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Product Interface Detection in batched multi-product liquid metering J.L. Larry Taylor, III ISA MEMBER 32081934 OMNTEC – Innovative Sensor Solutions ISA.

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Presentation on theme: "Product Interface Detection in batched multi-product liquid metering J.L. Larry Taylor, III ISA MEMBER 32081934 OMNTEC – Innovative Sensor Solutions ISA."— Presentation transcript:

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2 Product Interface Detection in batched multi-product liquid metering J.L. Larry Taylor, III ISA MEMBER OMNTEC – Innovative Sensor Solutions ISA (D) Expo 2005 Delhi, India 2 – 4 December 2005

3 Multi-Product Interface Detection The Challenge Conventional Approach The Solution The Future

4 Multi-Product Interface Detection: THE CHALLENGE

5 AA BB TRANSMIX Transmix Minimization

6 MARKETING TERMINAL $ $ CRUDE PIPELINE REFINERY PRODUCT PIPELINE AVGAS 93 OCTANE 91 OCTANE 87 OCTANE JET-A HS DIESEL LS DIESEL FUEL OIL BUTANE PIPELINE TERMINAL TRANSMIX FUEL: A Vicious Cycle

7 The Challenge REDUCE TRANSMIXREDUCE TRANSMIX IMPROVE PURITYIMPROVE PURITY

8 THE CHALLENGE How many slop tanks do you have?How many slop tanks do you have? How much loss in revenue does that represent?How much loss in revenue does that represent?

9 Conventional Approach Use densitometer to identify interface Move densitometer upstream

10 Shortcomings of Densitometers for interface detection Inadequate compositional resolution to detect product interfaces Too slow Too expensive to install very high resolution densitometers upstream of tank manifolds

11 THE SOLUTION FuelCheck ®

12 FuelCheck ® Overview FuelCheck ® is a totally fiberoptic petroleum pipeline interface detector which uses index of refraction to differentiate between adjacent batches of refined products

13 length up to 2 km pipeline FuelCheck ® sensor FuelCheck ® Probe fiberoptic interconnect Conduit j-box FuelCheck System FuelCheck ® System FuelCheck ® Controller Analog out to SCADA

14 5 mm 1.Sensor is a 5 mm diameter sapphire hemisphere. 2.Optical fibers are very precisely fused onto the flat side of the lens. 3.An LED is used to provide constant intensity light to the lens through either of the fibers. (LED located in the FuelCheck Controller, up to 2 km away from sensor) 4.The inner surface of the lens acts as a mirror: some of the light reflects inside the lens; however, some light refracts out of the lens into whatever fluid is wetting the lens. The amount of light lost to refraction is directly proportional to the refractive index of the fluid wetting the lens. 5.Whatever light is not lost to refraction returns to the FuelCheck Controller via the other fiber where its intensity is precisely measured and converted to a scaled value. reflected light refracted light fiberoptic length up to 2 km Fuel Check Fuel Check Operating Principle

15 FEATURES Completely fiberoptic sensor can be located up to 2 km from controllerCompletely fiberoptic sensor can be located up to 2 km from controller Installs into pipeline through 1 (or larger) valveInstalls into pipeline through 1 (or larger) valveBENEFITS No power or wiring requiredNo power or wiring required Remote sensors can be cheaply and easily installed upstream of control manifoldsRemote sensors can be cheaply and easily installed upstream of control manifolds No pipe fitting or special plumbing requiredNo pipe fitting or special plumbing required Immune to EMR and lightningImmune to EMR and lightning Inherently safeInherently safe process insertion fitting insertion tool adapter pipeline access valve (>= 1 full-opening) threadolet (>=2) flexible armor probe body conduit J-box FuelCheck ® Probe

16 FuelCheck Response FuelCheck ® Response

17 DIESEL minutes GASOLINE valve response time MOV MOVMOV SCADA FuelCheck FuelCheck ® Controller fiberoptic interconnect (<= 2 km) FuelCheck FuelCheck ® Probe A Tandem Sensor Technique FuelCheck FuelCheck ® Probe B

18 DIESEL GASOLINE MOV MOVMOV SCADA FuelCheck FuelCheck ® Controller FuelCheck FuelCheck ® Probe B fiberoptic interconnect (<= 2 km) FuelCheck FuelCheck ® Probe A Tandem Sensor Technique

19 DIESEL GASOLINE MOV MOVMOV SCADA FuelCheck FuelCheck ® Controller FuelCheck FuelCheck ® Probe B fiberoptic interconnect (<= 2 km) FuelCheck FuelCheck ® Probe A Tandem Sensor Technique

20 THE FUTURE AUTOMATED PIPELINE BATCH CONTROL

21 Goal of Pipeline Batch Automation fine tune valve actuation to coincide EXACTLY with operators command based upon observation of interface detection system and volumetric correction.

22 Components Required Interface detector system (FuelCheck ® )Interface detector system (FuelCheck ® ) Accurate flow measurementAccurate flow measurement Known values for pipe volumes (line pack)Known values for pipe volumes (line pack) Known values for valve activation timeKnown values for valve activation time Known values for min. and max. flow ratesKnown values for min. and max. flow rates Batch controller (flow computer or SCADA)Batch controller (flow computer or SCADA)

23 Flow Computer is Preferred Pipeline Batch Controller Flow computer has faster I/O cycleFlow computer has faster I/O cycle Flow computer vendor is more familiar with pipeline applicationFlow computer vendor is more familiar with pipeline application Some flow computers already have batch control parameters built into system together with line pack dataSome flow computers already have batch control parameters built into system together with line pack data

24 Flow Computer FLOWMETER TO TANK B TO TANK A FuelCheck Probe B fromFuelCheck Probe A HMI Recommended minimum distance is 1-1/2 times valve actuation time at maximum flow rate toFuelCheck Probe A Recommended minimum distance is 10 minutes at maximum flow rate (up to 2 km) Valve Control Automated Pipeline Batch Control (Flow Computer) A. operator selects desired cut point from FuelCheck Probe A input B. Flow computer uses flow rate, valve actuation time, and pipe volume (line pack) between meters/valves and sensors to compute and execute precise valve control at desired cut point. Control system comm. delays must also be considered.

25 fromFuelCheck Probe A SCADA valve control Automated Pipeline Batch Control (SCADA) A. operator selects desired cut point from input from FuelCheck Probe A B. SCADA system uses flow rate, valve actuation time, and pipe volume between valves and sensors to compute and execute precise valve control at desired cut point. System comm delays must also be considered. FLOWMETER TO TANK BTO TANK A FuelCheck Probe B Recommended minimum distance is 1-1/2 times valve actuation time at maximum flow rate toFuelCheck Probe A Recommended minimum distance is 10 minutes at maximum flow rate (up to 2 km) FuelCheck ® Controller

26 Pipeline Batching Strategy Low energy product (i.e., gasoline) High energy product (i.e., diesel) CUT HERE

27 Pipeline Batching Strategy Lower value product (i.e., regular gas) High value product (i.e., premium gasoline) CUT HERE

28 Pipeline Batching Strategy Lower energy Higher value product (i.e., Jet-A) High energy product (i.e., diesel) Long transmix Divert to slop tank

29 Recommended HMI trending and control enhancements Both axes must have user-controlled scaling X-axis on operators real-time trend should be volume instead of time Real-time trend scroll rate should be based on volume rather than time Use 3 vertical sliders to identify beginning and end of interface, and desired cut point Show calculated interface volume based on slider positions Show volume-driven (from flow meter) dynamic countdown timer for MUST COMMIT BATCH CUT Show valve position indicators (if available)

30 Future Upgrades Integrate interface detectors from upstream stations into batch control logic Create computation of interface contamination of tank volumes based on dynamic inventory to decide whether or not to divert flow to slop tank Total pipeline batch control automation (must do recommended enhancements first, and then will require a lot of programming, testing, and debugging to be reliable and trustworthy)


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