Tank overflowing early warning control algorithm for three-phase separator

Abstract

The invention relates to the technical field of oil and gas treatment, in particular to a three-phase separator over-tank early warning control algorithm which comprises the following steps: S1, a data acquisition module; liquid level height data are collected in real time through a high-precision liquid level sensor installed in the three-phase separator, and dynamic change information of the liquid level along with time is obtained; s2, a data processing module; s2.1, the collected liquid level height data are preprocessed; s2.2, data screening conditions are set; s3, an algorithm module; the interior of the horizontal three-phase separator is usually composed of an oil chamber and a settling chamber; and S4, a tank overflowing early warning control module. Based on the dynamic change of the liquid level data, in combination with the geometric characteristics of the container, the accurate calculation of the volume change is realized. Compared with a traditional mode depending on flow or other indirect parameters, the method is simpler, more convenient and more efficient, and the actual situation can be reflected in real time.

Description

Technical Field

[0001] The invention relates to the technical field of oil and gas processing, and in particular to an early warning control algorithm for a three-phase separator tank bursting. Background Art

[0002] The horizontal three-phase separator is the core equipment in the oil and gas processing system. It is mainly used to separate the three phases of oil, gas and water in the produced fluid. Its operating status is directly related to the safety and stability of the entire oil and gas processing process. However, in actual production, the drastic fluctuations in the produced fluid flow rate and the instability of the gas-liquid mixing ratio make the liquid level control face great challenges, and the problem of liquid level out of control occurs from time to time. Once the liquid level is out of control and is not dealt with in time, it may cause tank bursting, which will not only cause physical impact and damage to the separator body, but also interfere with the normal operation of downstream equipment, increase the risk of system failure, and even cause serious safety accidents, posing a major threat to the production process. Therefore, how to accurately predict and effectively control the liquid level changes and avoid tank bursting has become a core technical problem in the operation and management of three-phase separators. Summary of the invention

[0003] The purpose of the present invention is to solve the above-mentioned shortcomings in the prior art, and to propose a three-phase separator tank bursting early warning control algorithm, based on the technical solution of liquid level dynamic prediction and control, aims to achieve stable liquid level control and avoid the occurrence of tank bursting through real-time collection of liquid level data, accurate calculation of tank bursting time and execution of intelligent control strategy.

[0004] In order to achieve the above object, the present invention adopts the following technical solutions:

[0005] Design a three-phase separator tank bubbling early warning control algorithm, the three-phase separator tank bubbling early warning control algorithm is as follows:

[0006] S1, data acquisition module;

[0007] The high-precision liquid level sensor installed in the three-phase separator collects liquid level height data in real time and obtains information on the dynamic changes of liquid level over time;

[0008] S2, data processing module;

[0009] S2.1, pre-processing the collected liquid level height data;

[0010] S2.2, data screening conditions;

[0011] S3, algorithm module;

[0012] Calculation of tank bubbling time: The interior of a horizontal three-phase separator usually consists of two parts: an oil chamber and a sedimentation chamber;

[0013] S4, tank bursting warning control module;

[0014] The core goal of the tank burst warning control module is to divide the risks into different levels according to the calculated tank burst time T, and adopt targeted control strategies to achieve timely warning, graded response and effective control.

[0015] In detail, the solution in S2.1 is as follows: remove outliers and missing values, and extract data in time periods t (such as minutes).

[0016] In detail, in S2.2:

[0017] Condition 1: The last liquid level height data is greater than the initial data;

[0018] Condition 2: The last liquid level data is greater than the partition height + dynamic threshold.

[0019] In detail, the mechanism method in S3 calculates the tank bubbling time and dynamically adjusts the liquid level control strategy according to the calculation result.

[0020] In detail, the oil chamber level gauge in S3 dynamically monitors the liquid level height and accurately measures the volume change of the fluid inside the separator by analyzing the change pattern of the liquid level height over time.

[0021] In detail, the tank bubbling time in S4 is graded and includes a normal state, a warning state, a dangerous state and an extremely dangerous state.

[0022] In detail, the control strategy in S4 is:

[0023] Under normal conditions, conventional PID control is used to ensure that the liquid level changes smoothly within a safe range;

[0024] In warning and danger states, the control is enhanced by adjusting PID parameters to quickly respond to liquid level changes;

[0025] In extremely dangerous conditions, switch to emergency control mode and adopt the preset forced control strategy.

[0026] In detail, the PID control design in S4 is:

[0027] The PID controller is used to dynamically adjust the operating status of the tank bubbling system. It adjusts the proportional (P), integral (I), and differential (D) parameters in real time according to different tank bubbling time levels and actual working conditions to achieve efficient risk management.

[0028] The design scheme proposed by the present invention has the following beneficial effects during application:

[0029] 1. The present invention realizes accurate calculation of volume change based on the dynamic change of liquid level data and the geometric characteristics of the container. Compared with the traditional method that relies on flow or other indirect parameters, the method of the present invention is simpler, more efficient, and can reflect the actual situation in real time.

[0030] 2. The present invention innovatively introduces hierarchical PID control, which divides the calculated tank bubbling time into multiple risk levels, and uses different PID control strategies for dynamic adjustment. This method ensures control accuracy while avoiding the increase in energy consumption or insufficient regulation that may be caused by traditional single control strategies, thereby improving the stability and safety of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 A simplified flow chart of the tank bubbling early warning control scheme of the present invention;

[0032] Figure 2 The present invention provides a simple structure of a horizontal three-phase separator. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0034] Reference Figure 1-Figure 2 , a three-phase separator tank bubbling early warning control algorithm, the three-phase separator tank bubbling early warning control algorithm is as follows:

[0035] S1, data acquisition module;

[0036] By installing a high-precision liquid level sensor in the three-phase separator, the liquid level height data is collected in real time to obtain the dynamic change information of the liquid level over time.

[0037] S2, data processing module;

[0038] S2.1, pre-processing the collected liquid level height data;

[0039] The solution is as follows: remove outliers and missing values, and intercept the data in time periods t (e.g., minutes);

[0040] S2.2, Data screening conditions:

[0041] Condition 1: The last liquid level height data is greater than the initial data;

[0042] Condition 2: The last liquid level data is greater than the partition height + dynamic threshold;

[0043] The size of the dynamic threshold can be dynamically adjusted according to specific working conditions (such as pressure, flow, etc.).

[0044] S3, algorithm module;

[0045] In the production process of the petroleum industry, the three-phase separator is one of the key equipment, and its operating status is directly related to production efficiency and safety. However, during operation, due to factors such as the drastic fluctuation of the incoming liquid volume, the three-phase separator is at risk of bursting. Once a bursting occurs, it will not only cause equipment damage and production interruption, but may also cause serious environmental pollution and cause huge economic losses. Therefore, accurate early warning and effective control of the three-phase separator bursting are crucial.

[0046] The present invention calculates the tank bursting time based on a mechanism method, and dynamically adjusts the liquid level control strategy according to the calculation result, thereby effectively reducing the tank bursting risk and ensuring the safe operation of the equipment.

[0047] Calculation of tank bubbling time:

[0048] The interior of a horizontal three-phase separator usually consists of two parts: an oil chamber and a settling chamber;

[0049] This method is based on the dynamic monitoring of the liquid level by the oil chamber level gauge, and by analyzing the change of the liquid level over time, the accurate calculation of the volume change of the fluid inside the separator is achieved;

[0050] When the collected liquid level data exceeds the set height of the baffle, the liquid level change in a specific time period is used to calculate the tank bursting time of the separator;

[0051] Compared with the traditional method, this method does not need to rely on the inlet and outlet flow data of the three-phase separator, and can complete the prediction only through the dynamic monitoring of the liquid level height, which greatly simplifies the configuration requirements of the monitoring equipment and ensures the reliability of the prediction.

[0052] 1. When the liquid level height in the oil chamber h>H (partition height), the liquid level volume of the horizontal three-phase separator can be calculated according to the following formula:

[0053]

[0054] Where R is the cross-sectional radius of the cylinder;

[0055] L1----the length of the oil chamber cylinder;

[0056] L0----the length of the cylindrical body of the sedimentation chamber;

[0057] h----Liquid level height;

[0058] b---- radius of the minor axis of the ellipsoid;

[0059] 2. When the liquid level height in the oil chamber h≤H (partition height), the liquid level volume of the horizontal three-phase separator can be calculated according to the following formula:

[0060]

[0061] Where H is the height of the partition;

[0062] The meanings of other symbols are the same as above;

[0063] 3. The total volume calculation formula of the horizontal three-phase separator is as follows:

[0064]

[0065] The meaning of symbols is the same as above;

[0066] When calculating the tank bubbling time, the present invention needs to use valid data processed by the data processing module to ensure the accuracy and stability of the calculation results;

[0067] Assume that the collected data time period is t, and the data is [h0, h1] (representing the starting liquid level and the final liquid level respectively).

[0068] When the liquid level height h0≤H at the initial moment, the calculation formula of the tank bubbling time T is as follows:

[0069]

[0070] When the liquid level height h0>H at the initial moment, the liquid level volume at the initial moment is:

[0071]

[0072] At the end, the liquid level is h1 and the volume is:

[0073]

[0074] The calculation formula of the bubbling time T is as follows:

[0075]

[0076] S4, tank bursting warning control module;

[0077] The core goal of the tank burst warning control module is to divide the risks into different levels according to the calculated tank burst time T, and adopt targeted control strategies to achieve timely warning, graded response and effective control, thereby ensuring the safety and efficiency of the production process.

[0078] Tank bubbling time classification

[0079] According to the calculated tank bubbling time T, the risk level is divided into the following categories:

[0080] Normal state: T>T safe ;

[0081] Warning status: W warm <T≤T safe ;

[0082] Dangerous status: T danger <T≤T warm ;

[0083] Critical state: T≤T danger ;

[0084] Where T safe , T warm , T danger They respectively represent the time corresponding to the normal state, warning state and dangerous state, and can be set according to actual conditions.

[0085] Control strategies;

[0086] Under normal conditions, conventional PID control is used to ensure that the liquid level changes smoothly within a safe range.

[0087] In warning and danger states, the control is enhanced by adjusting PID parameters to quickly respond to liquid level changes.

[0088] In extremely dangerous conditions, switch to emergency control mode and adopt preset mandatory control strategies (such as fully opening the pump or starting safe discharge).

[0089] PID control design;

[0090] The PID controller is used to dynamically adjust the operating status of the tank bubbling system. It adjusts the proportional (P), integral (I), and differential (D) parameters in real time according to different tank bubbling time levels and actual working conditions to achieve efficient risk management.

[0091] The PID controller consists of proportional (P), integral (I) and differential (D) control, and the mathematical formula is as follows:

[0092]

[0093] in:

[0094] e(t) is the system error, i.e., the difference between the target liquid level and the current liquid level;

[0095] K p , K i , K d are proportional, integral and derivative gains respectively;

[0096] u(t) is the control output (such as adjusting valve opening or pump speed).

[0097] The following are specific adjustment measures based on actual operating conditions:

[0098] Safety level (Level 1): T>T safe ;

[0099] Adjustment target: Keep the system running normally and ensure the liquid level is stable.

[0100] Parameter settings:

[0101] Proportional coefficient P: A small value (such as 0.5) only responds slightly to changes in liquid level.

[0102] Integration time I: A larger value (e.g. 100) reduces the integration effect and avoids over-regulation caused by small deviations.

[0103] Derivative time D: A smaller value (e.g. 10) suppresses slight fluctuations.

[0104] Adjustment measures:

[0105] Monitor liquid level changes regularly to ensure there are no abnormal fluctuations.

[0106] Warning Level (Level 2): ​​W wam <T≤T safe ;

[0107] Adjustment target: gradually reduce the rate of increase of the liquid level in the tank to prevent it from reaching a dangerous level.

[0108] Parameter settings:

[0109] Proportional coefficient P: medium value (e.g. 1), moderate response to level deviation. Integral time I: medium value (e.g. 50), accelerated deviation correction.

[0110] Differential time D: A slightly larger value (e.g. 15) can enhance system stability.

[0111] Adjustment measures:

[0112] Appropriately reduce the feed flow rate, giving priority to ensuring that the liquid level in the tank drops slowly.

[0113] Danger Level (Level 3): T danger <T≤T warm ;

[0114] Adjustment goal: Quickly adjust the liquid level to reduce risks.

[0115] Parameter settings:

[0116] Proportional coefficient P: A larger value (e.g. 2) enhances the rapid response to liquid level changes. Integral time I: A smaller value (e.g. 20) quickly eliminates deviations.

[0117] Derivative time D: A moderate value (e.g. 30) that balances response speed and stability.

[0118] Adjustment measures:

[0119] To speed up liquid discharge or transfer, enable alternate three-phase separator diversion.

[0120] Severity level (Level 4): T≤T danger ;

[0121] Adjustment target: Emergency control of liquid level to avoid tank overflow accidents.

[0122] Parameter settings:

[0123] Proportional coefficient P: Maximum value (e.g. 3) to ensure fast response.

[0124] Integration time I: minimum value (e.g. 5), quickly corrects the liquid level deviation.

[0125] Derivative time D: A larger value (e.g. 50) can suppress sharp fluctuations.

[0126] Adjustment measures:

[0127] Close all liquid inlet valves.

[0128] Activate the emergency discharge system to force the liquid level down.

[0129] Strengthen manual monitoring to ensure the effectiveness of the implementation of control strategies.

[0130] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A three-phase separator tank bubbling early warning control algorithm, characterized in that: The algorithm for early warning control of three-phase separator tank leakage is as follows: S1, data acquisition module; The high-precision liquid level sensor installed in the three-phase separator collects liquid level height data in real time and obtains information on the dynamic changes of liquid level over time; S2, data processing module; S2.1, pre-processing the collected liquid level height data; S2.2, data screening conditions; S3, algorithm module; Calculation of tank bubbling time: The interior of a horizontal three-phase separator usually consists of two parts: an oil chamber and a sedimentation chamber; S4, tank bursting warning control module; The core goal of the tank burst warning control module is to divide the risks into different levels according to the calculated tank burst time T, and adopt targeted control strategies to achieve timely warning, graded response and effective control.

2. The three-phase separator tank rupture warning control algorithm according to claim 1 is characterized in that: The solution in S2.1 is as follows: remove outliers and missing values, and extract data in time periods t (such as minutes).

3. The three-phase separator tank rupture warning control algorithm according to claim 1 is characterized in that: In S2.2: Condition 1: The last liquid level height data is greater than the initial data; Condition 2: The last liquid level data is greater than the partition height + dynamic threshold.

4. The three-phase separator tank rupture warning control algorithm according to claim 1 is characterized in that: The mechanism method in S3 calculates the tank bubbling time and dynamically adjusts the liquid level control strategy according to the calculation result.

5. The three-phase separator tank rupture warning control algorithm according to claim 1 is characterized in that: The oil chamber level gauge in S3 dynamically monitors the liquid level height and accurately measures the volume change of the fluid inside the separator by analyzing the change pattern of the liquid level height over time.

6. The three-phase separator tank rupture warning control algorithm according to claim 1 is characterized in that: The tank bubbling time in S4 is classified into a normal state, a warning state, a dangerous state and an extremely dangerous state.

7. The three-phase separator tank rupture warning control algorithm according to claim 1 is characterized in that: The control strategy in S4 is: Under normal conditions, conventional PID control is used to ensure that the liquid level changes smoothly within a safe range; In warning and danger states, the control is enhanced by adjusting PID parameters to quickly respond to liquid level changes; In extremely dangerous conditions, switch to emergency control mode and adopt the preset forced control strategy.

8. The three-phase separator tank rupture warning control algorithm according to claim 1 is characterized by: The PID control design in S4: The PID controller is used to dynamically adjust the operating status of the tank bubbling system. It adjusts the proportional (P), integral (I), and differential (D) parameters in real time according to different tank bubbling time levels and actual working conditions to achieve efficient risk management.

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