Automation of Natural Gas Separation - Diploma

Contents

Entry

1 Description of GPU enterprise structure

1.1Productive Activity Analysis

1.2 GPU control structure

2 Operation of the existing process train diagram for gas preparation

2.1 Description of the process of the existing schema

2.2 Description of FSA using local automation systems

3 Description of developed process line diagram for gas preparation

3.1 Process description of the developed diagram

3.2 Description of developed microprocessor-based FSA

Conclusion

Introduction

In the field of automation, revolutionary changes have occurred over the past decade. This is especially true of Russia. The former Soviet electronics industry could not withstand market changes and could not meet the demand for high-quality new generation controllers in the early 1990s. By this time, new directions of automation of technological processes had already appeared in the world and completely took shape. And they were based primarily on the use of microprocessor technology, personal computers, controllers operating under the control of specialized software. By this time, a fairly large gap had formed between what had already been developed in the world in the field of automation and what Russia remained at the turn of the 1980s and 1990s.

Nowadays, it is difficult to find areas of production or technological processes (TP) in which computing technology would not be used or could not be used as an automated control tool.

Over the past decade, the level of automation of Russian industrial production has significantly increased and qualitatively transformed. High-reliability, functionally developed open distributed control systems (DCS) TPs are widely used in enterprises of different industries.

For our time, from the point of view of automation, the transition from local automated control systems (ACS) to multi-level automation of enterprises is characteristic. The creation of an integrated automated process control system for APCS gives the greatest effect in the automated control of the entire technology, and not only the main one.

The development of APCS in our country has passed three major stages, characterized both by the level of technical means used and the functions assigned to them.

The first stage of creating APCS is associated with the use of computers "Ural," "UM1," "Minsk-32." Such systems are characterized by the autonomous functioning of traditional means of processing and presenting operational information: instrument panel, mnemonic circuit, control panels (as a rule, individual version). Due to its high cost and limited capabilities, computing equipment (HT) was entrusted with the tasks of calculating set points for the optimal operation of the process and technical and economic indicators (TEP) of production work; preparation of reporting documents; recording and analysis of operational personnel actions; centralized monitoring of parameters on call; calculation of parameters, direct measurement of which is difficult. The mathematical support was individual for each system.

Process control (PT) in such systems is usually centralized at the level of production sites and departments. Changing technology is almost always associated with a lot of time and money for an adequate change in technical and mathematical support.

The second stage of APCS creation was based on computers of types EU, M6000, -7000, SM; they are characterized by the widespread use of centralized control and control, technical means previously used in telemechanics systems, such as mosaic-type mnemonic circuits, telemechanical devices for collecting analog and discrete information, universal control panels for technical means (including computing). The consoles are equipped with indication stations and printing devices. The functions of the computing part are expanded due to the introduction of direct digital control (NIC), the development of advice to operational personnel on the distribution of loads and other control effects. The instrument board is limited to recording instruments. Mathematical support is largely standardized by modules, blocks, tasks invariant to the number of incoming variables.

PI management is usually centralized at the workshop level, occasionally production. Changes in technology lead to relatively low costs for changes in APCS. Alterations can be made during several working shifts.

The third stage of APCS construction was formed based on the use of a PC. These ACS are characterized by the widespread use of microcontrollers, network methods of information exchange. The functions of the system are expanded due to the control of an increasing number of non-stationary TPs. Graphical SCDONBASS systems with large symbol libraries and rich animation capabilities are emerging and finding proper use. The multi-window interface allows you to most clearly present the necessary information, messages of alarm systems and advice to operational personnel; instrument panels and panels are eliminated. Mathematical software consists almost entirely of ready-made modules that create such operator interfaces, control programs and other functional applications, which are most suitable for solving specific problems.

PI management is generally centralized at production level. Changes in APCS related to changes in technology can be made without shutdown and introduced as process equipment is ready.

The use of APCS allows to minimize human participation in the technological process, which is especially important in high-risk industries, explosive and chemically hazardous facilities. Due to the presence of highly toxic and explosive-fire hazardous chemical products in the technological cycle of the object under consideration, it can be attributed to such industries.

The main objectives of the APCS are:

- provision of remote, automatic or software control of operations, individual units or process equipment elements from the central control room;

- provision of process control in normal, emergency and post-accident modes;

- provision of operational personnel with sufficient, reliable and timely information on operation modes, process progress, state of units or control elements

- optimization of technical and economic indicators;

- increased reliability of equipment operation;

- improvement of operating personnel working conditions.

Business Activity Analysis

The purpose of the GPU is to extract, prepare and transport gas and condensate for subsequent processing at gas processing plants in order to obtain raw materials for the chemical industry and other industries, as well as fuel for energy enterprises.

The main production units are the operational production services of the OPS (1, 2, 3, 6, 7, 8, 9, 12, 14, 15, the gas, oil, condensate production workshop), which serve the integrated gas treatment plants (UKPG -1-15) and the fund of production wells; gas compressor service consisting of three booster compressor stations (DCS 1, 2, 3) and booster pump station (CSN), linear operation service (LES), which serves the pipelines of the Navy and industrial effluents.

GPU control structure

Control and control of production, separation and transportation of oil, gas and condensate to gas supply control (GPU) is carried out by various services.

One of the main services at the enterprise is the Production and Dispatch Service (PDS), which includes all information about the production of oil, crude gas, condensate and the consumption of purified gas for production needs from all integrated gas treatment plants (UKPG) and booster compressor stations (DCS), about all emergencies and accidents. The PDS dispatcher is subordinate to all replacement masters of the UKPG, DKS and dispatcher of all GPU services. He manages all the special transport. The PPP manager can observe information on the computer monitor. He can contact any installation and monitor the replaceable dispatchers.

The GPU has a production automation service (SAP). It is responsible for all instrumentation and for the operation of APCS at all UCCS and DCS. At all UKPG and DKS there are watch teams of instrumentation and A fitters, who monitor the operation of instruments on the spot, carry out minor repairs of all instrumentation (instrumentation), and in case of serious malfunctions, emergency repair teams of this or that equipment are called. A replacement dispatcher is on duty in SAP. It is connected with all FGM and DCS, it also receives information on oil production, condensate crude gas and purified gas consumption. The SAP dispatcher can send emergency teams to any installation to eliminate accidents, if necessary.

There is also a power supply service (SES), which is responsible for the power supply of all UKPG and DKS with power supply and power supply 220V. Also, a shift electrician is on duty at all installations, who, if necessary, has the right to minor equipment repairs, and in case of complex accidents, causes a repair team. A replacement dispatcher is on duty in the SES, which communicates with the installations and, in case of accidents, emergency teams leave for the elimination of accidents, if necessary.

The company has a mechanical repair service (MRS), which is engaged in the repair, revision and manufacture of new gate valves, dampers, diaphragms, and so on. Each installation has one replaceable machine tool, which can produce simple single parts for on-site repair. The MRS includes a fleet of various metalworking machines, which are abbreviated by machine tools. There are also technologists who, if necessary, draw drawings for manufacturing on machines.

The GPU also has an Environmental Protection Laboratory (SPA), which monitors the maximum permissible concentrations (MPC) of harmful substances in the environment at GPU facilities and around settlements. LOOS has several visiting control teams subordinate to it, which daily leave in several directions and control the environment, especially control is carried out in nearby settlements, and during planned preventive repairs (PPR), environmental control is carried out more often. If the MPC is exceeded, the visiting brigades inform their replacement master, who in turn informs the GPU management, PDS dispatchers, SAP and gas boosters. Depending on the accidents, emergency crews leave.

The complex gas treatment unit - 1 is designed for preliminary separation of raw gas, its transportation and condensate to DCS - 2 and further to the gas processing plant (GPP). It has a central control panel, which has a panel of instrumentation, hands-free communications, communications with the production control service, the production automation service, and so on. A replaceable dispatcher can observe gas production on a computer monitor. It can control the gas and condensate production process through the instrument board. The replaceable dispatcher has teams of gas production operators and instrumentation and A fitters who can carry out on-site ongoing, minor repairs of the equipment.

UKPG-1 consists of three process lines for gas separation. For consideration, take the production line - 1.

The gas production area consists of wells, pipelines, there are also separators of the first stage C101 and second stage C102, there is also a tank with DEG, which heats the separators in the cold season, protecting the process from hydrate formation. It is serviced by replaceable operators and instrumentation instruments by instrumentation locksmith.

Gas metering section consists of differential pressure sensor, pressure sensor, temperature sensor and "IIE Superflow" computer. This drain is serviced by the instrumentation locksmith and A. From the computer, the information is transmitted to the control panel of the UKPG-1, at the same time this information is transmitted to the interchangeable dispatchers of the PDS, SAP and the accounting group.

Condensate measurement unit consists of turbine counter "Nord - 1," which is also served by instrumentation and A locksmith.

Process Description

Crude gas from wells along the plumes is suitable for UKPG - 1 to manifolds. Manifold is intended for collection of well products and its distribution along process lines. Manifold allows to connect the loop to one of the process lines, to start the well to the control separator, if necessary to blow the well to the flare. It is possible to supply gas to underground tanks for condensate displacement, as well as the possibility of ejecting gas from tanks with high-pressure gas from wells.

Crude gas is sent to the process line from the manifold. To disconnect the process line, a control valve is installed at the inlet, having three control positions (local, remote manual from the dispatcher's panel, automatic). The cutoff is automatically activated when the operating pressure in the C101 first stage separator and in the C102 second stage separator is increased when the electric contact pressure gauge (ECM) is actuated by the high gas pressure.

After the control valve, a C04 "pipe-in-pipe" corrosion control device is installed, made of the same material as the equipment of the production line, but with a wall thickness of the inner pipe less than that of the rest of the equipment. In case of corrosion destruction of the internal cavity of the device, gas penetrates into the external cavity, the pressure in which is controlled by the ECM. The signal from it is output to the dispatcher's shield .

After passing C04, the crude gas enters the C101 separator, where the gas and liquid (condensate and water methanol mixture (IUD)) are pre-separated.

The C101 separator is a horizontal type apparatus with a built-in partition, dividing it into two parts. Separation of liquid from gas is carried out due to gravitational forces.

The discharge gas from the C101 separator is supplied to the inlet of the C102 separator. Separator C102 is a vertical vessel. Separation of drip liquid from gas is carried out due to inert forces arising from a sharp change in the direction of gas movement in the separator. Gas inlet to separator is tangential along built-in partition. The liquid drains into the lower part of the apparatus, and the gas, sharply changing the direction of movement, rushes upwards with a vortex flow. At the gas outlet from the separator there is a drip breaker. The separation of hydrocarbon condensate and IUD in the C-102 separator is carried out due to gravitational forces.

The IUD from separator C102 and C101 is discharged into the common IUD header and then pumped into the beds.

From separator C102, the gas is sent to the metering unit. This unit consists of pressure, pressure drop, temperature sensors and a Superflow IIE computer. Then the gas enters the gas pipeline UKPG - 1 - DKS - 2.

Hydrocarbon condensate from the separator C102 and C101 is supplied to the condensate measurement unit and then to the condensate line UKPG - 1 - DKS - 2. All devices and pipelines, the contents of which can freeze, are covered with heat insulation and heated by a coil with hot DEG. DEG heating unit is represented by D102,302,402 heating boilers with circulation system and is intended for heating of process media in process units and heating of instruments, including: - separators of the first step S101, S-201, S301; - separators of the second step S102, S-202, S302; - control C501 separator; - torch C503 separator; - E208 heat exchanger; - drain tanks of E801, E-803 and tanks of installation of preparation of water; - gas-condensate mix of KoNGKM (E208 heat exchanger). A special comb is provided to distribute the DEG to the above streams. The heating system uses 60% DEG solution, which has the lowest freezing temperature. Fresh DEG is poured into the heating boilers and heated to a temperature of not more than 80 0С and supplied by the centrifugal pump J - 02 to the coils of the devices. Cooled glycol is returned to heating. The level of glycol in D-02 is controlled by the instrument involved from the level sensor. Alarm of maximum and minimum level of DEG in boilers LAH - 062, LAL - 062 are output to the dispatcher board. Visual monitoring of the temperature is carried out according to POS TIS - 061, the alarm for maximum and minimum temperature in the boilers is displayed on the TAL manager board - 061, TAH - 061. To visually monitor the pressure in the system, a pressure gauge is installed on the discharge of the pump J - 02, in addition, flowmeters are installed on the line of DEG supply from boilers to distribution combs and devices. When DEG flow rate decreases below the permissible one, the signal is transmitted from the device to the dispatcher panel. Glycol is heated with an open flame. Purified gas from the measuring unit under pressure of 45-50 kg/cm2 is sent for heating to heating boilers D-02 and then to the reduction unit of UNTS. After reduction, with a pressure of 2.53 kg/cm2, the purified gas is supplied to the nozzle of the boiler D - 02. To reduce the gas pressure to 0.5 - 0.8 kg/cm2 for boilers D - 202 - 302, to 0.2 - 0.5 kg/cm2 for boiler D - 102, which is required to supply the boiler nozzle, a control valve with a regulator is installed. To maintain the temperature in the heating boiler D - 02, a temperature sensor is installed, which outputs the pneumatic signal to the control valve. The gas supply control valve maintains the set temperature in the preheating boiler.

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