MFA Control and Optimization
of Oil Recovery Boilers
| Use
of CyboSoft's Technology |
|
|
| • Soft-sensor measurement of steam dryness
in CyboMax to monitor the steam quality. |
• Monitors boiler steam dryness online to
ensure consistent quality of steam for higher oil
yield. |
| • MFA control of steam dryness, temp, and
pressurewith optimal fuel-and-air ratio. |
• Improves boiler combustion efficiency
while optimizing steam production and oil yield.
|
| • Easy integration and startup. |
• ROI in 1 year on energy savings (yield
increase extra). |
CyboSoft's
EOR Steam Boiler Control and Optimization Solution
Process: Light crude
oil can be easily recovered by using the natural gas
pressure within the reservoir and sub-surface pumping.
However, heavy crude oil requires enhanced oil recovery
(EOR) such as steam flood recovery. High pressure steam
is injected into the reservoir. The steam and resultant
hot water lower the viscosity of the heavy crude oil
and enable it to flow into the reservoir and then be
pumped to the surface.
Challenges: High pressure steam is
generated by using special steam boilers. It is difficult
to monitor and control the quality of the steam-steam
dryness. The optimal steam dryness for oil recovery
is at 72%. If it is too dry, too much energy is wasted.
If it is not dry enough, the steam will not have enough
power to dissolve the oil.
Steam Dryness: Typically, steam dryness
is manually determined by measuring the pH value of
boiler inflow water and condensed water by using a test
kit. Since it requires pH titration, it is a tedious
job. The periodic test does not provide real-time data
for automatic control of steam dryness.
Goals: To efficiently achieve maximum
oil yield, it is desirable to monitor and control the
steam dryness automatically.
Solution: CyboSoft offers a turnkey
solution for steam dryness measurement and control.
By using a special soft-sensor technology, steam dryness
can be accurately calculated online. Model-Free Adaptive
(MFA)
controllers are used to automatically control steam
pressure, temperature, dryness, and water flow to ensure
efficient and smooth boiler operation.
MFA Control: A 3-element MFA control system
is implemented to control the dryness and critical process
variables. Fuel-and-air ratio is auto-adjusted to improve
combustion efficiency.
Application Story: PetroChina has deployed
multiple MFA control and optimization systems for its
EOR steam boilers in Liao-He Oilfield. PetroChina has
certified the following success:
• A 3% to 4% increase in boiler combustion efficiency;
• A 17.6% electricity savings;
• Steam dryness measurement accuracywithin +/-
1%;
• Steam dryness control within +/- 3% in all operating
conditions; and
• Improved production safety and productivity.
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