Amine Pump Override Control for Fail-Start and Trip Prevention
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Solution Overview
Problem
Current sour gas processing technologies are inefficient and unreliable, leading to energy waste, operational inconveniences, and reduced throughput due to fail-starts and safety trips of amine-based gas processing systems.
Innovation Solution
Implementing an override control system with a control loop that includes an override control component and flow indicator controller to precisely actuate flow control valves, overriding auto-start logic signals to maintain optimal flow and pressure in amine gas pumps, thereby preventing wasteful processing interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If auto-start logic control signals are used to manage amine pump operation, then automation extent is improved, but reliability deteriorates due to fail-starts and safety trips
Solution Approach 1:
An override control component is introduced as an intermediary between the auto-start logic component and the flow control valve. This mediator receives control signals from the auto-start logic, modifies them based on current system conditions (flow rate, pressure, pump status), and generates adjusted control signals for the flow control valve. This intermediary layer prevents direct, potentially harmful automated control actions while maintaining automation benefits.
Solution Approach 2:
The override control component continuously monitors system parameters including flow rate (via flow indicator), pressure, and pump operational status. Based on this feedback, the component dynamically adjusts control signals to prevent fail-starts and safety trips. The feedback loop enables the system to detect when automated control signals would cause harmful conditions and override them accordingly.
2Productivity
If flow control valves are actuated based on threshold range violations, then productivity is improved, but loss of time increases due to processing interruptions
Solution Approach 1:
The override control component performs preliminary evaluation of control signals before they are executed. When a parameter exits its threshold range, the component anticipates potential fail-starts or safety trips by pre-adjusting the flow control valve position or modifying the control signal characteristics. This preliminary action prevents processing interruptions before they occur, maintaining continuous throughput.
Solution Approach 2:
The system transitions from static threshold-based control to dynamic, condition-based control. The override control component continuously adapts control signals based on real-time system state, adjusting flow control valve positions dynamically to prevent interruptions. This dynamic approach allows the system to respond proactively to changing conditions rather than reacting passively to threshold violations.
3Use of energy by moving object
If amine pumps operate in active/standby mode, then energy consumption is reduced, but reliability deteriorates due to pump trips
Solution Approach 1:
The override control component dynamically manages the active/standby pump configuration based on real-time system conditions. Rather than static switching, the system dynamically adjusts pump operation to prevent fail-starts and safety trips. When a standby pump is activated, the component monitors conditions and adjusts flow control valves to ensure smooth transition, preventing reliability issues while maintaining energy efficiency.
Solution Approach 2:
The override control component provides beforehand cushioning by pre-conditioning the system before pump mode changes. When switching between active and standby modes, the component pre-adjusts flow control valve positions and monitors system parameters to prevent harmful conditions. This cushioning approach protects against reliability issues during transitions while preserving the energy benefits of active/standby operation.
Data Source
AI summary
The present disclosure generally relates to an override control component for natural gas processing. The control system may include a first memory and first set of one or more processors, the first set of one or more processors configured to cause the override control component to perform one or more steps. The steps may include receiving, from an auto-start logic component, one or more initial control signals generated in response to at least one parameter exiting a threshold range, wherein the at least one parameter exiting the threshold range is caused by an active/standby mode change at one or more amine pumps. The steps may include generating one or more control signals based on the one or more initial control signals. The steps may include outputting the one or more control signals, the one or more control signals configured to cause an adjustment at a flow control valve.