Automatic Pig Launcher Control Using Pipeline Pressure Waves
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Solution Overview
Problem
Current pipeline maintenance systems, particularly automatic multiple pig launchers (AMPLs), face limitations in determining optimal launch times for pipeline inspection gauges due to reliance on manual labor and pre-defined schedules, which can lead to inefficient use and high initial costs if future pigging requirements are uncertain.
Innovation Solution
A system utilizing dynamic pressure wave propagation to monitor the pipeline's unobstructed hydraulic diameter and debris levels, automatically determining the optimal launch time for pipeline inspection gauges by comparing pressure responses to clean simulation profiles and activating an automatic multiple pig launcher when criteria are met.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor and pre-defined schedules are used to determine pig launch times, then operational simplicity is maintained, but maintenance efficiency deteriorates and costs increase
Solution Approach 1:
The patent replaces manual labor and pre-defined schedules with an automated electronic system that uses pressure wave propagation monitoring to determine optimal pig launch times. The system substitutes mechanical decision-making processes with electronic sensors, processors, and automated control mechanisms that continuously monitor pipeline conditions and trigger pig launches based on actual debris accumulation rather than fixed schedules.
Solution Approach 2:
The pipeline maintenance system becomes self-service by automatically monitoring its own condition through pressure wave sensors and autonomously determining when pigging operations are needed. The system serves itself by eliminating the need for external manual assessment and scheduling, using its own sensor data to trigger maintenance actions only when actually required.
2Reliability
If pigs are launched frequently to ensure pipeline cleanliness, then pipeline reliability is improved, but wear and tear on hardware increases and costs rise
Solution Approach 1:
The system implements feedback by continuously monitoring pipeline conditions through pressure wave propagation and using this information to determine when pigging is actually needed. The feedback loop prevents unnecessary pig launches by only triggering maintenance actions when sensor data indicates debris accumulation has reached levels that require cleaning, thereby reducing wear on trap doors and hardware while maintaining pipeline reliability.
Solution Approach 2:
Instead of launching pigs on fixed schedules that may be excessive, the system applies partial action by launching pigs only to the extent actually needed based on real-time condition monitoring. The system avoids over-maintenance by using sensor feedback to determine the precise moment when pigging becomes necessary, reducing unnecessary hardware wear while ensuring pipeline cleanliness when required.
3Loss of time
If pre-defined schedules are used for pigging operations, then operational simplicity is maintained, but loss of time occurs due to unnecessary launches
Solution Approach 1:
The system transitions from static pre-defined schedules to dynamic condition-based scheduling. Instead of fixed time intervals, the pig launch timing becomes dynamic and adapts to actual pipeline conditions as detected by pressure wave sensors. This allows the system to optimize launch times based on real-time debris accumulation rates, reducing time loss from unnecessary launches while maintaining operational effectiveness.
4Measurement precision
If manual monitoring of pipeline conditions is performed, then system complexity is minimized, but measurement precision deteriorates
Solution Approach 1:
The patent replaces manual monitoring with an electronic sensor system that uses pressure wave propagation to precisely detect debris accumulation. The substitution of mechanical human assessment with electronic measurement devices dramatically improves measurement precision, enabling the system to detect subtle changes in pipeline conditions that would be imperceptible to manual monitoring methods.
Solution Approach 2:
The system introduces pressure wave sensors as intermediaries between the pipeline contents and the monitoring system. These sensors act as mediators that translate physical debris accumulation into measurable electrical signals, enabling precise indirect measurement of pipeline conditions without requiring direct physical inspection or complex intrusive devices.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for automated, optimized control of pig launch times, reducing manual labor and costs by launching pigs only when necessary, thereby improving maintenance efficiency and reducing wear and tear on pipeline hardware.
Implementation Method 1
generating a pressure wave in the pipeline, recording a reflex pressure pulse as a function of time in response to the pressure wave
Data Source
AI summary
Dynamic pressure wave propagation can be used in pipelines to provide information about the available, unobstructed diameter and any partial or complete blockages in the pipeline. Based on this information, a system can automatically determine optimal times to launch pipeline inspection gauges for cleaning or other purposes. A pipeline inspection gauge is sometimes referred to as a pig. Certain aspects and features include a system that can launch pigs as needed automatically by activating an automatic multiple pig launcher at appropriate times.