time efficient version of Compositional Tracking

MEG-Tracking tracks MEG/Methanol and H2O in liquid water and H2O in vapor

Full mass equation is solved for the inhibitors

Hydrate Curve, Liquid Density and Viscosity changes with inhibitor concentration
Tracer Tracking
Extended Tracer Tracking functionality

Tracks tracer concentration through a pipeline

Uses age groups to track inhibitor at different degeneration levels

No mass equation is solved for the inhibitors

Hydrate Curve, Liquid Density and Viscosity does not change with inhibitor concentration

Typical for low concentration inhibitors like Low Dosage Hydrate Inhibitors (LDHI) and
Corrosion Inhibitors (CI)
52

26
 11/22/2010

Black Oil

Tracks Black-oil components (oil, gas and water) described by a

minimum of information
Specific Gravity of of the oil and gas components

Gas/Oil ratio or equivalent

With water
Specific gravity of the water

Salinity

Watercut

Water is assumed to be inert

No water vapor and no hydrocarbons in liquid water

53

BLACKOILCOMPONENT
Contains a minimum of physical properties for the
Different components

Gas
Gas Specific Gravity

H2S, CO2 and N2 Mole Fractions

Oil
Oil Specific Gravity OR API Gravity

Water
Water Specific Gravity
OLGA help file gives good explanations of the equations used in the model
54

27
 11/22/2010

BLACKOILFEED

Description of a Black Oil stream containing

gas-oil ratio and possibly water cut

55

BLACKOILOPTION
Using the Black Oil Options it is possible to change/tune

GOR correlation
Standing, Beggs, Glas or Lasater (Default)

RSGO (gas dissolved in oil) and Bubble Point

Tuning
Bubble Point Pressure at a given Bubble Point
Temperature

Oil Viscosity Tuning

Oil Viscosity can be tuned at ONE given pressure and
temperature
56

28
 11/22/2010

Summary
Compositional tracking

provides detailed fluid description

keeps track of local composition

reduces uncertainty

Typical cases

merging network with different fluids

track individual components

transient operations (blow-down, shut-in, re-start)

57

be dynamic

58

29
 11/22/2010

Pipeline Geometry in OLGA

Typical Challenges for Hydrocarbon Systems

Liquid management

Sizing of pipelines

Sizing of Slug Catcher

System for liquid inventory control

Operational procedures

- Rate changes

- Pigging

- Shut-down and Restart

Pressure loss

Heat transfer challenges

A good profile is necessary for accurate results

60

30
 11/22/2010

Important Aspects for Modelling

Pipe profile description

Flow model

Liquid Hold-up sensitivity to

Pipe inclination

Production rate

The significance of fluid properties.

Calculation uncertainties
61

Off-Shore Gas-Condensate Field Development

Platform with complete processing
Pipes for single phase transfer of gas and liquids

Platform with de-hydration

Pipes for two-phase flow

Plattform without any processing

Pipes for three-phase flow

Subsea templates (no platform)

Pipes for three-phase flow

Exact calculations are important when the

developments become complex

Good design allows for huge cost savings

62

31
 11/22/2010

Pipeline Profile Survey

Surveys may be too detailed

Noise

Not high enough resolutions results in poor angle distribution

Countour maps will most times be too little??????? detailed

20

-20
Depth [meter]

-40

-60

-80

-100

-120
0 10000 20000 30000 40000 50000 60000 70000 80000
Distance [meters] 63

Angle Distribution for The Pipe

Poor angle distribution (every
0.6) resulting from data
0.45 resolution in a 1 meter survey. (1
cm inclination in 1 m is an angle
0.4 of 0.6)
Fraction per 0.1 degree

0.35
0.3
0.25 Survey
Screened
0.2
0.15
0.1
0.05
0
-2 -1.5 -1 -0.5 0 0.5
1 1.5 2
Angle [degrees] Well balanced angle distribution
for the screened data (screened
every 40 m)
64

32
 11/22/2010

Simplified Profiles

It might be beneficial to divide the

20
profile into areas with similar slope
to better improve the angle
0
distribution filtering of the profile
-20
Depth [meter]

-40

-60

-80

-100

-120
0 10000 20000 30000 40000 50000 60000 70000 80000
Distance [meter]

65

Steps to Simplify a Profile

Do a sscreening of urveys with very high resolutions

Run a steady state simulation at both high and low flow

rate with the original screened profile

Simplify the profile using the angle distribution filter

Compare total pipeline pressure drop for original screened

profile and filtered profile at high flow rate

Compare total liquid (and water) content and pipeline

pressure loss for original screened profile and filtered
profile at low flow rate

66

33
 11/22/2010

The Barrau Method for Pipeline Profile Generation

Bertrand Barrau, Total, developed a method to
characterise pipelines (O&G J, Feb. 21, 2000, p. 61

He uses a pipeline indicator (PI) to generate

random hills and valleys within a given pipeline
length and a given total elevation

67

Background
Based on empirical data

PI is a measurement of the liquid content in the pipeline at a

given set of reference conditions

The reference conditions are a fluid velocity and GLR which is so

low it minimizes the GLR influence, but not so low that PI will differ
dramatically with a small change in pipeline angle

PI is

Dimensionless

Independent of pipeline length and diameter

Independent of the fluid transported

Independent of the operating conditions

0 for perfectly horisontal pipelines

68

34
 11/22/2010

Theory L
S

Where
F(si) = liquid content in segment i
F(0) = liquid content in segment with reference conditions
Li = length of segment i

Reference Terrain Induced liquid content in cubic meters will then be

Where
L = Total length of pipeline (km)
PI = Pipeline Indicator
S = Cross sectional area (m2)
69

Some Rules for PI

0 < PI 20: pipeline is essentially horizontal

20 < PI 40: pipeline is relatively flat

40 < PI 80: Pipeline crosses hilly terrain

PI > 80: Terrain is very hilly - mountainous

PI values less than 20 are very seldom encountered in

reality and are often the sign of an oversimplified profile

70

35
 11/22/2010

Some Regional PI-values for Specific Lines

Offshore Middle-East PI = 26.8

Offshore North Sea PI = 27.8
Offshore North Sea PI = 46.0
Offshore Middle-East PI = 50.1
Offshore Norway PI = 52.0
Onshore Indonesia PI = 88.0

71

3 Profiles Were Tested

78.6 km long

Total elevation: 100 m

PI: 46

A spreadsheet model was used:

it subdivides the pipeline in 50 equally long segments
and creates a random profile between start and end.

The profiles have the same inclination angle distribution

The generation of the profiles are completely random

72

36
 11/22/2010

The 3 Pipe Profiles

73

Inclination Angle Distribution - II

Length of pipe within the 9 angle groups found for the 3

profiles

25000
Total length of pipe within

P-I
20000
P-II
P-III
group (m)

15000

10000

5000

0
1 2 3 4 5 6 7 8 9
Angle group

74

37
 11/22/2010

Pressure 1000 MMScfd - 30 Pipe for All Cases

75

Pressure 250 MMScfd

76

38
 11/22/2010

Liquid Inventory 1000 MMScfd

77

Liquid Inventory 250 MMScfd

78

39
 11/22/2010

OLGA Certainty
Good field data are rare
At low pressure losses the uncertainty in the measurements are
considerable

Difficult to measure liquid inventory methods applied are

cumbersome and quite in-direct
- Pigging
- Rate-changes
Expected uncertainty for gas condensate systems
Pressure 10%

Total liquid inventory 20%

Water inventory >20%

If possible use available data for comparison

Add other uncertainties

79

High Quality Pressure Loss Data Versus OLGA

1.4

1.2
Pressure Drop Predicted/Measured

0.8

0.6
Value = 1 means 100%
match between OLGA and
field data
0.4

0.2

0
0 2 4 6 8 10 12 14 16
Normalized Gas Velocity [m/s]

80

40
 11/22/2010

High Quality Liquid Hold-up Data Versus OLGA

1.4

1.2
Predicted Holdup/Measured Holdup

0.8

0.6
Value = 1 means 100%
match between OLGA and
0.4
field data

0.2

0
0 2 4 6 8 10 12
Normalized Gas Velocity [m/s]

81

Conclusions
Use a profile which follows the sea-bed (terrain) in a realistic
manner

Maintain inclination distribution during simplifications

Liquid hold-up is extremely sensitive to the pipe inclination

The Barrau method seems a good starting point for creating

relevant profiles.

Even apparant large discrepancies in pipe profile

may give similar results for pressure loss and liquid inventory
provided that the pipe angle distributions are equal

Use available measured data to determine the expected

uncertainty
82

41
 11/22/2010

be dynamic

83

Separators with OLGA

42
 11/22/2010

Model Schematics

85

Separator Geometry
A separator can be 2-phase or 3-phase

A separator is modelled as a cylinder

A separator can be horizontal/vertical/table specified

86

43
 11/22/2010

Separator Geometry

Two ways to specify the geometry

Specifying separator length (LENGTH) and diameter (DIAMETER)

Surface area and volume

Specifying level table (LEVELTABLE)

Defined values giving V = f(level)

SURFACEAREA also has to be given

87

Separator
A network component

Can not be inserted the same way as inline process equipment (sources/valves)

Four types of terminals

INLET/GAS/OIL and WATER

One or more flowpaths leads into the separator

Connect at least one flowpath to each terminal type

All terminals allow both in and out flow from the separator
88

44
 11/22/2010

Connections to External Flow Paths

Two phase separator
INLET_1, INLET_N inlets
GAS_1, GAS_N outlets (Use GAS_2 to model flare outlet)
OIL_1, OIL_N outlets (Use OIL_2 to model emergency outlet)

Three phase separator

INLET_1, INLET_N inlets
GAS_1, GAS_N outlets (Use GAS_2 to model flare outlet)
OIL_1, OIL_N outlets (Use OIL_2 to model emergency outlet)
WATER_1, WATER_N outlets (Use WATER_2 to model emergency outlet)
89

Separators Valves/Controllers
Separator has no internal valves and controllers

Valves
Connected to the valves
Must also be defined outside the separator

Controllers
Connected to the valves
Must also be defined outside the separator

Recommendations
Water valve opening is controlled by a water level controller
Oil valve opening is controlled by a oil level controller
Gas valve opening is controlled by a separator pressure controller
90

45
 11/22/2010

Output

Number of separator specific plot variables also are available

Separator Levels (liquid level LIQLV)

Separator Efficiency (SEPEFF)
Separator Pressure (PTSEP)
Separator Temperature (TMSEP)
Liquid Film Volume Fraction (BE)
Separator Oil/Water Level (OILLV/WATLV)
Flowrates on each outlet

91

Separator Levels

92

46
 11/22/2010

Separator Levels
Separator levels
HHWATHOLDUP/LEVEL
water holdup/level above which water drains together with oil

Initial conditions
Key INITTEMPERATURE
gives initial value for the separator temperature

Key INITPRESSURE
gives initial value for the separator pressure

Key INITWATLEVEL
gives initial value for the water level

Key INITOILLEVEL
gives initial value for the oil level
93

Separator Efficiencies
Liquid carry-over
Controlled by gas/liquid separation efficiency effg

Volume fraction of droplets in gas = 1.0 - effg

Droplets flow with gas through gas outlet

Oil/Water separation
Oil volume fraction in water = 1 effo

Separation efficiency effo = 1 - Kso/Trsp

Water volume fraction in oil = 1 effw

Separation efficiency effw = 1 - Ksw/Trsp

Kso = Time constant for separating oil from water, input value
Ksw = Time constant for separating water from oil, input value
Trsp = Liquid residence time

94

47
 11/22/2010

Hints

Drain flow calculation

Drain flow responds instantaneously to changes in driving pressure

or valve openings because inertia of the fluid in the drain piping is
neglected

Separator walls as for pipes

Separator assumed to be a cylinder, vertical or horizontal

Heat transfer through end surfaces neglected

95

Graphical Configuration/Multiphase Coupling of

Separator
Add a node/separator from component view
Connect a flowpath from the node to the separator

Click the node and drag

Release on separator
Connect to in-terminals/connect from out-terminals (node)

96

48
 11/22/2010

Graphical Configuration/Multiphase Coupling of

Separator

Add another node

Connect a flowpath from one of the separator outlets to the node
Click the separator and drag
Release on the node
Connect to in-terminals/connect from out-terminals (node)

97

A Separator in OLGA 6 GUI

98

49
 11/22/2010

Turn-down Ramp-up

Liq. Flow into

separator

Sep. Liq Level

Source flow

99

Separatpr

100

50
 11/22/2010

If You Want a Model of This

101

Complex separator network

102

51
 11/22/2010

be dynamic

103

Controllers with OLGA

52
 11/22/2010

Control General Requirements

Measurement at location
Temperature
Pressure
Level
Flow (mass, volume, phase, at STD conditions )

Set point
Check success
Deviation from the desired state, Error
Continuous update
Control decision
Output signal

Action device
Valve
Heater
Speed
105

Control Objectives

Keep close to or at a set-point

Controller in manual Controller in auto Controller in manual

150

Keep within bounds

Inlet Pressure [Bar]

100

Achieve stability 50

- stabilizing control 0 5 10 15 20 25 30 35

100
Controller
Controller startsstarts
Control value [%]

Inventory control 50

Supervisory control 0 5 10 15 20 25 30 35

Time [hour]

Slug flow Slug control Slug flow (build-up)

Optimizing control
106

53
 11/22/2010

Controllers in OLGA - Brief Introduction

ANTISURGE: Unique to compressors

CASCADE

ESD: Binary output (0-1) if condition is exceeded or Reset

MANUAL
OVERRIDE
PID

PSV: Binary output (0-1) if condition is exceeded or Reset

SELECTOR

Table : Use to define a non-linear relation for a process variable

The controller types marked blue is discussed further in this presentation

107

Manual Controller
Setpoint given as a time series

TIME = (0,10,100) s, SETPOINT = (1,0.5, 0), STROKETIME = 20 s

S
Valve opening and controller set-point vs. time p
1.5 1.5
Relative valve opening (-)

Controller set-point (-)

Valve opening
1 1
Controller set-point

0.5 0.5

0 0
0 20 40 60 80 100 120
108

54
 11/22/2010

PID - Controller
P Proportional: How big is the
P I
D
error NOW?
1 t
de(t )
u Kc e e(t) dt d bias I Integral: How big has the error
i 0 dt been over i?
D Derivative: Is the error
increasing or decreasing?
Where
u = Controller signal, Output
e = Input error = (measured value set-point)
Note
Kc = Amplification factor Kc is outside the parenthesis
ti = Integral time constant
d = Derivative time
Error as defined in OLGA is
bias = Initial value
opposite of negative feedback
definition

109

Sp

PID - Controller FT FC Sp

PT PC

Sp

Used to control V-101 LT LC

Liquid level
LT
Pressure
LC
Flow
Sp

Compressor anti-surge
etc
PT - Pressure transmitter (measurement)
FT - Flow transmitter
LT - Level transmitter
PC - Pressure controller
FC - Flow controller
LC - Level controller 110

55
 11/22/2010

Proportional Control
u Kc ( y ysp ) bias
With
u = output signal from controller (dimensionless)
y = the variable that shall be controlled (units)
ysp = the desired value of y ( i.e. the set-point)
Kc = amplification factor (with dimension 1/units)

Notes
At t = 0 (start-up) u = bias i.e. it is the initial value of the signal. Bias is user specified
When y=ysp i.e. at perfect control, u = bias for a purely P-controller

111

Proportional Control
Kc
u ( y ysp ) bias
NORMRANGE
With

u = output signal from controller (dimensionless)

y = the variable that shall be controlled (units)
ysp = the desired value of y ( i.e. the set-point)
Kc = amplification factor (dimensionless)

Normrange = Optional user-defined value (units of y) which means that

Kc is then dimensionless 112

56
 11/22/2010

Proportional Control

Proportional-control does not eliminate the error

e.g.: we end up with a constant offset

51.0 0.25
50.9 Controller set-point

Control signal (-)

Pressure offset
50.8 0.2
Control signal
50.7
P (bara)

50.6 0.15
50.5
50.4 0.1
50.3
50.2 0.05
50.1
50.0 0
0 10 20 30 40 50 60 70
Time (min)
113

Proportional Integral (PI) Control

Adding Integral time will move the controlled variable towards its

set-point, eliminating off-set

51.0 0.25
50.9
Area
Control signal (-)

50.8 0.2
50.7 Controller setpoint
P (bara)

50.6 Pressure 0.15

50.5 Control signal
50.4 0.1
50.3
50.2 0.05
50.1
50.0 0
0 10 20 30 40 50 60 70
Time (min)

114

57
 11/22/2010

Proportional Integral (PI) Control

The PI-controller is given by the equation

A

t
1
u Kc e
0 e(t) dt bias

i


With
u = Controller signal
Kc = Amplification factor
e = Input error (measured value setpoint)
i = Integral time constant
bias = Initial value

115

Cascade Controller
Combination of controllers (usually 2 PID-controllers) cascaded
Output from PID#1 (overall view, usually slow acting)
is fed as the set-point for (local, usually faster acting) PID#2

Sp

Level-flow cascade
FT FC Sp

PC

PT
Sp
V-101 LT LC
sp
FT FC
LT

LC
Sp

116

58
 11/22/2010

Selector Controller

This controller uses two sub-controllers that are selected based on the
value of selected variables relative to low and high limits of these variables

Sp
LC1: Slow controller, controlling
FT FC Sp
Scaler when liquid level is within normal level
controller
PC

PT
Sp Sp LC2: Fast controller, controlling
V-101 LT LC1 LC2 when liquid level reached high level

LT

LC
Sp
Selector controller objective
switch between the two controllers according to
operating conditions
117

Override Control
The override controller uses the Max or Min value
of two or more sub-controller signals

Sp
Sp
Controllers
Man Min.
Sel.
FC FT manual, PID and override

Override controller objective

W Select the minimum signal of the PID flow
controller and the manual controller

118

59
 11/22/2010

Over-Ride Example

Blowdown at maximum possible rate

Subject to process constraints

Flare limit: 100 MMscf/d of gas................................PID Controller#1
Knock-out drum limit: 1000 bbl/d of liquid................PID Controller#2

Subject to pipeline material constraint

Pipeline temperature limit: 0C.................................PID Controller#3

Let-down valve opening is controlled by Over-ride output

Output = MIN (Output#1, Output#2, Output#3)

119

PI - Controller Tuning

For field matching of existing systems, get the ACTUAL system PID
settings, units, and defined range
Set NORMRANGE to be a reasonable range for the system in the units of
the measured variable (e.g. vessel diameter for level, or Twice the set-point
for pressure or flow)
Set Amplification = [+/-] 0.1 to 1 (dimensionless), If an off-set is not
acceptable, set integral time = 10 to 1000 s

Rule of thumb!

Controller too slow increase Amplification.

Controller unstable decrease Amplification or increase integral action

120

60
 11/22/2010

Controller Tuning Amplification for e.g. Pressure

Estimate Amplification Kc

u u max - u min
Kc
y y acceptable,max y acceptable,min

Dy = acceptable variation in separator pressure (ex. 0.5 bar)

Du = acceptable variation in the controller signal (ex. 0.1)

Estimated amplification Kc is good start for amplification tuning

121

Direct or Reverse Acting Control

Direct acting
Measured value exceeds Set-point (too high)
Increase control output signal (open valve some more)
Kc needs to be POSITIVE
Examples: Level, Upstream pressure (vessel, wellhead)

Reverse acting
Measured value exceeds Set-point (too high)
Decrease control output signal (close valve a bit)
Kc needs to be NEGATIVE
Examples: Flowrate, Downstream pressure (flowline, manifold)

Try it and see whether it goes the right way!

122

61
 11/22/2010

Controller Tuning Integral Time Constant

Very fast process control loops
Dynamic response less than one second
Large amplification - typically
no integral action
Ex: Compressors
Fast process control loops
Dynamic response less than 10
seconds
Integral time in the range of
10seconds
Ex: Pressure controllers
Medium speed process control loops
Dynamic response from 1 to 5 minutes
Integral time constant from 1 to 3
minutes
Ex: Level controllers
Slow process control loops
Integral time constant from 5 to 10
minutes
Ex: Long distance between measurements
and actuator
123

Controller in OLGA

Add Controller
Select the controller type (Manual, PID, ESD, etc)

124

62
 11/22/2010

Controller in OLGA

Specify main controller specifications

125

Controller in OLGA

Add transmitter
To specify the position of
input signal to controller

Specify position by specifying

distance from branch inlet or
by pipe and section numbers

126

63
 11/22/2010

Controller in OLGA

Controller Connections
Use connections page to specify the
controller input and output signals

First method Specify process

Specify branch of Specify variable (pressure,
From display input signal transmitter level,) and its unit
Current object tab

Specify input signal

Specify output signal

Specify branch of Valve receiving

output signal output signal

127

Controller in OLGA

Second method
From display case tab (showing
all control loops)

Specify destination Signal from Signal to Signal type Signal variable and unit
eg: Flowpath (Eg: Transmitter ) (Eg: controller ) (Eg:measurment) (Eg: pressure)

128

64
 11/22/2010

be dynamic

129

Pressure Surges with OLGA and

Simplified Centrifugal Pump

65
 11/22/2010

Safety Related OLGA Applications

Release due to riser/pipeline leakage/rupture

Pressure transients in J-tubes due to rupture in risers
Pressure transients in separators due to valve failures
Pressure transients in heat exchangers due to tube rupture
Flare analyses
Under balanced drilling
Material problems due to cool-down
during pressure transients

131

Gas/Liquid Systems Hazards

Normal production

then compressor trips

P=?

pressure build-up

132

66
 11/22/2010

Gas/Liquid Systems Hazards

Normal production

then separator gas outlet

valve closes suddenly

P=?
pressure build-up

133

Gas/Liquid Systems Hazards

Normal production shut-in

High P

then a valve opens suddenly

P=?

pressure build-up
134

67
 11/22/2010

Example Case: Separator Outlet Blockage

System description
High Pressure gas well PSV (115 bara)

Top of riser choke valve Gas

Platform arrival
choke P ~ 70 bara
Separator design pressure (125 bara)

P ~ 200 bara
10 % overshooting allowed
above the separator design
pressure

Liquid
Tie-back pipeline
Over-Pressure Protection System
High pressure (OPPS) shuts-in the pipeline if a
gas well high pressure is detected upstream
of the platform choke
CITHP ~ 700 bar

135

Example: Vessel Pressure Transient

Event: Blockage of separator outlet valves with platform choke valve open. Well
choke remains at fixed opening. High pressure and high level trips cannot be
relied on. PSV is the only outlet

Result
HIPPS requirement
Set point and activation time calculation using transient simulation
136

68
 11/22/2010

Some Advice and Modelling Aspects

Define system with client

Agree on

system boundaries
initial conditions
incident events in detail including sequence of events
cases that have priority (worst cases)
pressure limits (e.g. 10% above design pressure)
simplifications - systems are complicated!

137

Some Advice and Modelling Aspects

Pipes can accumulate gas: include all relevant compressible volumes

(from isometric drawings)
Maintain detailed accuracy of critical components e.g.
valve Cvs and stroketime
pipe IDs and lengths of primary flowpaths
vessel compressible volumes
OLGA PSV-controller is binary acting
For progressive opening (maximum discharge flare-rate at 10%
over-pressure) use a PID controller with
Set-point = Lift pressure
NORMRANGE=10% x Lift pressure
Amplification, Kc=1

138

69
 11/22/2010

Relevant Simplifications
Lump production use an average GOR

Lump compressible volumes which are not part of primary flow-path

Subtract normal liquid volume from separator model volume during

separator pressure gas transientsmass transfer in separator can be too
efficient i.e. too much gas can condense, which is not conservative

Use OLGA pressure LOSS coefficients for bends

Lump parallel lines if feasible, to avoid split-nodes

A gas compressor can often be modelled with a critical valve

139

Water Hammer
What is water hammer?

140

70
 11/22/2010

Water Hammer Fast Liquid Transients

Water = 3-phase tab file, 3-phase simulation
Set source/boundary to give water inflow only
Small spatial resolution (resolution of the pressure wave)
Uniform spatial resolution (aids solver stability)
Valve closure time < 2L / c
L = Pipeline length
Small fixed time step (MAXDT = MINDT = t)
t = 2Ls/c
Ls = Minimum Section length,
c = speed of sound in liquid = (dl / dp)-1/2
Pressure surge occurs, magnitude dp = l c vl
Fast trend/profile interval to capture the pressure wave
Pipe walls in OLGA are inelastic
141

Accounting for Pipe Wall Elasticity

Pipe wall elasticity reduces the magnitude of the pressure surge

and causes more rapid decay
Speed of sound reduced by a correction factor

l = liquid density
K = Bulk modulus

Pipe wall elasticity correction

(denominator) :
D = inner diameter
e = wall thickness
E = modulus of elasticity
142

71
 11/22/2010

...Pipe Wall Elasticity

Pipe wall elasticity can therefore be accounted for directly in

OLGA by editing the table of pressure derivative of liquid density
in the tab file. Warning: this table is used for critical flow through
valves

Or divide inelastic peak surge pressure by correction factor

143

SIMPLIFIED PUMP APPLICATIONS

Multiphase & Single phase pump
Centrifugal Pump
Positive Displacement Pump (limited application)

Limitation
It can result in error when pump moves beyond the rated point
Recycle flow/ bypass flow is not modelled/ controlled

In general for modelling with accurate pump curves

Advanced pump module is reqired

144

72
 11/22/2010

SIMPLIFIED PUMP EQUATIONS

Po = Pr . (1 + D1 . (N-Nr) + D2 . (Q-Qr) ) . (1-D3)

= r . (1 + E1 . (N-Nr) + E2 . (Q-Qr) ) . (1-E3)
P = Po x /r

With
D1,2,3 = Input coefficients for pressure increase
E1,2,3 = Input coefficients for efficiency increase
= Gas volume fraction
P = Pump pressure increase
po = Pump pressure increase at rated density
Pr = Pump pressure increase at rated flow rate

145

Modelling Simplified Single Phase Centrifugal Pump

Put D3 = 0, as = 0
Calculate D2 = based on flow / head curve
Calculate D1 = based on flw/hd curves at different RPM
For fixed speed pump operating at rated speed, D1 = 0

146

73
 11/22/2010

Example DCOEFF2 Estimation

P = Pr . (1 - D2 . Qr )

D1 and D3 can be zero for fixed speed single phase pump

operating at rated speed
Q = 0 at shutoff head

147

Example DCOEFF2 Estimation

Shut off
head
Actual Pump
Curve
Differential Head (bar)

Simulated
pump
operating line
Rated point

Flow (M3/hr)

The DCOEFF2 should be given considering shut off head if the pump
operation is to be studied from the rated point to the shutoff head
The shaded portion represents the degree of deviation (or error)
between the actual curve and the simulated curve when the pump is
operating from rated point to shut-off head 148

74
 11/22/2010

Example DCOEFF2 Estimation

Shut off
head
Simulated
pump
operating line

Differential Head (bar) Actual Pump

Rated point Curve

Flow (M3/hr)

The DCOEFF2 should be given considering end of curve head if the

pump operation is to be studied from the rated point to the end of curve
The shaded portion represents the degree of deviation (or error)
between the actual curve and the simulated curve when the pump is
operating from rated point to end of curve 149

Example DCOEFF2 Estimation

Deviation from
actual curve
Differential Head (bar)

Deviation from
actual curve

Rated point

Flow (M3/hr)

If DCOEFF2 is given considering end of curve head then the degree of

error from the operating curve would be lower from rated point to the
end of curve
However if the pump moves to shutoff head during the simulation then
the % of error from actual curve will be large 150

75
 11/22/2010

Example DCOEFF2 Estimation

Original
Rated point

Differential Head (bar)

Best fit curve

Shifted Curve from shut off

rated head to end of
point curve

Flow (M3/hr)

Alternatively the rated point could be moved, such that the

entire line could be covered effectively.
However in this case there will be error, even when the pump
is operating at the simulated or actual rated point
151

Modelling of Pumps in Series Tips

Model the suction of
the first pump as a
pressure boundary

Also, a flow controller can

If suction is modelled as a closed
be added, either on a
boundary with a source, model the
discharge valve or on
suction pressure controller (regulating
pump speed
the pump speed)

152

76
 11/22/2010

Modelling of Pumps in Series Tips

The second pump in a series should have a suction pressure
controller (to avoid suction pressure falling too low during
transient operations)

PCs

SC FC

FC

P-03
Pipeline
P-01

P-04

P-02
Booster Pumping station

Pumping
Station

Typical Control structure for pumps in Series 153

Modelling of Pumps in Series Tips

As we know for liquid filled pipelines - the inlet / outlet elevations and
axial length are important to model the system correctly

Overview
286
284
282
y [m]

280
278
276
274

0 200 400 600 800 1,000 1,200 1,400 1,600

x [m]

However, the highest elevation and the lowest elevation in between the
two stations should be captured
(important for the overall hydraulics of the system)
154

77
 11/22/2010

Modelling of Pumps / Liquid Pipelines with

OLGA Application Advantages
On the top of a hill, liquid filled pipelines can face very low
pressures during a
transient operation Overview
286
284
282
Phase separation prediction

y [m]
280
278
(Not just warning!) 276
274

Difficult to restart after a 0 200 400 600 800 1,000 1,200 1,400 1,600
x [m]
shutdown due to phase

separation

During commissioning the flow is essentially multiphase and

commissioning procedures could be made using OLGA
Extent of slugging

Important if there are no slug catcher arrangement 155

be dynamic

156

78
 11/22/2010

Single Component Modelling with OLGA

Multicomponent fluids Single component fluids

(H20, CO2)
(hydrocarbons)

Standard OLGA OLGA Single Component Module

158

79
 11/22/2010

Where do we encounter
single component fluids

159

Steam Injection in Reservoirs - SAGD

(Steam Assisted Gravity Drainage)

160

80
 11/22/2010

CO2 Transport Pipelines and Injection Wells

CO2 injection at the Sleipner A platform in the North

Sea (source: www.statoilhydro.com).

Ground entry of a land based CO2 pipeline in the

Jackson Dome (USA) operated by Denbury Onshore
LLC (source: Polytec report POL-O-2007-138-A).
161

Product Transport Pipelines (Ethylene, Acetylene)

Laying of an ethylene pipeline in northern Germany (source: www.sensornet.co.uk)

162

81
 11/22/2010

It is Recommended to Use The Single

Component Module (SCM) When Simulating...
Pure single component systems
in particular when it involves phase transitions
in general for CO2 and H2O since the fluid properties for these
fluids are modelled more accurately in the SCM

Combined hydrocarbon and steam systems

SteamWater-HC option
can f.ex. simulate systems including both steam and combined
H2O-hydrocarbon pipelines

Drying of pipelines
SteamWater-HC option with modified hydrocarbon properties can also
be done with CompTrack, but simpler, faster and more robust with SCM

163

Standard OLGA is Designed for Simulation of

Multi Component Hydrocarbon Fluids
For such fluids phase changes occur gradually
over a range of pressures and temperatures

164

82
 11/22/2010

Multi Component HC Fluids contd.

Two features of single component phase diagrams create problems for standard
OLGA numerics

Single component fluid no phase envelope

Strong nonlinearities in fluid properties close to critical points
165

Multi Component HC Fluids contd.

issues resolved in new single component module

The solution follows

the saturation line
until enough energy
has been
supplied/removed

Energy considerations when computing mass transfer terms

166

83
 11/22/2010

Multi Component HC Fluids contd.

These issues have been resolved in the new single component module

Energy considerations when computing mass transfer terms

Numerical smoothing of nonlinearities close to critical point
167

Multi Component HC Fluids contd.

Fluid properties change very rapidly from liquid to gas like in a region
close to the critical point
1000 120

Example: CO2 Density

900

800
110

100
Such singular conditions
700 90 are extremely hard to
Pressure (bara)
Density (kg/m3)

600
Critical point 80
handle for a numerical
500 70

400 60
simulator
300 50

200 40

100 30

0 20
0 5 10 15 20 25 30 35 40 45 50
Temperature (C)

To make the numerics robust

and stable in this region, a
buffer zone is introduced

168

84
 11/22/2010

CO2: Comparison of Properties Computed by

OLGA and The NIST WebbookC

169

CO2: Comparison of Properties Computed by

OLGA and The NIST WebbookC

170

85
 11/22/2010

Basic Assumptions for The Mass Transfer

Computations in The SCM
As in standard OLGA, the gas and liquid have equal temperatures,
TM, and pressures, PM

PM, TM

The saturation temperature, TSAT, is computed from PM

Provided that both phases are present

TM > TSAT leads to boiling of liquid
TM < TSAT leads to condensation of the gas

For the SteamWater-HC option, there is also the alternative

TSV < TM < TSAT leading to evaporation of water since the gas is not saturated with H2O
171

Basic Assumptions contd.

For single component systems there is either condensation or boiling

Condensation only occurs if there is available gas and boiling

only occurs if there is available liquid 172

86
 11/22/2010

Basic Assumptions contd.

For SteamWater-HC there is also the possibility of evaporation

Condensation only occurs if there is available gas and

evaporation/boiling only occurs if there is available liquid
173

Basic Assumptions contd.

Fluid Property :To optimize computational speed, fluid property tables are
computed at the start of simulations

The resulting properties are written to a .tab file if

WRITEPVTTABLE = YES, and can be plotted in the GUI
174

87
 11/22/2010

Thermodynamic Properties
CO2: Span and Wagner EOS
S. Span and W. Wagner :A New Equation of State for Carbon Dioxide
Covering the Fluid Region from the Triple-Point Temperature to 1100 K
at Pressures up to 800 MPa J. Phys. Chem. Ref. Data, Vol. 25, No 6, 1996
Up to 300 bar and 250 deg C
- < 0.05 % in density
- < 1.5 % in thermal capacity

H20: IAPWS-IF97 (Intern. Ass. for the Prop. of Water and Steam)
W. Wagner et al., "The IAPWS Industrial Formulation 1997 for the T
hermodynamic Properties of Water and Steam," ASME J. Eng. Gas
Turbines and Power, Vol. 122, pp. 150-182, 2000

Other: Soave Redlich-Kwong EOS with Peneloux correction

Input parameters specified through GUI
Accuracy dependent on fluid
175

Transport Properties:
The Corresponding States Principle (CSP)
Johannes Diderik van der Waals

Substances at corresponding states behave alike

P T v
Pr Tr vr
Pc Tc vc

K. S. Pedersen et al. Properties of Oils and Natural gases. Gulf

Publishing Company, 1989, Houston, Texas
Methane used as reference fluid
176

88
 11/22/2010

New Input for Single Somponent Simulations

1 3

CO2, H2O or Other

Min / Max pressure and

temperature values in the
fluid table generated

These inputs are only

required when
component is selected
as Other

PC = Critical Pressure
2
TC = Critical Temperature

OMEGA = Accentric factor

MW = Molecular Weight

CPIC = Coefficients in
equation for Sp heat

VOLX = Volume tuning

factors to adjust calculated Z

177

New Input for The SteamWater-HC Option

Water and steam fractions can be set in sources and initial conditions

178

89
 11/22/2010

PSAT, PVAP, TSAT and TSV are New Output

Variables in The SCM

In addition, setting WRITEPVTTABLES -> YES writes the saturation

line to a .env file that can be plotted
179

Typical Example- Shut-down and Blowdown of a

CO2 Transportation System

init.
cond.
liquid
gas

Minimum
Temperature
Final
druing
cond
blowdown
180

90
 11/22/2010

be dynamic

181

91