Pump Efficiency Control via In-Line Blending Spillback
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Solution Overview
Problem
Current methods for blending hydrocarbon liquids, such as tank mixing and parallel mixing, are inefficient and costly, lacking precision and requiring significant infrastructure, with pumps often not operated at their best efficiency points.
Innovation Solution
An in-line mixing system that adjusts pump operation to maintain a preselected range of the best efficiency point using a spillback loop and control valves to divert fluid flow, ensuring accurate blending and efficient pump operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If tank mixing or parallel mixing methods are used for blending hydrocarbon liquids, then blending capability is provided, but energy efficiency deteriorates because pumps are not operated at their best efficiency points
Solution Approach 1:
The system implements a feedback control mechanism where the controller continuously monitors pump operating conditions and adjusts the pump speed or flow rate to maintain operation at or near the best efficiency point (BEP). This feedback loop ensures that energy consumption is optimized while still achieving the required blending capability, directly resolving the contradiction between energy efficiency and productivity.
Solution Approach 2:
The invention employs dynamic adjustment of pump operating parameters (speed, flow rate, or pressure) based on real-time conditions. By making the pump operation dynamic rather than fixed, the system can adapt to varying blending requirements while consistently operating at peak efficiency points, thereby simultaneously improving energy efficiency and maintaining productivity.
2Adaptability or versatility
If tank mixing or parallel mixing infrastructure is implemented, then hydrocarbon liquid blending is enabled, but device complexity and cost increase due to extensive piping and tank requirements
Solution Approach 1:
The invention merges the blending function directly into the existing pipeline transport system by using in-line mixing sections. This eliminates the need for separate tank mixing infrastructure or parallel mixing systems, reducing device complexity while maintaining full blending capability. The mixing occurs within the pipeline itself, combining transport and blending functions into a single integrated system.
Solution Approach 2:
The invention extracts the blending function from traditional complex infrastructure (tanks and extensive piping) and implements it through a simplified in-line mixing section within the pipeline. By taking out the blending capability from the heavy infrastructure and placing it directly in the flow path, the system achieves the same adaptability with significantly reduced complexity and cost.
3Productivity
If pump flow rate is increased to meet blending demands, then productivity improves, but pump efficiency deteriorates by operating away from the best efficiency point
Solution Approach 1:
The system dynamically adjusts pump operating parameters (speed, flow rate, or pressure) based on real-time blending demands. When higher throughput is required, the pump speed is increased, but the control system simultaneously adjusts other parameters to maintain operation at or near the best efficiency point. This dynamic coordination allows the system to meet varying productivity requirements without sacrificing energy efficiency.
Solution Approach 2:
The invention changes multiple pump operating parameters simultaneously (speed, flow rate, pressure, or valve positions) to maintain optimal efficiency across different throughput levels. By coordinating changes in multiple parameters rather than adjusting a single parameter, the system can achieve higher productivity while keeping the pump operating at peak efficiency points throughout the operating range.
Data Source
AI summary
Methods and systems of operating a pump at an efficiency point during an in-line blending operation. In an embodiment, such a method may include transporting a fluid from a tank to a pump through a first pipe. The method may include discharging, via the pump, the fluid at a specified flow rate through a second pipe. The method may include measuring a flow rate of the first portion of the fluid flowing from the main control valve through the mixing pipe. The method may include measuring a flow rate of the second portion of the fluid flowing through the spillback loop. The method may include determining a current pump efficiency point and operating the pump within a range of percentages of the best efficiency point.