Novel Topside and Subsea Production Optimization, Operational Scheduling, and a Generic Plantwide MPC for Process Systems Control and Production Maximization: Oil, Gas, Water and Utilities Decision-Making with Offloading to Supply Chains and Sustainability

Abstract

The main challenges in oil platforms are how to define optimal setpoints and decision-making for controlling variables due to many existing dynamical production uncertainties while conceding safe operation and minimizing discharge to sea and atmosphere without killing plantwide inventory. A novel scheduling model to optimize the whole essential units of an oil platform production gathering topside and subsea variables is disclosed. A proper topside and subsea scheduling model enables and creates harmony between optimal production, supply chain, costs, and market dynamics, satisfying demands, environmental and operations constraints leading to stability. The interest of the present research lies in determining the optimal topside and subsea operational settings and decision-making, establishing maximum E&P performance and production control setpoints while predicting and manipulating reservoir lifespan and its revitalization. This objective is attained through a novel multiperiod large-scale model for the planning and operational production scheduling and model predictive control (MPC) in oil platforms complying with sustainability, profitability, platform design capacities, and offloading of oil and gas to supply chains or to pipeline exportation. The present model details heat and mass transfer, PVT, flow profiles along a planning horizon and can be used to any oil platform since comprises all the essential unit operations for oil, gas, CO2, H2S and water. The model maximizes the total oil production over any planning horizon. The model is versatile, and decision-making can be either linear or nonlinear but rather a MILP or LP as best choice on optimizing large-scale systems. If the model is applied with auto rescheduling on site within variable hours or minutes, it becomes a real-time optimization schedule approach. Due to its high-velocity performance and robustness, a novel multi-objective function strategy, acting as an LP generic plantwide MPC with industrial scope to maximize production while controlling the process is presented, and as an example is here used to control slug flow to avoid equipment trips and inventory instability, at the same time production is maximized. The output from the decision-making was compared to actual plant data, and the results proved compliance to the design capacity with process safety and sustainability. Comparing to official Brazil's government data for oil, the case study showed superiority to the same size platforms, like FPSOs P-75 and MV32, e.g., more than 101.5% more capacity to produce oil in beginning of campaign after first oil, and 10.5% during campaign. The present work indicates that: 1) the production of millions of barrels is being delayed or left aside; 2) not scheduling production harms the environment and diminish process safety; 3) not scheduling production can create stochastic supply chain deliveries instead of organizing it by deterministic offloading days; 4) scheduling is essential to manipulate, revitalize and monitor reservoir's pressure and content under uncertainty; 5) the oil platform can be automatic optimized by a plantwide MPC reducing human activity/dependency; 6) scheduling gives more transparency to stakeholders and contractors by forecasting business data and capability, and can design, develop or enable new businesses.