フラッシュガス圧縮システムにおける制御スキーム最適化によるフレア削減・脱炭素化の推進と運用レジリエンス強化

Unofficial AI-generated summary based on the public title and abstract. Not an official translation.

🔬研究者:動的シミュレーションが定常解析で見逃す短時間の低温逸脱を捉える重要性を示す実証事例。

🏢実務担当者:機器投資なしでフレアとトリップを削減できる制御哲学の再設計手法を、ブラウンフィールド圧縮系に応用できる。

🏛政策担当者:フレア削減規制や排出インベントリ精度向上に向け、運用最適化の費用対効果の高さを示す根拠となる。

Abstract Objectives/Scope This paper demonstrates a field-proven, low-cost control-system optimization that eliminated recurrent flaring, prevented hydrate-induced flash gas compressor trips, and strengthened operational resilience in a condensate stabilization facility. The work combined dynamic simulation, root-cause identification, control-philosophy redesign, field implementation, and performance validation. The solution required no equipment replacement, additional insulation, or chemical-injection package. Methods, Procedures, Process A steady-state and dynamic process simulation model was developed from plant operating data, equipment specifications, piping configuration, control-valve characteristics, and measured temperatures. The model was validated under summer operating conditions and then applied at a winter ambient temperature of 5 C. Six winter cases were evaluated: steady state, dynamic gap control, and continuous modulating control, each with one liquid control valve or both parallel valves in service. Hydrate-formation temperature was compared with the minimum calculated temperature downstream of the third-stage separator liquid control valves. Results, Observations, Conclusions The existing gap-control philosophy accumulated liquid between the controller limits and then drove the valve output to 100%. Under winter conditions, the resulting high transient flow and pressure drop produced severe Joule-Thomson cooling. The predicted downstream minimum temperature reached 13.25 C with one valve and 11.70 C with two valves, both below the 16.12 C hydrate-formation temperature. The optimized continuous modulating strategy stabilized liquid flow and maintained downstream temperatures at 21.62 C and 20.44 C for the one- and two-valve cases, respectively. Field implementation eliminated hydrate-related trips and associated flaring. Before optimization, a compressor trip could flare up to 10 MMSCF of gas, defer approximately 5,000 bbl of condensate production, and generate about 550 tCO2 of avoidable emissions. Novel/Additive Information The study shows that hydrate risk in high-pressure liquid letdown service can be removed through dynamic control-philosophy optimization rather than mechanical or chemical mitigation. It also demonstrates why steady-state analysis alone can miss short-duration low-temperature excursions created by intermittent valve action. The approach is scalable to brownfield compression systems in which transient liquid dumping, winter heat loss, and large pressure reduction interact.

• crossref https://doi.org/10.2118/236472-msfirst seen 2026-11-08 06:05:22