Online Monitoring and Control of Flow rate in Oil Pipelines Transportation System by using PLC based Fuzzy‐PID Controller
Abstract
Along with the development of urban construction and industrial requirements, more and more long distance oil pipelines have built and served. For this, the industries require more reliable, robust, efficient and flexible control system for the automation in oil pipeline system to prevent leakages during transportation. In this paper, a new PLC based Fuzzy-PID controller is designed to automatically regulate the flowrate of the petroleum products at destination by controlling the multiple pressure signals range in the long transmitting concrete pipes. The performance of the Fuzzy-PID controller is compared with the PLC based Cascade-PID controller. The developed PLC based Fuzzy and Cascade-PID controllers are implemented for the lab scale experimental setup and their performance analyses are verified experimentally. The real time data of pressure and flow are monitored through SCADA screen used to provide instantaneous trends using datalogging. From the real time experimental results, it is inferred that Fuzzy-PID controller provides most superior performance with minimum time delay as compared to Cascade-PID controller on upholding flow at specified range by implanting multiple pressures as manipulated parameters.
Keywords:
Oil pipelines ,PLC ,Fuzzy-PID ,Cascade-PID Controller ,SCADA
1. Introduction
Oil transportation pipelines and transferring pump units are the crucial parts of the oil transportation system, whereas it would impede the daily production, cause pecuniary loss [1], even environmental disruption due to the leak of pipeline [9] or abnormal running of power mechanical equipment with certain faults [17]. With the advanced technology development, pipelines are installed with fault diagnosis system [6], leak detection system at the control centre [19], safety monitoring and control of physical parameters [20] etc. The spacing of the cut-off valves being the components of the protection system should be selected depending on the area that the pipelines run through in order to regularize pressure, flow and flash point [5] for the petroleum products to preclude the occurrences of crack in the pipelines.
Various experimental works have been performed by researchers to enhance the performance of oil pipeline transportation systems [2,4] in their pioneering work and developed a method of transportation of viscous oil by injecting small amount of water to reduce pressure drop during flow. Russell et al. [16] proposed a flow pattern in horizontal pipelines on oil–water flow and formulated an architectural model of Computational Parameter Monitoring [7,10] which takes information from the field related to such as pressures, flows, and temperatures to estimate the hydraulic behavior of the product being transported, which may be related to a leak or pressure drops [12,13].
Currently there are many special linear structures deployed with sensors on pipelines to monitor and regulate flow and pressure [3] by implementing suitable conventional controllers [11,15] for monitoring and control of physical parameters. But there is no consideration by insisting remote communication for the operation of control valves for the envisioned petroleum product transportation system [8].In order to overcome the difficulty of maintaining constant pressure ranges [21] at distinct points in long range transmission [17] to obtain the required flowrate at endpoint by control valves based on instantaneous real time data of manipulated parameters, this paper spectacles the implementation of PLC based Fuzzy-PID controller to enhance the performance of control valves operation to get the desired pressure and flow set ranges at the destination to avoid environmental interruptions [14] like leakage or crack/burst in the pipelines transport system.
2. Experimental setup
The replica of the industrial construction (up to 9km long) is built as the lab scale experimental set up of 7m long is shown in Fig. 2. The setup includes the pumping unit, the transmitting pipes for the efficient and long range transmission and multiple analog pressure sensors at various distinct location [3,18] in addition with analog flow sensor at the destination. Along the pipeline, there are usually several pumping booster stations where control valve is installed, which compensate for the pressure loss in the pipeline over these long distances.
A Process and Instrumentation Diagram is visualized in Fig. 1 correspondstothemaintenanceandmodificationofthepipelinestransport system for envisioning the physical sequences of equipment used in the labscaleexperimentalsetupasshowninFig.2andalsodemonstratesall the piping with flow direction and instruments details with their controls [17]. The lab scale set up has three sections includes pressure transmitter (PT),pressure gauge(PG)and gate valve(GV).At the end of two sections equal percentage flow characteristic control valve (CV) is implemented and at the end of third section flow transmitter (FT) has been placed. The controller section includes pressure indicating controller (PIC), flow indicating controller (FIC) and flow controlling controller (FCC). PLC mounted FCC decides the level of control valve opening on the basis three PIC signals in which this FCC is not accessible by the operator which is tuned by PLC-PID controller for operation in the pipeline transport system.
2.1. SCADA SCREEN FOR FLOW CONTROL OF AN OIL PIPELINE SYSTEM
A SCADA model is developed to monitor the entire process and to view/vary the tuning values of the PLC based Fuzzy and Cascade PID controller remotely as shown in Fig. 3. The alarm light blinks when the pressure of the petroleum or the flow rate of the petroleum crosses the safer limit. Once
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Online Monitoring and Control of Flow rate in Oil Pipelines Transportation System by using PLC based Fuzzy‐PID Controller
Abstract
Along with the development of urban construction and industrial requirements, more and more long distance oil pipelines have built and served. For this, the industries require more reliable, robust, efficient and flexible control system for the automation in oil pipeline system to prevent leakages during transportation. In this paper, a new PLC based Fuzzy-PID controller is designed to automatically regulate the flowrate of the petroleum products at destination by controlling the multiple pressure signals range in the long transmitting concrete pipes. The performance of the Fuzzy-PID controller is compared with the PLC based Cascade-PID controller. The developed PLC based Fuzzy and Cascade-PID controllers are implemented for the lab scale experimental setup and their performance analyses are verified experimentally. The real time data of pressure and flow are monitored through SCADA screen used to provide instantaneous trends using datalogging. From the real time experimental results, it is inferred that Fuzzy-PID controller provides most superior performance with minimum time delay as compared to Cascade-PID controller on upholding flow at specified range by implanting multiple pressures as manipulated parameters.
Keywords:
Oil pipelines ,PLC ,Fuzzy-PID ,Cascade-PID Controller ,SCADA
1. Introduction
Oil transportation pipelines and transferring pump units are the crucial parts of the oil transportation system, whereas it would impede the daily production, cause pecuniary loss [1], even environmental disruption due to the leak of pipeline [9] or abnormal running of power mechanical equipment with certain faults [17]. With the advanced technology development, pipelines are installed with fault diagnosis system [6], leak detection system at the control centre [19], safety monitoring and control of physical parameters [20] etc. The spacing of the cut-off valves being the components of the protection system should be selected depending on the area that the pipelines run through in order to regularize pressure, flow and flash point [5] for the petroleum products to preclude the occurrences of crack in the pipelines.
Various experimental works have been performed by researchers to enhance the performance of oil pipeline transportation systems [2,4] in their pioneering work and developed a method of transportation of viscous oil by injecting small amount of water to reduce pressure drop during flow. Russell et al. [16] proposed a flow pattern in horizontal pipelines on oil–water flow and formulated an architectural model of Computational Parameter Monitoring [7,10] which takes information from the field related to such as pressures, flows, and temperatures to estimate the hydraulic behavior of the product being transported, which may be related to a leak or pressure drops [12,13].
Currently there are many special linear structures deployed with sensors on pipelines to monitor and regulate flow and pressure [3] by implementing suitable conventional controllers [11,15] for monitoring and control of physical parameters. But there is no consideration by insisting remote communication for the operation of control valves for the envisioned petroleum product transportation system [8].In order to overcome the difficulty of maintaining constant pressure ranges [21] at distinct points in long range transmission [17] to obtain the required flowrate at endpoint by control valves based on instantaneous real time data of manipulated parameters, this paper spectacles the implementation of PLC based Fuzzy-PID controller to enhance the performance of control valves operation to get the desired pressure and flow set ranges at the destination to avoid environmental interruptions [14] like leakage or crack/burst in the pipelines transport system.
2. Experimental setup
The replica of the industrial construction (up to 9km long) is built as the lab scale experimental set up of 7m long is shown in Fig. 2. The setup includes the pumping unit, the transmitting pipes for the efficient and long range transmission and multiple analog pressure sensors at various distinct location [3,18] in addition with analog flow sensor at the destination. Along the pipeline, there are usually several pumping booster stations where control valve is installed, which compensate for the pressure loss in the pipeline over these long distances.
A Process and Instrumentation Diagram is visualized in Fig. 1 correspondstothemaintenanceandmodificationofthepipelinestransport system for envisioning the physical sequences of equipment used in the labscaleexperimentalsetupasshowninFig.2andalsodemonstratesall the piping with flow direction and instruments details with their controls [17]. The lab scale set up has three sections includes pressure transmitter (PT),pressure gauge(PG)and gate valve(GV).At the end of two sections equal percentage flow characteristic control valve (CV) is implemented and at the end of third section flow transmitter (FT) has been placed. The controller section includes pressure indicating controller (PIC), flow indicating controller (FIC) and flow controlling controller (FCC). PLC mounted FCC decides the level of control valve opening on the basis three PIC signals in which this FCC is not accessible by the operator which is tuned by PLC-PID controller for operation in the pipeline transport system.
2.1. SCADA SCREEN FOR FLOW CONTROL OF AN OIL PIPELINE SYSTEM
A SCADA model is developed to monitor the entire process and to view/vary the tuning values of the PLC based Fuzzy and Cascade PID controller remotely as shown in Fig. 3. The alarm light blinks when the pressure of the petroleum or the flow rate of the petroleum crosses the safer limit. Once
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