product interface detection in batched multi-product liquid metering j.l. larry taylor, iii isa...
TRANSCRIPT
Product Interface DetectionProduct Interface Detectionin batched multi-product liquid meteringin batched multi-product liquid metering
J.L. “Larry Taylor, IIIJ.L. “Larry Taylor, IIIISA MEMBER 32081934ISA MEMBER 32081934
OMNTEC – Innovative OMNTEC – Innovative Sensor SolutionsSensor Solutions
ISA (D) Expo 2005ISA (D) Expo 2005Delhi, IndiaDelhi, India
2 – 4 December 20052 – 4 December 2005
Multi-Product Interface Detection
• The Challenge
• Conventional Approach
• The Solution
• The Future
MARKETING TERMINALMARKETING TERMINAL
$ $ $ $
CRUDE PIPELINE
REFINERY
PRODUCT PIPELINE
AVGAS
93 OCTANE
91 OCTANE
87 OCTANE87 OCTANE
JET-A
HS DIESEL
LS DIESEL
FUEL OILFUEL OIL
BUTANE
PIPELINE TERMINALPIPELINE TERMINAL
TRANSMIX
FUEL: A Vicious CycleFUEL: A Vicious Cycle
The Challenge
SLOP SLOPSLOP SLOP
• REDUCE REDUCE TRANSMIXTRANSMIX
• IMPROVE IMPROVE PURITYPURITY
THE CHALLENGETHE CHALLENGE
• How many slop tanks do How many slop tanks do you have?you have?
• How much loss in revenue How much loss in revenue does that represent?does that represent?
Conventional Approach
• Use densitometer to identify interface
• Move densitometer upstream
Shortcomings of DensitometersShortcomings of Densitometersfor interface detectionfor interface detection
• Inadequate compositional resolution to detect product interfaces
• Too slow
• Too expensive to install very high resolution densitometers upstream of tank manifolds
FuelCheckFuelCheck®®
Overview Overview
FuelCheckFuelCheck®® is a totally fiberoptic is a totally fiberoptic petroleum pipeline petroleum pipeline interface interface detectordetector which uses index of which uses index of refraction to differentiate between refraction to differentiate between adjacent batches of refined adjacent batches of refined productsproducts
length up to 2 km
pipeline
FuelCheck®
sensor
FuelCheck® Probe
fiberopticinterconnect
Conduit j-box
FuelCheckFuelCheck® SystemSystem
FuelCheck® Controller
Analog out to SCADA 12.3
100.0
16.6 -39.4
-46.112.3
100.0
16.6 -39.4
-46.1
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.
reflectedlight
refractedlight
fiberoptic lengthup to 2 km
Fuel CheckFuel Check Operating Principle
FEATURESFEATURES
• Completely fiberoptic sensor Completely fiberoptic sensor can be located up to 2 km from can be located up to 2 km from controllercontroller
• Installs into pipeline through Installs into pipeline through 1” (or larger) valve1” (or larger) valve
BENEFITSBENEFITS
• No power or wiring requiredNo power or wiring required
• Remote sensors can be Remote sensors can be cheaply and easily installed cheaply and easily installed upstream of control manifoldsupstream of control manifolds
• No pipe fitting or special No pipe fitting or special plumbing requiredplumbing 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
FuelCheckFuelCheck®®
Probe Probe
12/18 0:00 12/18 12:00 12/19 0:00 12/19 12:00 12/20 0:00 12/20 12:00
93 oct (52.7°)
JET-A (43.7°)buffer
HS diesel (35.2°)
87 oct reg (58.3°)
87 oct RFG (58.8°)
LS diesel (36.0°)
93 oct (52.9°)
FuelCheckFuelCheck®
Response Response
DIESEL
5 - 10 minutes
GASOLINE
valveresponse
time
MOV
25
30
35
40
45
50
55
60
65
70
75
13:00 13:01 13:02 13:03 13:04 13:05 13:06 13:07 13:08 13:09 13:10 13:11 13:12
Time
Infe
rred
Den
sity
, °A
PI
25
30
35
40
45
50
55
60
65
70
75
13:00 13:01 13:02 13:03 13:04 13:05 13:06 13:07 13:08 13:09 13:10 13:11 13:12
Time
Infe
rred
Den
sity
, °A
PI
MOV
SCADA
FuelCheckFuelCheck®
Controller
fiberopticinterconnect
(<= 2 km)
FuelCheckFuelCheck®
Probe A
Tandem Sensor TechniqueTandem Sensor Technique
FuelCheckFuelCheck®
Probe B
DIESEL
25
30
35
40
45
50
55
60
65
70
75
13:06 13:07 13:08 13:09 13:10 13:11 13:12 13:13 13:14 13:15 13:16 13:17 13:18
Time
Infe
rred
Den
sity
, °A
PI
GASOLINE
MOV
MOV
SCADA
FuelCheckFuelCheck®
Controller
FuelCheckFuelCheck®
Probe B
fiberopticinterconnect
(<= 2 km)
FuelCheckFuelCheck®
Probe A
Tandem Sensor TechniqueTandem Sensor Technique
25
30
35
40
45
50
55
60
65
70
75
13:12 13:13 13:14 13:15 13:16 13:17 13:18 13:19 13:20 13:21 13:22 13:23 13:24
Time
Infe
rred
Den
sity
, °A
PI
25
30
35
40
45
50
55
60
65
70
75
13:12 13:13 13:14 13:15 13:16 13:17 13:18 13:19 13:20 13:21 13:22 13:23 13:24
Time
Infe
rred
Den
sity
, °A
PI
DIESEL
GASOLINE
MOV
MOV
SCADA
FuelCheckFuelCheck®
Controller
FuelCheckFuelCheck®
Probe B
fiberopticinterconnect
(<= 2 km)
FuelCheckFuelCheck®
Probe A
Tandem Sensor TechniqueTandem Sensor Technique
THE FUTURETHE FUTURE
AUTOMATED PIPELINE BATCH AUTOMATED PIPELINE BATCH CONTROLCONTROL
Goal of Pipeline Batch Goal of Pipeline Batch AutomationAutomation
““fine tune” valve actuation to fine tune” valve actuation to coincide coincide EXACTLYEXACTLY with with operator’s command based operator’s command based upon observation of interface upon observation of interface detection system and detection system and volumetric correction.volumetric correction.
Components RequiredComponents Required
• Interface detector system (FuelCheckInterface 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 Batch controller (flow computer or SCADA)SCADA)
Flow Computer is Preferred Flow Computer is Preferred Pipeline Batch ControllerPipeline Batch Controller
• Flow computer has faster I/O cycleFlow computer has faster I/O cycle
• Flow computer vendor is more Flow computer vendor is more familiar with pipeline applicationfamiliar with pipeline application
• Some flow computers already have Some flow computers already have batch control parameters built into batch control parameters built into system together with line pack datasystem together with line pack data
Flow Computer
FLOWMETER
TO
TA
NK
T
O T
AN
K
BB TO
TA
NK
T
O T
AN
K
AA
FuelCheckFuelCheckProbe BProbe B
fromfromFuelCheckFuelCheckProbe AProbe A
HMI
Recommended minimum distance is 1-1/2 times valve actuation time at maximum flow rate
totoFuelCheckFuelCheckProbe AProbe A
Recommended minimum distance is 10 minutes at maximum flow rate (up to 2 km)
Valve Control
Automated Pipeline Batch Control Automated Pipeline Batch Control (Flow Computer)(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.
HMI
12.3
100.0
16.6 -39.4
-46.112.3
100.0
16.6 -39.4
-46.1
fromfromFuelCheckFuelCheckProbe AProbe A
SCADA
valve control
Automated Pipeline Batch Automated Pipeline Batch Control (SCADA)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
TA
NK
B T
O T
AN
K
A
FuelCheckFuelCheckProbe BProbe B
Recommended minimum distance is 1-1/2 times valve actuation time at maximum flow rate
totoFuelCheckFuelCheckProbe AProbe A
Recommended minimum distance is 10 minutes at maximum flow rate (up to 2 km)
HMI
FuelCheckFuelCheck®® Controller ControllerFuelCheckFuelCheck®® Controller Controller
Pipeline Batching StrategyPipeline Batching Strategy
Low energy productLow energy product(i.e., gasoline)(i.e., gasoline)
High energy productHigh energy product(i.e., diesel)(i.e., diesel)
CU
T
HE
RE
Pipeline Batching StrategyPipeline Batching Strategy
Lower value productLower value product(i.e., regular gas)(i.e., regular gas)
High value productHigh value product(i.e., premium gasoline)(i.e., premium gasoline)
CU
T
HE
RE
Pipeline Batching StrategyPipeline Batching Strategy
Lower energyLower energyHigher value productHigher value product(i.e., Jet-A)(i.e., Jet-A)
High energy productHigh energy product(i.e., diesel)(i.e., diesel)
Long transmixDivert to slop tank
Recommended HMI trending Recommended HMI trending and control enhancementsand control enhancements
• Both axes must have user-controlled scaling• X-axis on operator’s 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)
Future UpgradesFuture 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)