Automated Transmix Diversion in Petroleum Pipelines
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Solution Overview
Problem
Petroleum pipelines face the challenge of minimizing the volume of transmix created when shipping products of different specifications, as current methods lack efficient mechanical buffers to prevent contamination, resulting in off-specification products that are not marketable without re-processing.
Innovation Solution
Implementing an automated system that uses pre-defined 'cut-points' for physical properties to divert hydrocarbon flows between different subtypes in a pipeline, ensuring that only on-specification products are maintained in the transmission pipe, and diverting transmix to a separate pipe when specific criteria are met, using a central processing unit and transmix valve to manage the flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If products of different specifications are shipped sequentially on a pipeline, then pipeline utilization is maximized, but transmix is created at the interface between products
Solution Approach 1:
The system performs preliminary action by predicting the arrival of transmix at the juncture based on batch information and flow rates, and pre-positioning the diversion valve to the transmix pipe before the transmix actually arrives. This proactive approach ensures immediate diversion upon transmix arrival, minimizing the volume created while maintaining continuous pipeline operation.
Solution Approach 2:
The system implements feedback by continuously monitoring batch information, flow rates, and product specifications, then using this data to dynamically control the diversion valve. The central processing unit receives real-time data about product batches moving through the pipeline, calculates when transmix will arrive at the juncture, and automatically adjusts the valve position accordingly, creating a closed-loop control system that minimizes transmix volume.
2Manufacturing precision
If transmix is diverted to a separate pipe when it reaches a juncture, then on-specification product retention is improved, but the complexity of the pipeline system increases
Solution Approach 1:
The system replaces manual mechanical monitoring and decision-making with an automated control system. The central processing unit uses computer algorithms to predict transmix arrival, calculate optimal diversion timing, and control the diversion valve automatically. This substitution of mechanical/manual operations with automated computational control improves precision while the complexity is managed through software rather than additional physical infrastructure.
Solution Approach 2:
The system implements self-service by enabling the pipeline operation to automatically monitor its own product batches, predict transmix formation, and divert transmix without external intervention. The central processing unit uses embedded batch information and real-time flow data to autonomously control the diversion valve, making the system self-regulating and reducing the need for external monitoring and manual operations.
3Adaptability or versatility
If the pipeline operator manually monitors product properties to determine when transmix is present, then flexibility in handling different products is maintained, but the time required to make the interface cut increases
Solution Approach 1:
The system performs preliminary calculation of transmix arrival time using batch information and flow rate data before the transmix actually reaches the juncture. By predicting the arrival in advance and pre-positioning the diversion valve, the system eliminates the time delay associated with manual detection and reaction, while the flexible prediction algorithm can adapt to different product types and shipping scenarios.
Solution Approach 2:
The system replaces manual visual inspection and human decision-making with automated computational analysis. The central processing unit continuously calculates product properties based on sensor data and batch information, automatically determines when transmix is present, and triggers valve diversion instantaneously. This substitution eliminates human reaction time delays while maintaining the ability to handle diverse products through programmable logic.
4Manufacturing precision
If more time is taken to ensure accurate identification of transmix, then product specification compliance is improved, but the volume of transmix created increases
Solution Approach 1:
The system implements continuous feedback monitoring of product specifications and batch information, comparing actual measurements against expected values to accurately identify transmix formation. The central processing unit receives real-time data from multiple sensors and continuously updates its prediction of transmix arrival, allowing for accurate identification without delay. The feedback loop ensures high precision in transmix detection while the predictive algorithm minimizes the time the diversion valve remains in the wrong position.
Solution Approach 2:
The system performs preliminary analysis of batch information and flow rates to predict transmix arrival before it occurs. By calculating the expected composition changes in advance and preparing the diversion valve accordingly, the system achieves accurate transmix identification at the moment of formation, preventing any unnecessary transmix volume creation while maintaining high specification compliance.
Data Source
AI summary
Automated methods and systems for diverting transmix from a petroleum pipeline are provided to reduce the overall production of transmix on the pipeline, based on pre-defined programmed cut-points associated with the various subtypes of hydrocarbon carried on the pipeline.