Advance Control System and Optimization OTSG MPC & Optimizer

The Mukhaizna field in the Sultanate of Oman is a leading EOR in heavy oil recovery, where innovative strategies are continually sought to optimize production and minimize environmental impact. Among these strategies, the optimization of Once Through Steam Generators (OTSG) plays a pivotal role. This paper presents a comprehensive study on the implementation of an advanced control system and optimization strategies for OTSGs in Mukhaizna, aiming to enhance operational efficiency and environmental sustainability. In recent years, the oil and gas industry has increasingly focused on reducing carbon emissions and optimizing resource utilization. The Mukhaizna field, characterized by its unique geological structure and operational challenges, provides an ideal setting to explore these objectives. This study outlines the deployment of a Model Predictive Controller (MPC) and Bank Optimizer, tools designed to maximize the thermal efficiency of OTSGs. The primary goal was to optimize steam quality and quantity, reduce fuel gas consumption, and, consequently, lower CO2 emissions. It currently necessitates approximately 630K barrels of steam per day to satisfy its extensive steam flooding requirements. This substantial volume of steam is a critical element in the enhanced oil recovery efforts, ensuring the viability and longevity of the field's production capabilities. The generation of this steam is achieved through a combination of 13 Heat Recovery Steam Generators (HRSG) and 78 Once Through Steam Generators (OTSGs) arranged in Thermal Banks. This setup represents one of the field's most significant operational factors, underpinning the need for optimized control and management to maintain production efficiency and cost-effectiveness. The following discourse details the development of an advanced adaptive control system tailored to enhance the operation of these OTSG units, underscoring our commitment to operational excellence and environmental stewardship.