Integrated Stabilizer Column Control for Stable Crude Oil Demand
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Solution Overview
Problem
In crude oil processing facilities, the independent operation of oil stabilizer columns leads to fluctuations in crude oil demand, causing process upsets and requiring operator intervention, which can be time-consuming and prone to human error.
Innovation Solution
A computer-implemented process control strategy that integrates multiple crude oil stabilizer columns under a common control strategy, using real-time process data to determine targeted oil flow rates and maintain continuous crude oil supply across various operating scenarios, including process upsets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple stabilizer columns operate independently with bottom pumps, then each column can process sour crude to sweet crude autonomously, but the total crude oil demand in the header fluctuates causing process upsets
Solution Approach 1:
The patent combines multiple independent stabilizer columns into a single integrated control system. The centralized controller receives feedback from all columns and coordinates their operations to maintain stable total crude oil demand in the header, eliminating the fluctuations that occur when columns operate independently.
Solution Approach 2:
The system implements continuous feedback monitoring of crude oil demand from each stabilizer column and the total header demand. The centralized controller uses this real-time data to dynamically adjust column operations, ensuring that the total demand remains stable even when individual columns experience variations.
2Reliability
If operator action is taken to restore crude oil demand after process upsets, then the crude oil supply can be restored, but the response is time-consuming and subject to human error
Solution Approach 1:
The centralized control system automatically detects process upsets and restores crude oil demand without human intervention. The controller monitors real-time data, identifies when demand falls outside the specified range, and automatically adjusts stabilizer column operations to restore demand, eliminating the need for manual operator response.
Solution Approach 2:
The patent replaces manual operator actions with an automated control system that uses sensors, controllers, and communication networks to monitor and adjust stabilizer column operations. This substitution of mechanical/manual control with automated electronic control eliminates response delays and human errors.
3Reliability
If a common control strategy is implemented for multiple stabilizer columns, then crude oil demand stability is maintained, but the system complexity increases
Solution Approach 1:
The centralized controller serves multiple functions: it monitors crude oil demand from each stabilizer column, calculates total header demand, compares demand against specified ranges, and automatically adjusts column operations. This multi-functional approach consolidates control complexity into a single device rather than requiring separate control systems for each column.
Solution Approach 2:
The centralized controller acts as an intermediary between the multiple stabilizer columns and the crude oil header. It receives data from all columns, processes the information, and coordinates their operations to maintain stable total demand, simplifying the overall system architecture compared to distributed independent control.
Data Source
AI summary
Systems and methods include a computer-implemented method for managing crude oil demand at a crude oil processing plant. Real-time process data is received for the plant and includes quantitative values for conditions and operations at the plant. A multiple stabilizer oil flow control strategy is determined for crude oil stabilizer columns of the plant using the real-time process data. A targeted oil flow rate is determined for each stabilizer column using the strategy. The targeted oil flow rate provides a continuous and on-target crude oil supply to components of the plant in multiple operating scenarios. The on-target crude oil supply includes a range of oil flow volumes required for continuous operation. The plant is operated using the strategy, including maintaining, using the targeted oil flow rate for each stabilizer column, crude oil demand for different combinations of the crude oil stabilizer columns and multiple operating scenarios.