Optimizing FPSO Oil Processing: An Expert System with Genetic Algorithms for Setpoint Control

Increasing the productivity of an offshore oil production unit is a challenge in environments such as the Brazilian pre-salt. Since controlling the oil treatment process is essential for the continuity of the platform and considering that most current units use conventional feedback control, there was a need to optimize the control system for the separation process, well flow control and ballast tank filling to reduce the number and duration of process shutdowns. This article shows how an expert system control logic was designed with closed-loop genetic algorithm optimization to control the production of emerging subsea oil wells in order to maintain continuous supply to the platform’s treatment process and correct disturbances. For this purpose, a genetic algorithm was developed that calculates the best separation condition for the process for each imposed production flow rate and controls the change of the process setpoint to this optimal condition via an expert control system. Several simulations were performed to demonstrate the system’s operation, and it was seen that the productivity of this system was superior to the conventional system in all simulations.