DAS-UFSC R&D Efforts for the oil industry

1. Brazil-Norway R&D workshop DAS-UFSC R&D Efforts for the oil industry • Rio de Janeiro, May 26, 2011 AgustinhoPlucenio Laboratory for Smart Fields Automation Department of Automation and Systems Engineering Federal University of Santa Catarina

2. Topics DAS-UFSC R&D Efforts for the oil industry • Who we are • PRH-ANP Program – PRH34 • Research Projects • LACI • INPetro • Ongoing R&D Project • NTNU Cooperation

3. Who we are

4. Who we are • The Federal University of • Santa Catarina • Located in Florianopolis • (pop. 600,000) • 25,000 undergraduates • 3,500 graduates • ≃ 2,000 faculty members

5. Who we are • Department of Automation and Systems Engineering • http://www.das.ufsc.br/das/index.php • 24 faculty members • 360 undergraduates (1st of its kind in Brazil) • 40 M.Eng. students • 50 Ph.D. students

6. Research areas at DAS-UFSC • Control theory and applications • Linear and nonlinear control • Discrete event systems • Predictive control • Robotics • Industrial informatics • Real-time embedded systems • Industrial networks • General computing • Fault tolerance • Secure network systems • Algorithms • Optimization

7. Oil &Gas R&D Evolution Program PRH-ANP34 Multiphase Flow Lab Construction (CNPQ) 1 R&D Project with Petrobras-CENPES NW Control Lab (CNPQ) LACI Project with Petrobras-CENPES Construction Distilation column 2 R&D Project with Petrobras-CENPES 3 R&D Project with Petrobras-CENPES 2006 2001 2004 2008 2009 2010

8. The Program PRH34 Program financed by the National Agency of Petroleum, Gas and Bio fuels for Human Resources Development with the theme Automation and Control for the Oil and Gas Industry.

9. PRH-34is formed by members of the Department of Automation and Systems, Chemical and Mechanical Engineering. Chem. Eng. C&A Eng. Main objective: To complement the education of engineers at the under-graduate and graduate levels in the area of automation, control and instrumentation to work in the petroleum industry. Mech. Eng.

10. Ex PRH34 students

11. Some of PRH34 researches • Automation and Control of wells with elevation by gas-lift, • Optimization of gas-lift operations, • Drilling bit wear prediction using neural networks, • Oscillation control using switched systems applied to severe slug control, • Variable Structure Control for the suppression of oscillations in oil well drilling systems, • ARMAX and NARMAX model identification of oil wells operating by gas-lift, • Model Predictive Control for nonlinear systems, • Low cost water fraction meter based on micro-wave, • Multiphase flow meter based on online partial separators, • Development of New Drilling control techniques based on the theory of • non-smooth dynamical systems, • Nonlinear Model Predictive Control applied to a water injection development • project, • Gas-lift optimization with constraints on transportation and handling • facilities of produced fluids,

12. Research projects • Development of control algorithms for artificial lift methods (Petrobras-CENPES) (2006-2009) • Multiphase Flow meter for heavy oil phase 1 (CNPQ-CTPetro) (2008-2010) • LACI – Laboratory for the Automation of Intelligent oilfields (Petrobras-CENPES) (2008-2011) • Advanced control systems and production real time optimization (Petrobras-CENPES) (2010-2013) • Intelligent agents for distributed control of complex system (Petrobras-CENPES) (2009-2010)

13. Development of Control Algorithms for artificial lift methods-Petrobras CENPES-(2006-2009) Objective: To develop solutions for the automation of oil wells that optimize production using online surface and down hole measurements. One feature of the project is the utilization of Programmable Logic Computers connected with the well simulators and running the control algorithms (HIL concept).

14. Some developments: For continuous gas lift: • Use of different WPC models • pwfsteady state detection via MPA • Automatic procedure via MPA for model parameter update • Automatic procedure for gas re-allocation due to: • gas flow rate availability • well model changes • well put in forced operation • separation capacity constraints • Introduction of control and optimization algorithms in LAPLACE and MPA • Automatic procedures to re-start gas lift wells • Study of a a solution based on NMPC

15. WPC - Well Production Curve

16. Pwf steady state detection

17. Optimization algorithms

18. Control strategies and algorithms

19. GLoptim Main Laplace screen Screen for variables configuration

20. Automatic GL Well restarting During the project 3 approaches were studied for automatically re-starting gas lift wells with: • Classical control • algorithms • Switching Control • Fuzzy Logic

21. GL Control with NMPC GL Hammerstein dynamic model • Control of gas lift wells with NMPC • optimize gas allocation • stabilize GLM pressure • minimizes wellhead flow rate • oscillations during gas lift flow rate • changes GLM Setup

22. Sucker rod pump with down hole pressure measurements Sucker rod pump well • Developments: • Development of a dynamic • simulator • Development of control • strategies using down hole • pressure measurements • Fault detection techniques • using down hole measurements

23. Controller strategy Conventional fluid pound level detection used to update Down hole pressure set-point

24. Fault detection PCA approach Fault patterns a) Normal operation b) Leak in the standing valve c )Leak on the traveling valve d) Fluid pound

25. Multiphase Flow Laboratory LEEM (CTPetro-CNPQ) (2008-2010) Main objective: To initiate research on low cost measurement techniques for multiphase flow for heavy oil.

26. LEEM • Other objectives: • installation of a multiphase flow laboratory for teaching purpose, • to study sensors for water in oil content, flow-rate measurements of gas flow, gas-liquid flow, • to test techniques for the control of severe slug flow, • to study new separation • techniques.

27. Water cut meter using MW cavity ressonator Prototype being developed in the LEEM

28. Inline liquid-gas separator

29. Low volume 3 Phase partial separation multiphase flowmeter Gasflow-ratemeasurement Levelmeasurement Gastreatment (scrubber-compression, etc.) Gas Control system Output valuesofoil, waterandgasflow-rates In linegas-liquidseparator Oil-water Secondstageseparator Liquidflow-ratemeasurement Watercut meter

30. LACI-Laboratory for intelligent oilfield automation-Petrobras CENPES – (2008-2011) Motivation: What is needed to develop and test reliable, catastrophic failure proof automation systems to control remote offshore production facilities like unmanned platforms? Is simulation enough? To build a laboratory to test automation and control of production facilities including oil wells is similar to what was done in the airplane industry with the construction of Wind Tunnels.

31. LACI objectives The facility should be designed for testing optimization algorithms, fault detection and control algorithms conceived to a remote operation scenario. • It should allow: • To test new down hole instruments • To test fault detection (real induced fault) • To test new control and automation surface instruments • To test constraint handling like gas injection flow rate, leaks, etc.

32. LACI Well design

33. Formation static pressure controlled Fluid level controlled to simulate different depletion levels

34. Gravelpackpermeabilitytests Gravelwith 4 grainsizeswereinvestigated: • Gravel 1: 0,59mm a 1,00mm • Gravel 2: 0,71mm a 1,41mm • Gravel 3: 1,00mm a 2,00mm • Gravel 4: 2,00mm a 3,36mm.

35. Dynamic behavior of LACI simulated with OLGA™ Simulations with OLGA™ confirm expected dynamic behavior

36. LACI wells setup The wellheads are installed inside a pit

37. INPetro – UFSC Petroleum, Gas and Energy Institute Created by Research groups from Mechanical , Automation and Systems and Chemical Engineering with financing of Petrobras.

38. INPetro – UFSC Petroleum, Gas and Energy Institute INPetro in the Sapiens Park – art. view Localization in Florianopolis Island INPetro – art. view

39. Inpetro - Construction status May 06,2011 Main building outside view Main building inside view

40. Advanced control systems and production real time optimization (Petrobras-CENPES)(2010-2013) Research Goals: Develop systems for real-time optimization, control and automation of production units and oil fields.

41. Areas to develop • Modeling • Control strategies • Optimization • Fault detection

42. Simplified dynamic models GL - density wave behavior GL - heading behavior

43. Local controllers

44. Local controller Without control With control applied

45. Local controller-Density wave control

46. Optimization modeling and algorithms • Research goals • Models for mathematical optimization of equipment and production processes • Efficient algorithms for real-time optimal operation • Frameworks for system-wide optimization

47. Optimization modeling and algorithms Current research topics • Piecewise-linear models for • optimal lift-gas allocation • and separator alignment • Piecewise-linear models of • multidimensional functions • for pressure constraints • Models for compressor allocation and scheduling

48. Reservoir recovery enhacement with NMPC Using simulators SENSOR ™ and ECLIPSE™ Our initial strategy is to use the knowledge existent in the simulator to build the dynamic representation of the process variables as function of the manipulated variables. Challenge: Is the solution the global optimum?

49. UFSC-NTNU cooperation Since 2007 researchers of DAS-UFSC, NTNU and Petrobras-CENPES have had academic meetings in congress and workshops. Prof. Dr. Ricardo Rabelo, Chief of the Automation and Systems Engineering Department-DAS UFSC talks minutes before signing an academic cooperation term with NTNU . COPPE-UFRJ - February 18/2011.

50. Brazilian Congress of R&D in Oil and Gas Florianópolis, October 9-13, 2011