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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
Pipeline Installations
40 miles
1, 2 or 3 pumps in service
Discharge pressure to prevent line overpressure
Suction pressure override to prevent pump cavitation
<
PIC
Dis c harg e
Pre s s ure
Cas e
Pre s s ure
S uc tio n
Pre s s ure
PT
PIC
PT
PT
Pipeline Characteristics
Pipeline diameters from 20 - 48
Large valves (12 20)
Ball and globe
Electro-hydraulic actuators
Valve/actuators costly (> $100K for capital)
Remote locations
Servicing costly (e.g. frequent field tuning not practical)
Northern Alberta
Andes Mountains,
Columbia
Operating Characteristics
Hardisty 3-PCV-1
Valve Position Histogram
50
40
30
20
Frequrency (%)
10
0
0
10
20
30
40
50
60
70
80
90
100
Performance Characteristics
Typical response from wide open conditions
Effectively open-loop
140
100
120
80
100
60
80
60
40
Pressure (psig)
Alarm Breached
Unit Start
Controller Engaged
40
Unit Stopped
Valve Position
20
20
0
17-Mar-03 12:29:10
0
17-Mar-03 12:29:20
17-Mar-03 12:29:30
17-Mar-03 12:29:40
17-Mar-03 12:29:50
17-Mar-03 12:30:00
17-Mar-03 12:30:10
Performance Requirements
Set-point tracking
Maintain desired flow rate (discharge pressure)
Stable operation required
Value of Simulation
Field Tests
Field Tests
Data Analysis
Field Tests
Data Analysis
Simulation Modelling
Field Tests
Data Analysis
Simulation Modelling
Generate Optimal Settings
Field Tests
Data Analysis
Simulation Modelling
Generate Optimal Settings
Implement Settings
Field Tests
Data Analysis
Simulation Modelling
Generate Optimal Settings
Implement Settings
Verify Performance
Field Tests
Perf. Criterion
Spec.
Unit
Travel
90
deg
Stroke Time
<5
sec
Dead Time
< 0.5
sec
Time Constant
< 1.0
sec
T86
< 2.0
sec
< 0.15
< 1.0
Data Analysis
Installed Cv determination
Ineffective Control
Data Analysis
Features:
Choked flow with cavitation versus flashing distinction
Cavitation index (ISA-RP75.23-1995)
Piping geometry effect (line size reduction)
Reynolds Number effect (high viscosity)
Verified examples
Output Linearization
Counteract process nonlinearities in controller
Controller
Linearization
Process
Process
Linearization
Output Linearization
Controller Tunings
Maximum process gain (PG) from gain curves
Simulated bump test:
60
246
55
244
50
psig
IDEAS Simulation
242
45
240
40
0
10
15
Time (sec)
20
25
30
Controlle
$10,000 Cdn/yr
Pressure Drop
Torque Requirements
Cavitation
Cavitation prediction over allowable operating
range
Select valve with lowest cavitation potential
Advise operations of potential cavitating operating regions
Economics
Faster control = closer operation to constraints
Allows pipelines to operate at lower pressures
Large potential pumping energy cost savings
$20-30K/yr (Cdn) for each pump station
Required Actuator Speed
50
45
Existing
40
Re-Engineered
35
30
25
20
15
5
0
0
25
50
75
100
125
150
175
200
225
Conclusions
Engineered approach means:
Predictable performance
Optimal settings for current service conditions
Increased line stability
Higher throughput, lower pumping energy costs
To date in Enbridge:
40+ evaluations
11 commissioned