Note: Descriptions are shown in the official language in which they were submitted.
METHODS AND SYSTEMS FOR IN-LINE MIXING OF HYDROCARBON LIQUIDS
FIELD OF DISCLOSURE
[0001] The disclosure herein relates to systems and methods for providing in-
line mixing of
hydrocarbon liquids using mixing jumpers, and one or more embodiments of such
systems and
methods may be suitable for providing multi-component mixing of two or more
hydrocarbon
liquids.
BACKGROUND
[0002] Different types of hydrocarbon liquids, such as petroleum and renewable
liquid products
(e.g., such as crude oil), are often mixed upstream of a refinery to reduce
the viscosity of heavy
crude and maximize capacity, or to create a desired set of properties (TAN,
sulfur, etc.). Given
the multitude of crude types, the potential mixtures and component ratios are
numerous. In some
situations, multiple different types of hydrocarbon liquids, e.g., crude oil
and renewable
products, from different tanks may need to be mixed in a particular ratio.
Further, there may also
be a need to create a desired mixture on demand and ship the mixture through a
pipeline as one
homogenous product. In such examples, the mixing of different types of
hydrocarbon liquid, e.g.,
crude and renewable liquid, may be performed at a pipeline origination
station. Often, the
pipeline origination station may include a tank farm (e.g., having multiple
tanks for storage and
mixing of the crude oils) and extensive piping capable of transporting
hydrocarbon liquids from
each of the tanks to one or more mainline booster pumps, which raise the
hydrocarbon liquids to
high pressures for traveling on a long pipeline.
[0003] Historically, crude mixing occurred by blending the crude oils in one
or more tanks. Tank
mixing is the most common form of crude mixing in the oil and gas industry.
While relatively
inexpensive, such methods have several undesirable drawbacks. For example, the
extent and/or
accuracy of the mixing may be less precise (e.g., having an error rate of +/-
about 10% based on
a target set point). Such methods typically require an entire tank to be
dedicated to blending the
crude oils along with separate distribution piping therefrom. In addition, the
mixed crude product
tends to stratify in the tank without the use of tank mixers, which also
require additional capital
investment. Further, the mixed crude product is generally limited to a 50/50
blend ratio.
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Date Recue/Date Received 2022-07-06
[0004] An alternative to tank mixing is parallel mixing, which uses two pumps
to pump two
controlled feed streams (e.g., one pump per feed stream) on demand from
separate tanks and into
the pipeline. While parallel mixing is typically more precise than tank
mixing, it is also more
difficult to control because both streams are pumped by booster pumps into a
common stream.
Typically, the two pumped streams are individually controlled by variable
speed pumps or
pumps with flow control valves; therefore, the two sets of independent
controls may interfere
with each other and/or may have difficulty reaching steady state if not
programmed correctly.
[0005] Applicant has recognized, however, that in parallel mixing operations,
both streams need
to be boosted to about 50-200 psi of pressure in the tank farm to provide
adequate suction
pressure to a mainline booster pump that is positioned downstream of the
boosters. Even if one
stream operates at a fixed flow while the other varies, the need to boost the
pressure of each
stream to about 50-200 psi may require high horsepower boost pumps dedicated
to each line.
Such dedicated pumps may be needed to supply streams at adequate pressure to
the mainline
pumps and may require significant capital investment. From a commercial
standpoint, for
example, parallel mixing operations require much more infrastructure,
representing a 180% to
200% increase in cost difference compared to the in-line mixing systems
disclosed herein.
Therefore, there is a need in the industry for accurate and cost-effective
blending methods and
systems for crude and other hydrocarbon liquid products.
SUMMARY
[0006] The disclosure herein provides embodiments of systems and methods for
in-line fluid
mixing of hydrocarbon liquids. In particular, in one or more embodiments, the
disclosure
provides for in-line mixing via mixing jumpers from tanks positioned at a tank
farm. Such
systems and methods may enable each of two or more tanks to provide a single
hydrocarbon
liquid as a product, via a larger pipeline, or enable two of the two or more
tanks to provide a
blend of hydrocarbon liquids as a blended product via corresponding mixing
jumpers. In other
words, the in-line mixing system is positioned to admix two or more of those
hydrocarbon
liquids contained within the two or more of tanks to provide a blended mixture
within a single
pipeline. In some embodiments, the systems and methods of the disclosure may
provide for in-
line mixing of at least two hydrocarbon liquids, at least three hydrocarbon
liquids, or more to
form a blended fluid flow in a single pipeline, e.g., which may be referred to
herein as two-
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Date Recue/Date Received 2022-07-06
component blend, three-component blends, or a blend containing more than three
hydrocarbon
liquids. Further, such embodiments, may provide the blended mixture
efficiently and utilizing a
low or a minimal amount of power.
[0007] The mixing jumpers utilized in such operations may be comprised of
pipes, an isolation
valve, a meter and/or sensor, and/or a flow control device. The flow control
device may be a
control valve. Other devices may be utilized such as a turbine, a pump (e.g.,
a variable speed
pump or fixed pump), a control valve and pump, or some combination thereof.
The mixing
jumper may allow fluid to flow therethrough when the isolation valve is
opened. In an
embodiment, opening the isolation valve prevents flow through a corresponding
tank's main
pipe. In another embodiment, the tank's main pipe may include an isolation
valve to prevent/
allow fluid to flow therethrough. The meter and/or sensor may determine the
amount of fluid
flowing through, or some other characteristics or aspect of the fluid, the
mixing jumper. The
meter and/or sensor may be a flow meter and/or a pressure sensor. Other meters
and/or sensors
may be positioned throughout the system, such as tank level meters,
temperature sensors, and/or
other flow meters or pressure sensors. The flow control device may allow for
control of a final
blend. For example, a blend may include 40% of a fluid from tank A and 60% of
another fluid
from tank B. In such examples, the flow control devices may adjust to drive
the blend to a
correct ratio, based on measurements from, at least, the meter and/or sensor.
[0008] Accordingly, an embodiment of the disclosure is directed to an in-line
fluid mixing
system. The in-line fluid mixing system may be positioned at a tank farm to
admix hydrocarbon
liquids from a plurality of tanks into a single pipeline. The in-line fluid
mixing system may
comprise two or more tanks positioned at a tank farm with at least one tank
containing a
hydrocarbon liquid therein. The in-line fluid mixing system may comprise two
or more first main
pipes. Each one of the two or more main pipes may be connected to one of the
two or more
tanks. The in-line fluid mixing system may comprise two or more main valve.
Each of the two or
more main valves may be connected to one of the two or more main pipes. The
hydrocarbon
liquid may flow from one tank through one first main pipe to a corresponding
main valve. The
in-line fluid mixing system may comprise two or more second main pipes. Each
one of the two
or more second main pipes may be connected to a corresponding main valve. The
in-line fluid
mixing system may comprise two or more mixing jumpers. Each of the mixing
jumpers may be
connected to a corresponding first main pipe of the two or more first main
pipes. Each of the two
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Date Recue/Date Received 2022-07-06
or more mixing jumpers may, when a corresponding main valve is closed, control
hydrocarbon
liquid flowing from two or more tanks. The in-line fluid mixing system may
comprise a mixing
pipe or a header connected to each of the two or more second main pipes and
each of the two or
more mixing jumpers. The mixing pipe may be configured to transport
hydrocarbon liquid from
one or more of the two or more tanks. The in-line fluid mixing system may
include one or more
controllers in signal communication with the isolation valve, the sensor, and
the flow control
device of each of the mixing jumpers and with each of the one or more main
valves. The one or
more controllers may control the flow control device for each of the one or
more mixing jumpers
thereby to control an amount of hydrocarbon liquid flowing therethrough. Such
control may be
based on one or more of a specified hydrocarbon liquid blend percentage and a
current flow rate,
from a corresponding sensor, of a specified hydrocarbon liquid flowing from a
specified tank
[0009] The mixing jumpers described above may include an isolation valve to,
when closed,
prevent hydrocarbon liquid to flow therethrough and, when open, allow
hydrocarbon liquid to
flow therethrough. Further, the mixing jumper, may include a sensor to
determine a characteristic
(e.g., flow rate, pressures, temperature, viscosity, and/or other
characteristics) of hydrocarbon
liquid flowing through the one of the one or more mixing jumpers. The sensor
may include one
or more of a flow meter, density sensor, pressure sensor or transducer, or a
temperature sensor.
The mixing jumper may also include a flow control device to control
hydrocarbon liquid flowing
through the one of the one or more mixing jumpers. The flow control device may
be or include
one or more of a control valve or a turbine. The mixing jumper may finally
include a mixing
jumper pipe to connect the mixing jumper to the mixing pipe or corresponding
second main pipe.
[0010] In an embodiment, when one of the one or more main valves is open and
hydrocarbon
liquid is flowing therethrough, each of the isolation valves for the one or
more mixing jumpers
may be closed, thus preventing fluid flow through the mixing jumpers.
[0011] Another embodiment of the disclosure is directed to a method of
admixing hydrocarbon
liquids from two or more tanks into a single pipeline to provide in-line
mixing thereof. The
method may include initiating a hydrocarbon liquid process that includes
blending specified
percentages of two or more hydrocarbon liquids over a period of time each of
the two or more
hydrocarbon liquids stored in one of two or more tanks. The method may include
closing, for
each one of the two or more tanks, a main valve. The method may include
opening, for each one
of the two or more tanks, an isolation valve of a mixing jumper. The method
may include
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Date Recue/Date Received 2022-07-06
determining, for the mixing jumper of each one of the two or more tanks, a
flow rate of
hydrocarbon liquid. The method may include, in response to a difference
between a mix ratio
and a ratio of each determined flow rate of hydrocarbon liquid: (1)
determining a corrected ratio
based on one or more of the difference between the mix ratio, the ratio of
each determined flow
rate of hydrocarbon liquid, or one or more of each flow rate of each
hydrocarbon liquid, and (2)
adjusting a flow control device of the mixing jumper for each of the two or
more tanks based on
the corrected ratio to modify flow rate of hydrocarbon liquid to drive the
ratio towards the target
ratio.
[0012] Another embodiment of the disclosure is directed to a method of
admixing liquid from
two or more tanks into a single pipeline to provide in-line mixing thereof.
The method may
include receiving blend parameters of a blend process. The blend parameters
may include
specified or selected percentages of one or more hydrocarbon liquids. The
method may include,
in response to blend parameters with two or more specified percentages of two
or more
hydrocarbon liquids, (1) opening, for each of the corresponding tanks, a
jumper valve of a
mixing jumper and (2) closing, for each of the corresponding tanks, a main
valve. Each of the
two or more hydrocarbon liquids may be stored in the corresponding tanks. The
method may
further include determining, for the mixing jumper of each of the
corresponding tanks, a flow
rate of hydrocarbon liquid. The method may include, in response to a
difference between a mix
ratio and a ratio of each determined flow rate of hydrocarbon liquid, (1)
determining a corrected
ratio based on one or more of the difference between the mix ratio, the ratio
of each determined
flow rate of hydrocarbon liquid, or one or more of each flow rate of each
hydrocarbon liquid, and
(2) adjusting a flow control device of the mixing jumper for each of the
corresponding tanks
based on the corrected ratio to modify flow rate of hydrocarbon liquid to
drive the ratio towards
the target ratio. In an embodiment, the corrected ratio may further be based
on one or more of a
density of each of the two or more hydrocarbon liquids or a level of
hydrocarbon liquid in each
of the corresponding tanks.
[0013] In another embodiment, the method may include, in response to blend
parameters with a
specified percentage of one hydrocarbon liquid, (1) opening, for a
corresponding tank, a main
actuated valve to allow the one hydrocarbon liquid to flow to a header
therethrough for a selected
time, and (2) closing, for the corresponding tank, a jumper actuated valve of
a mixing jumper to
prevent flow of the one hydrocarbon liquid through the mixing jumper.
Date Recue/Date Received 2022-07-06
[0014] Another embodiment of the disclosure is directed to a controller for an
in-line mixing
system for admixing hydrocarbon liquids from one or more tanks into a single
pipeline via
mixing jumpers. The controller may include a first input in signal
communication with a first
meter to measure a first flow rate of the first liquid. The first meter may be
positioned along a
first mixing jumper that is connected to a first tank. The controller may be
configured, in relation
to the first input, to obtain the first flow rate from the first meter via the
first input after initiation
of a blending operation. The controller may include a second input in signal
communication with
a second meter to measure a second flow rate of the second liquid. The second
meter may be
positioned along a second mixing jumper that is connected to a second tank.
The controller may
be configured to, in relation to the second input, obtain the second flow rate
from the second
meter via the second input after initiation of the blending operation. The
controller may include
an input/output in signal communication with a first control valve and a
second control valve.
The first control valve may be designed to adjust flow of the first liquid via
the first mixing
jumper thereby modifying the first flow rate. The second control valve may be
designed to adjust
flow of the second liquid via the second mixing jumper thereby modifying the
second flow rate.
The controller, in relation to the input/output, may be configured to, after
initiation of the
blending operation: (1) determine whether one or more of the first flow rate
or the second flow
rate are to be modified based on one or more of a target mix ratio, a ratio of
the first flow rate
and second flow rate, the first flow rate, or the second flow rate; and (2) in
response to a
determination that the first flow rate is to be modified, adjust a position of
the first flow control
valve that adjusts flow through the first mixing jumper, thereby modifying the
first flow rate; and
(3) in response to a determination that the second flow rate is to be
modified, adjust a position of
the second flow control valve that adjusts flow through the second mixing
jumper, thereby
modifying the second flow rate.
[0015] Still other aspects and advantages of these embodiments and other
embodiments, are
discussed in detail herein. Moreover, it is to be understood that both the
foregoing information
and the following detailed description provide merely illustrative examples of
various aspects
and embodiments, and are intended to provide an overview or framework for
understanding the
nature and character of the claimed aspects and embodiments. Accordingly,
these and other
objects, along with advantages and features of the present disclosure herein
disclosed, will
become apparent through reference to the following description and the
accompanying drawings.
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Date Recue/Date Received 2022-07-06
Furthermore, it is to be understood that the features of the various
embodiments described herein
are not mutually exclusive and may exist in various combinations and
permutations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other features, aspects, and advantages of the disclosure
will become better
understood with regard to the following descriptions, claims, and accompanying
drawings. It is
to be noted, however, that the drawings illustrate only several embodiments of
the disclosure
and, therefore, are not to be considered limiting of the scope of the
disclosure.
[0017] FIG. 1A, FIG. 1B, FIG. 1C, FIG. 1D, FIG. 1E, and FIG. 1F are schematic
block diagrams
of respective N-component in-line mixing systems positioned at a tank farm to
admix up to N
amount of hydrocarbon liquids from separate tanks into a single pipeline,
according to
embodiments of the disclosure.
[0018] FIG. 2A, FIG. 2B, FIG. 2C, and FIG. 2D are schematic block diagrams of
respective N-
component in-line mixing systems positioned at a tank farm to admix up to N
amount of
hydrocarbon liquids from separate tanks into a single pipeline, according to
embodiments of the
disclosure.
[0019] FIG. 3A and FIG. 3B are simplified block diagrams illustrating control
systems for
managing a multi-component in-line mixing system, according to embodiments of
the disclosure.
[0020] FIG. 4 is a flow diagram of a method for managing a multi-component in-
line mixing
system, according to an embodiment of the disclosure.
[0021] FIG. 5 is another flow diagram of a method for managing a multi-
component in-line
mixing system according to an embodiment of the disclosure
DETAILED DESCRIPTION
[0022] So that the manner in which the features and advantages of the
embodiments of the
systems and methods disclosed herein, as well as others that will become
apparent, may be
understood in more detail, a more particular description of embodiments of
systems and methods
briefly summarized above may be had by reference to the following detailed
description of
embodiments thereof, in which one or more are further illustrated in the
appended drawings,
which form a part of this specification. It is to be noted, however, that the
drawings illustrate
only various embodiments of the systems and methods disclosed herein and are
therefore not to
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Date Recue/Date Received 2022-07-06
be considered limiting of the scope of the systems and methods disclosed
herein as it may
include other effective embodiments as well.
[0023] The present disclosure provides embodiments of systems and methods for
in-line fluid
mixing of hydrocarbon fluids and/or liquids. "Hydrocarbon liquids" as used
herein, may refer to
petroleum liquids, renewable liquids, and other hydrocarbon based liquids.
"Petroleum liquids"
as used herein, may refer to liquid products containing crude oil, petroleum
products, and/or
distillates or refinery intermediates. For example, crude oil contains a
combination of
hydrocarbons having different boiling points that exists as a viscous liquid
in underground
geological formations and at the surface. Petroleum products, for example, may
be produced by
processing crude oil and other liquids at petroleum refineries, by extracting
liquid hydrocarbons
at natural gas processing plants, and by producing finished petroleum products
at industrial
facilities. Refinery intermediates, for example, may refer to any refinery
hydrocarbon that is not
crude oil or a finished petroleum product (e.g., such as gasoline), including
all refinery output
from distillation (e.g., distillates or distillation fractions) or from other
conversion units. In some
non-limiting embodiments of systems and methods, petroleum liquids may include
heavy blend
crude oil used at a pipeline origination station. Heavy blend crude oil is
typically characterized as
having an American Petroleum Institute (API) gravity of about 30 degrees or
below. However, in
other embodiments, the petroleum liquids may include lighter blend crude oils,
for example,
having an API gravity of greater than 30 degrees. "Renewable liquids" as used
herein, may refer
to liquid products containing plant and/or animal derived feedstock. Further,
the renewable
liquids may be hydrocarbon based. For example, a renewable liquid may be a
pyrolysis oil,
oleaginous feedstock, biomass derived feedstock, or other liquids, as will be
understood by those
skilled in the art. The API gravity of renewable liquids may vary depending on
the type of
renewable liquid.
[0024] In particular, in one or more embodiments, the disclosure provides an
in-line mixing
system that may be positioned at a tank farm that includes a plurality of
tanks configured to store
one or more hydrocarbon liquids. Such an in-line mixing system may provide
admixing of two or
more of those hydrocarbon liquids contained within the plurality of tanks to
provide a blended
mixture within a single pipeline. In some embodiments, the systems and methods
of the
disclosure may provide for in-line mixing of at least two hydrocarbon liquids,
at least three
hydrocarbon liquids, or more than three hydrocarbon liquids to form a blended
fluid flow in a
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Date Recue/Date Received 2022-07-06
single pipeline, e.g., which may be referred to herein as two-component
blends, three-component
blends, or a blend containing more than three hydrocarbon liquids.
Advantageously, in-line
mixing operations (sometimes referred to as "series mixing") may utilize one
or more controlled,
tank output streams (e.g., controlled via a mixing jumper including a flow
control device among
other devices and/or sensors), all of which are upstream of a common booster
pump used to
pump a blended fluid stream through a pipeline. Further, the in-line mixing
system may include
sensors, disposed throughout the tank farm, to determine various fluid
characteristics, allowing
for the in-line mixing system to blend the hydrocarbon liquids according to a
target blend
percentage, density, and/or gravity, providing a precisely blended fluid or
liquid stream. Further,
based on the configuration of such an in-line mixing system, any number of
component blends or
simply a single fluid may be formed or transported with low energy
utilization.
[0025] In some embodiments, the systems and methods as described herein may
provide for in-
line, on-demand, blending of crude oil, other hydrocarbon liquids, and/or
renewable liquids at a
pipeline origination station. A pipeline origination station is typically
located at or near a tank
farm (e.g., having a plurality of tanks containing hydrocarbon liquids). The
pipeline origination
station includes extensive piping capable of transporting the hydrocarbon
liquids from each of
the nearby tanks in the tank farm to one or more mainline booster pumps, which
raise the
hydrocarbon liquids to very high pressures for passage through the long
pipeline. A "tank farm"
as used herein, refers to a plurality of tanks positioned in an area, each of
the plurality of tanks
configured to hold one or more hydrocarbon liquids therein. In some
embodiments, the plurality
of tanks may be positioned proximate to each other or the plurality of tanks
may be spread out
across a larger area. In some embodiments, the plurality of tanks may be
positioned sequentially
such that each tank is equally spaced apart. Generally, the number of
individual tanks in a tank
farm may vary based on the size of the pipeline origination station and/or
based on the amount of
hydrocarbon liquids being stored in that facility. For example, the tank farm
may include at least
2, at least 4, at least 6, at least 8, at least 10, at least 12, or more
individual tanks within the tank
farm.
[0026] As noted above, typical pipeline origination stations require blending
of two or more
different hydrocarbon liquids in a blending tank prior to pumping the blended
hydrocarbon
liquids from the blending tank itself. However, the systems and methods of
this disclosure
advantageously provide in-line, on-demand mixing directly in a pipe in the
tank farm prior to the
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Date Recue/Date Received 2022-07-06
blended liquid being pumped to the pipeline. Such pipe blending may eliminate
stratification of
mixed oil in tanks and does not require the use of individual tank mixers in
each of the tanks.
These systems and methods may also eliminate the need to mix the hydrocarbon
liquids in one or
more tanks before the hydrocarbon liquids are pumped therefrom, which
advantageously allows
for the changing of the blend on-demand and on-demand blending during
operation of the
pipeline origination station. In some embodiments, for example, a separate
blending tank in the
tank farm is not necessary, and thus, one or more tanks in the tank farm
previously used for
blending may beneficially be used for storage of additional hydrocarbon
liquids, which may also
be blended in-line. Further, basing blending operations on various
measurements of fluids to be
mixed (e.g., flow and/or density or gravity) may increase accuracy and
precision of blending.
[0027] Other typical pipeline origination stations may use parallel mixing of
two or more
hydrocarbon liquids, which may be expensive and of lower efficiency. In
particular, typical
parallel mixing operations require a dedicated high horsepower mixing booster
pump (e.g.,
greater than 750 hp, greater than 850 hp, greater than 950 hp or even greater
than 1050 hp) for
each of the mixing streams and an additional static mixer to blend the
hydrocarbon liquids
pumped through each of the mixing streams. However, the systems and methods of
this
disclosure advantageously provide cost and energy savings, because such
systems and methods
do not require high horsepower mixing booster pumps or the additional static
mixer. For
example, the mixing booster pumps, if any are utilized, typically used in the
mixing streams of
the systems and methods described herein, have lower horsepower ratings (e.g.,
less than 250 hp,
less than 200 hp, less than 150 hp, or even less than 100 hp). In addition,
the in-line mixing
systems, according to this disclosure, may eliminate the need for any pumps,
other than the
downstream booster pump to transport fluids to other locations, while
including an amount of
isolation valves and control valves (e.g., one of each for each of the
streams). An isolation valve
may include an electrically actuated valve, a hydraulically actuated valve, a
manually actuatable
valve, a maintenance valve, and/or any valve configured to open or close based
one or more of a
transmitted signal or manual actuation. A control valve may include a valve
configured to open
to various positions, based one or more of a transmitted signal or manual
actuation, to control a
flow of fluid. Such isolation valves and control valves may utilize little
power in relation to
pumps, fixed or variable speed, and, in some embodiments, may utilize no
power, as actuation is
performed manually. The other devices utilized in such a tank farm may utilize
low power as
Date Recue/Date Received 2022-07-06
well, e.g., sensors and/or meters. Further, in-line mixing systems as
described herein may
provide for more accurate control of blended hydrocarbon liquids, for example,
within 1.0
percent or less of the desired set point (e.g., desired flow rate and/or
density or gravity) for the
blended fluid flow.
[0028] FIG. 1A, FIG. 1B, FIG. 1C, FIG. 1D, FIG. 1E, and FIG. 1F depict process
diagrams of a
non-limiting, N-component in-line mixing system positioned at a tank farm to
admix up to N
amount of hydrocarbon liquids from separate tanks into a single pipeline,
according to
embodiments of the disclosure. Turning first to FIG. 1A, the in-line mixing
system may include
two or more tanks 102A up to 102N (e.g., tank A 102A, tank B 102B, and up to
tank N 102N).
The tanks 102A-102N may store various hydrocarbon fluids or liquids. Such
hydrocarbon fluids
or liquids may include petroleum liquids and/or renewable liquids. The tanks
102A-102N may be
filled completely or partially prior to a blending operation. In another
embodiment, during a
blending operation the tanks 102A-102N may be re-filled. Such actions may
alter the flow rate
from such tanks 102A-102N, as well as, in some examples, the density or
gravity of the
hydrocarbon fluid or liquid therein. Further, as a tank empties during a
blending operation, the
flow rate may change (e.g., as a tank level decreases, the flow rate from the
tank may decrease).
Further still, other factors may affect flow rate from a tank, e.g., liquid
viscosity, density,
distance from mixing pipe 120, pipe diameter, and/or other characteristics.
The diameter of first
main pipe 104A-104N and second main pipe 105A-105N may be about 36 inches,
while the
diameter of the mixing jumper pipe 110A-110N may be about 16 inches to about
17 inches,
about 16 inches to about 18 inches, about 16 inches to about 19 inches, about
16 to about 20
inches, about 17 inches to about 18 inches, about 17 inches to about 19
inches, about 17 to about
20 inches, about 18 inches to about 19 inches, about 18 to about 20 inches,
about 19 inches to
about 20 inches, about 16 inches, about 17 inches, about 18 inches, about 19
inches, or about 20
inches, thereby allowing for greater control of flow from the tanks 102A-102N
when utilizing
the mixing jumper 116A-116N. In an embodiment, the first main pipe 104A-104N
and second
main pipe 105A-105N may be a larger or smaller than 36 inches in diameter. In
such an
embodiment, the mixing jumper pipe 110A-110N may be sized less than first main
pipe 104A-
104N and second main pipe 105A-105N. For example, if the first main pipe 104A-
104N and
second main pipe 105A-105N include a 16-inch diameter, then the mixing jumper
pipe 110A-
110N may be about 12 inches or less in diameter. Various other sizes of pipe
may be used based
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Date Recue/Date Received 2022-07-06
on the type of blending operations to be performed. Size of the first main
pipe 104A-104N and
second main pipe 105A-105N may be selected to minimize pressure drop and/or
increase flow of
fluid.
[0029] The in-line mixing system may include pipes corresponding to each of
the tanks 102A-
102N. A first main pipe 104A-104N or an output pipe may connect, at a first
end of the first
main pipe 104A-104N, each of the tanks 102A-102N to an isolation valve, at
second end of the
first main pipe 104A-104N. In other words, the isolation valve may be
positioned along the first
main pipe 104A-104N. Fluid flowing from the tanks 102A-102N may flow through
the first
main pipe 104A-104N to the isolation valve. As depicted in FIG. 1A, two
isolation valves (e.g.,
isolation valves 106A-106N and isolation valves 108A-108N) may control flow to
different
pipes (e.g., second main pipe 105A-105N and mixing jumper 116A-116N,
respectively). For
example, isolation valves 106A-106N may control (e.g., prevent or allow) flow
through the first
main pipe 104A-104N to the second main pipe 105A-105N. Isolation valves 108A-
108N may
control (e.g., prevent or allow) flow through first main pipe 104A-104N to the
mixing jumpers
116A-116N. In an embodiment, when one isolation valve is open, the other
isolation valve may
be closed (e.g., if isolation valve 106A-106N is open then isolation valve
108A-108N are closed
and if isolation valve 108A-108N is open then isolation valves 106A-106N are
closed). The
isolation valves (e.g., isolation valves 106A-106N and isolation valves 108A-
108N) may fully
open or fully close, rather than opening or closing to different positions or
degrees/percentages.
In another embodiment, rather than utilizing isolation valves, the in-line
mixing system may
utilize control valves. Control valves, as used herein, may open or close to
varying positions or
different degrees or percentages open or closed.
[0030] As noted, the in-line mixing system may include a mixing jumper 116A-
116N. The
mixing jumper 116A-116N may control the flow from a corresponding tank 102A-
102N (e.g.,
when two or more isolation valves 106A-106N are closed and two or more
isolation valves 1-
8A-108N are open allowing fluid to flow from the tanks 102A-102N through the
first main pipe
104A-104N to the mixing jumper 116A-116N). In an embodiment, if one tank is
providing fluid
to mixing pipe 120 (e.g., isolation valve 106A-106N is open and isolation
valves 108A-108N is
closed), then no other tank in the in-line mixing system may provide fluid to
the mixing pipe
120. In other words, if the main pipe 106A-106N is in use for one tank for a
blending operation
12
Date Recue/Date Received 2022-07-06
(e.g., a single component blend), then no other tank may be utilized in such a
blending operation,
either via main pipe or mixing jumper corresponding to the other tank.
[0031] The mixing jumper 116A-116N may include a number of devices or
components. The
mixing jumper 116A-116N may include a mixing jumper pipe 110A-110N, isolation
valve
108A-108N, a meter 112A-112N, and/or control valve 114A-114N. The mixing
jumper 116A-
116N may include more or less additional devices or components. Further, other
components
may be used in place of the components listed. For example, a pump may be
utilized rather than
or in addition to the control valve 114A-114N. In another embodiment, a
turbine may be utilized
rather than or in addition to the control valve 114A-114N. In such an
embodiment, the turbine
may control the flow rate through the mixing jumper 116A-116N, while in turn
generating
electrical power. Such electrical power may be utilized to power devices or
components of the
in-line mixing system or may be stored in on-site energy storage devices
(e.g., batteries or
capacitor based energy storage devices). Further, in such embodiments, the
turbines may limit
flow therethrough based on a gearbox corresponding to the turbine or based on
a variable
resistance rotor, or some combination thereof.
[0032] In an embodiment, once a blend operation is initiated isolation valves
106A-106N may
close and isolation valves 108A-108N corresponding to tanks 102A-102N utilized
in the
blending operation may be opened, allowing fluid to flow from selected tanks
102A-102N
through the first main pipe 104A-104N and isolation valve 108A-108N to the
mixing jumpers
116A-166N. The control valves 114A-114N corresponding to tanks 102A-102N
utilized in the
blending operation may be opened to a specified position, based on, for
example, the percentage
of fluids to be blended. As a blending operation begins, flow rates, as noted
above, may vary
over time, potentially altering the blend percentage. As such, each mixing
jumper 116A-116N
may include a meter 112A-112N or sensor to measure one or more characteristics
of the fluid
flowing from a corresponding tank 102A-102N. For example, the meter 112A-112N
may
measure the flow rate from the corresponding tank 102A-102N. A controller
(e.g., controller 122
as depicted in FIG. 1D) may receive the flow rate and/or other characteristic
as measured by
each meter 112A-112N or other sensors. Based on the flow rates, the controller
(e.g., controller
122) may determine a current blend ratio (e.g., the amount of fluid being
blend from each tank in
relation to the total blend). The controller may compare the current ratio to
a specified blend
ratio. Based on a difference between the current ratio and the specified blend
ratio, the controller
13
Date Recue/Date Received 2022-07-06
may transmit a signal to corresponding control valves 114A-114N indicating a
position that each
control valve 114A-114N may adjust to. Such measurements and adjustments may
occur
continuously, substantially continuously, or at specified time intervals.
[0033] As depicted in FIGS. 1A-1E, the mixing jumper 116A-116N may include an
inlet to
connect to the first main pipe 104A-104N and an outlet to directly connect to
the mixing pipe
120. The mixing pipe 120 may comprise a pipe of a different or the same
diameter as the first
main pipe 104A-104N and second main pipe 105A-105N (e.g., about 36 inches) or
the mixing
jumper pipe 110A-110N (e.g., about 30 inches or less or some other diameter
less than that of the
first main pipe 104A-104N and second main pipe 105A-105N).
[0034] As depicted in FIG. 1B, the in-line mixing system may include one
isolation valve 106A-
106N positioned along the main pipe, while omitting isolation valve 108A-108N.
As such, when
the isolation valve 106A-106N is open, fluid may flow through the first main
pipe 104A-104N
and second main pipe 105A-105N. When the isolation valve 106A-106N is closed,
fluid may
flow through the mixing jumper 116A-116N.
[0035] As depicted in FIG. 1C, the in-line mixing system may include other
meters or sensors
disposed in varying other locations. The in-line mixing system may include
tank meters 124A-
124N to measure the level in a corresponding tank 102A-102N. The level of a
tank may change
over time based on various actions (e.g., fluid flowing from a tank or fluid
filling the tank). The
tank level may offer an indication of the flow rate or how a flow rate may
change to a controller
122. Based on such an indication, the controller 122 may send signals to
control valves 114A-
114N to adjust to maintain a particular blend ratio during a two or more
component blending
operation. The in-line mixing system may additionally include a meter and/or
sensor 126A-126N
downstream of a corresponding tank 102A-102N. Such meters and/or sensors 126A-
126N may
measure some other characteristic of the fluid, e.g., flow, viscosity,
density, pressure,
temperature, and/or some other characteristic. Based on such measurements, the
controller 122
may transmit signals to the control valves 114A-114N to adjust to maintain a
particular blend
ratio during a two or more component blending operation based on the
additional measurements
and/or characteristics of the fluids.
[0036] In an example, the meters and/or sensors positioned throughout the in-
line mixing system
may be hydrometers, gravitometers, densitometers, density measuring sensors,
gravity measuring
sensors, pressure transducers, flow meters, mass flow meters, Coriolis meters,
viscometers,
14
Date Recue/Date Received 2022-07-06
optical level switches, ultrasonic sensors, capacitance based sensors, other
measurement sensors
to determine a density, gravity, flow, tank level, or other variable as will
be understood by those
skilled in the art, or some combination thereof. In such examples, the meters
and/or sensors may
measure the density and/or gravity of a liquid, the flow of the liquid, the
pressure of the liquid,
the viscosity of the liquid, and/or a tank level. As noted above, the
controller 122 may be in
signal communication with the sensors or meters. The controller 122 may poll
or request data
from the meters and/or sensors at various points in a blending operation or
process. The meter
and/or sensor may be in fluid communication with a liquid to measure the
density, gravity, or
flow rate or may indirectly measure density, gravity, or flow rate (e.g., an
ultrasonic sensor). In
other words, the sensor or meter may be a clamp-on device to measure flow
and/or density
indirectly (such as via ultrasound passed through the pipe to the liquid).
[0037] As depicted in FIG. 1F, rather than or in addition to the mixing
jumpers 116A-116N
utilizing a control valve, the mixing jumpers 116A-116N may utilize a flow
control device
130A-130N (also referred to as a mechanical flow controller, a flow control
apparatus, and/or
flow control subsystem). The flow control device 130A-130N may include a pump,
a meter, a
pressure transducer, a flow control valve, and/or some combination thereof. In
another example,
any of the meters and/or sensors of the in-line mixing system may be included
with or a part of
the flow control device 130A-130N. In such examples, each component of the
flow control
device 130A-130N may be in signal communication with the controller 122. The
flow control
device 130A-130N may allow for mix ratio adjustments of the liquids being
blended thereby to
adjust a blend ratio. For example, the flow control device 130A-130N may, as
noted, include a
flow control valve. The flow control valve may adjust the flow and/or pressure
of the liquid
based on opening or closing/pinching the flow control valve. In another
example, the flow
control device 130A-130N may include a pump and variable speed drive. The
variable speed
drive may increase/decrease the speed of the pump to increase/decrease the
flow rate of a liquid
to adjust the ratio of liquids to be blended.
[0038] The in-line mixing system, as noted may include a mixing pipe 120. The
mixing pipe 120
may include one or more connections to allow connections between the mixing
pipe 120 and
corresponding main pipes 104A-104N thereby enabling fluid communication
between the
mixing pipe 120 and corresponding main pipes 104A-104N. A booster pump 118 may
be
positioned downstream of each connection thereby pumping blended fluid to a
location further
Date Recue/Date Received 2022-07-06
downstream. The mixing pipe 120 may be a header. A header may be defined as a
pipe
arrangement that connects flowlines from several sources (e.g., tanks 102A-
102N) into a single
gathering line. In another embodiment, the mixing pipe 120 may include, for
example, a static
in-line mixing element or other mixing element configured to further
incorporate and/or blend
two or more fluids.
[0039] In an embodiment, the ratio of the flow of a second fluid to the flow
of a first fluid, and
potentially third, fourth, or more fluids, may be referred to herein as the
mix ratio or blend ratio
of the blended fluid flow. In some embodiments, the mix ratio may be varied in
the range of
about 1:99 (second fluid : first fluid) to about 99:1 (second fluid: first
fluid). For example, in
some embodiments, the blended fluid flow may include the flow of the second
fluid in an
amount of at least 5 percent, at least 10 percent, at least 15 percent, at
least 20 percent, at least 25
percent, at least 30 percent, at least 35 percent, at least 40 percent, at
least 45 percent, at least 50
percent, at least 55 percent, at least 60 percent, at least 65 percent, at
least 70 percent, at least 75
percent, at least 80 percent, at least 85 percent, at least 90 percent, at
least 95 percent, or more. In
some embodiments, the blended fluid flow may include the flow of the first
fluid in an amount of
at least 5 percent, at least 10 percent, at least 15 percent, at least 20
percent, at least 25 percent, at
least 30 percent, at least 35 percent, at least 40 percent, at least 45
percent, at least 50 percent, at
least 55 percent, at least 60 percent, at least 65 percent, at least 70
percent, at least 75 percent, at
least 80 percent, at least 85 percent, at least 90 percent, at least 95
percent, or more. Varying
percentages for multi-component blends may be utilized, e.g., 60:30:10,
30:30:40, 20:20:20:20,
etc.
[0040] FIG. 2A, FIG. 2B, FIG. 2C, and FIG. 2D depict process diagrams of a non-
limiting, N-
component in-line mixing system positioned at a tank farm to admix up to N
amount of
hydrocarbon liquids from separate tanks into a single pipeline, according to
embodiments of the
disclosure. The in-line mixing system of FIGS. 2A-2D include similar or the
same components
as those illustrated in FIGS. 1A-1F. For example, the in-line mixing system of
FIGS. 2A-2D may
include a plurality of tanks, such as tank A 102A, tank B 102B, and up to tank
N 102N. Each of
the tanks 102A-102N may include an outlet or port connected to a first end of
a first main pipe
104A-104N. The first main pipe 104A-104N may connect to the inlets of two
isolation valves,
e.g., an isolation valve 106A-106N for single component blends and an
isolation valve 108A-
108N of a mixing jumper 202A-202N for multiple component blends.
16
Date Recue/Date Received 2022-07-06
[0041] For example, if a multiple component blend is specified for a
particular blend or blending
operation, each isolation valve 106A-106N corresponding to tanks 102A-102N
utilized in the
blend or blending operation may be closed, while the isolation valves 108A-
108N corresponding
to tanks 102A-102N utilized in the blend or blending operation may be opened.
In such an
example, fluid may flow from the tanks 102A-102N through the first main pipe
104A-104N to
the isolation valve 108A-108N and through the isolation valve 108A-108N into
the mixing
jumper 202A-202N. The mixing jumpers 202A-202N may then adjust control valves
114A-114N
to drive the blend or mixture in the mixing pipe 120 to a specified blend
ratio (e.g., based on
characteristics provided by meters 112A-112N and/or other meters and/or sensor
positioned
throughout the in-line mixing system).
[0042] Rather than the outlet of the mixing jumper 202A-202N connecting at a
point along the
mixing pipe 120, the mixing jumper 202A-202N may connect at a point along the
second main
pipe 105A-105N downstream of the isolation valve 106A-106N. In other words,
flow of fluid
may be controlled via a mixing jumper 202A-202N bypassing the isolation valve
106A-106N. In
such examples, the fluid flowing from the mixing jumpers 202A-202N may flow to
the second
main line 105A-105N at a point downstream of the isolation valve 106A-106N.
Further, the
particular connection point (e.g., along the second main pipe 105A-105N or
mixing pipe 120)
may be determined based on physical factors of the in-line mixing system. For
example, the
mixing jumper 202A-202N may be positioned at a substantial distance from the
mixing pipe 120
(e.g., 50 feet, 100 feet, 200 feet, 300 feet, or even further). As such,
running a pipe from the
mixing jumper 202A-202N to the mixing pipe 120 may not be economical or, in
some cases,
physically possible. While the configuration described and depicted for FIGS.
1A-1F may depict
the mixing jumper 116A-116N (e.g., from the mixing jumper pipe 110A-110N to
the mixing
pipe 120), the configuration of the in-line mixing system for FIGS. 2A-2D may
utilize less
material (e.g., pipe). Further, the configuration in FIGS. 2A-2D may be
utilized when space or
real estate is limited at a site or tank farm. For example, a mixing pipe or
header at an existing
tank farm may include little to no available space based on current pipe
connections. As such, the
configurations depicted in FIGS. 2A-2D may be a configuration to utilize space
apart or separate
from the mixing pipe or header.
[0043] In an embodiment, the mixing jumpers 202A-202N of FIGS. 2A-2D or the
mixing
jumpers 116A-116N of FIGS. 1A-1F may be included in kits to be added to
existing tank farm
17
Date Recue/Date Received 2022-07-06
infrastructure. Such a kit may include each component and/or part illustrated
of the mixing
jumpers 202A-202N of FIGS. 2A-2D or the mixing jumpers 116A-116N of FIGS. 1A-
1F. In
another embodiment, the mixing jumpers 202A-202N of FIGS. 2A-2D or the mixing
jumpers
116A-116N of FIGS. 1A-1F may be constructed or installed along with a newly
constructed tank
farm. In yet another embodiment, some tanks at a tank farm may include the
mixing jumpers
202A-202N of FIGS. 2A-2D or the mixing jumpers 116A-116N of FIGS. 1A-1F, while
other
tanks may not. In such embodiments, some tanks at the tank farm may provide
gravity-fed
streams, via pipe sized similarly to the mixing jumper pipe used in the mixing
jumpers, to the
mixing pipe 120.
[0044] Further, FIG. 2D illustrates an in-line mixing system with a controller
122 and additional
meters and/or sensors (e.g., tank meter 124A-124N and meters and/or sensors
126A-126N). Such
meters and/or sensors may be utilized by the controller 122 to determine how
to adjust the
control valves 114A-114N to utilized in a blend or blending operation. In
another embodiment, a
meter or sensor may be positioned downstream of where the mixing jumper 202A-
202N
connects to the second main pipe 105A-105N, rather than in the mixing jumper
202A-202N. In
such examples, the meter or sensor may, in addition to determining
characteristics of a fluid from
the mixing jumper 202A-202N, determine the same characteristic flowing through
the isolation
valve 106A-106N. Another meter or sensor may be positioned along the mixing
pipeline 120, for
example, immediately upstream or downstream of the booster pump 118. Such a
meter or sensor
may be utilized by the controller 122 to determine additional characteristics
of a blend or mixture
to be utilized in a blend or blending operation.
[0045] FIG. 3A and FIG. 3B are simplified diagrams illustrating control
systems for managing a
multi-component in-line mixing system, according to an embodiment of the
disclosure. The
control system, as described herein, may be a controller 302, one or more
controllers, a PLC, a
SCADA system, a computing device, and/or other components to manage a blending
operation.
The controller 302 may include one or more processors (e.g., processor 304) to
execute
instructions stored in memory 306. In an example, the memory 306 may be a
machine-readable
storage medium. As used herein, a "machine-readable storage medium" may be any
electronic,
magnetic, optical, or other physical storage apparatus to contain or store
information such as
executable instructions, data, and the like. For example, any machine-readable
storage medium
described herein may be any of random access memory (RAM), volatile memory,
non-volatile
18
Date Recue/Date Received 2022-07-06
memory, flash memory, a storage drive (e.g., hard drive), a solid state drive,
any type of storage
disc, and the like, or a combination thereof. As noted, the memory 306 may
store or include
instructions executable by the processor 304. As used herein, a "processor"
may include, for
example one processor or multiple processors included in a single device or
distributed across
multiple computing devices. The processor 304 may be at least one of a central
processing unit
(CPU), a semiconductor-based microprocessor, a graphics processing unit (GPU),
a field-
programmable gate array (FPGA) to retrieve and execute instructions, a real
time processor
(RTP), other electronic circuitry suitable for the retrieval and execution
instructions stored on a
machine-readable storage medium, or a combination thereof.
[0046] As used herein, "signal communication" refers to electric communication
such as hard
wiring two components together or wireless communication, as understood by
those skilled in
the art. For example, wireless communication may be Wi-FiO, Bluetooth0,
ZigBee, forms of
near field communications, or other wireless communication methods as will be
understood by
those skilled in the art. In addition, signal communication may include one or
more intermediate
controllers, relays, or switches disposed between elements that are in signal
communication with
one another.
[0047] As noted, the memory 306 may store instructions executable by the
processor 304. The
instructions may include instructions 308. Such instructions 308 may determine
various
characteristics of fluid flowing within the in-line mixing system 300. The
controller 302 may
poll various meters and/or sensors positioned throughout the in-line mixing
system 300
continuously, substantially continuously, or at a specified interval. For
example, and as
illustrated in FIG. 3A, the controller 302 may receive measurements from
meters 316A-316N,
e.g., via an input. As illustrated in FIG. 3B, the controller may receive, in
addition to or separate
from measurements from meters 316A-316N, measurements from tank meters 326A-
326N
and/or meters/sensors 324A-324N, e.g., via an input. Such measurements may
include a tank
level, flow rates of fluids at various points within the in-line mixing system
300, density or
gravity of each liquid within the in-line mixing system 300, temperature
and/or viscosity of each
liquid within the in-line mixing system 300, and/or any other relevant
characteristic of the fluid
within the in-line mixing system 300.
[0048] The memory 306 may store instructions 310 to determine a corrected
ratio of fluids being
mixed in a blending operation. The corrected ratio may be based on a specified
blend ratio (e.g.,
19
Date Recue/Date Received 2022-07-06
a ratio of fluids to be blended at specific percentages for a blending
operation), the previous
determined blend ratio, the currently measure characteristics of the fluid
within the in-line
mixing system. Using the currently determined blend ratio and the specified
blend ratio, the
controller 302 may determine a corrected blend ratio. The corrected blend
ratio may include
indications as to what particular flow rates may require adjustment (e.g.,
what position a control
may be adjusted to, to drive a blend to the corrected ratio). In some
examples, the signal may
include positions of control valves (e.g., the position one or more of the
control valves may
adjust to, to drive a blend to the corrected ratio), speed of a pump (e.g., to
increase or decrease a
particular component of a blend), or adjustment of another flow control device
of the in-line
mixing system 300.
[0049] The memory 306 may include instructions 312. Instructions 312 may
include transmitting
a signal to a device indicating a position for the device to adjust to, to
control flow of liquid
through the mixing jumper (e.g., via adjusting position of a jumper control
valve 322A-322N).
The signal may be transmitted from an output or input/output of the controller
302 to the device.
Other flow control devices may be adjusted. Such adjustments may drive a blend
to the corrected
blend ratio and thus to the specified blend ratio. In other words, flow may be
increased or
decreased through one particular mixing jumper, while increased or decreased
in another mixing
jumper to correct an altered blend ratio (e.g., such alteration occurring
based on various factors,
such as variable flow rates based on operating conditions or tank levels
and/or other factors). For
example, the controller 302 may poll a tank level meter or gauge periodically
(e.g., determine a
tank level at selected times or substantially continuously). As the tank level
decreases overtime,
the controller 302 may automatically adjust an open position of a
corresponding control valve to
offset any fluid flow rate reduction based on the measured tank level (e.g.,
increase the open
position to adjust for decreasing tank levels and/or decrease open position to
adjust for increasing
tank levels).
[0050] In an embodiment, the memory 306 may include instructions related to
blend operation
initiation. Such instructions may include the opening or closing of isolation
valves (e.g., main
isolation valves 318A-318N, also referred to as a main valve, and jumper
isolation valves 320A-
32N, also referred to as a jumper valve). For example, for a single fluid
operation, a main
isolation valve corresponding to a tank in the operation may open, while the
corresponding
jumper control valve may close. In another embodiment, for a multiple
component blend, the
Date Recue/Date Received 2022-07-06
controller may indicate to two or more main isolation valves to close and two
or more jumper
control valves to open.
[0051] In another embodiment, the memory 306 may store instructions to drive
flow rates of any
particular fluid utilized in a blend operation to a specific set point. For
example, a user may set a
specific flow rate for two or more different fluids for a particular blend
operation. The controller
302 may determine, based on meters and/or sensors positioned at each mixing
jumper, a flow
rate. If the flow rate does not match, the controller 302 may transmit a
signal to any particular
control valve to adjust the flow rate of a corresponding fluid to the set
point flow rate.
[0052] FIG. 4 is a flow diagram, such as implemented in a controller, of a
method 400 for
managing a multi-component in-line mixing system according to an embodiment of
the
disclosure, according to an embodiment of the disclosure. The method 400 is
detailed with
reference to the controller 302 and in-line mixing system 300 of FIG. 3.
Unless otherwise
specified, the actions of method 400 may be completed within the controller
300, for example,
but it also may be implemented in other systems and/or computing devices as
will be understood
by those skilled in the art. Specifically, method 400 may be included in one
or more programs,
protocols, or instructions loaded into the memory 306 of the controller 302
and executed on the
processor 304 or one or more processors of the controller 302. The order in
which the operations
are described is not intended to be construed as a limitation, and any number
of the described
blocks may be combined in any order and/or in parallel to implement the method
400.
[0053] At block 402, a controller 302 may receive blend parameters for a
blending operation.
The blend parameters may include a ratio of one or more different liquids from
one or more
corresponding tanks. The blend parameters may additionally include a length of
time of the
blend operation. Other factors or variables may be included in the blend
parameters, including
type of fluids, gravity or density of the fluids, and/or other relevant
information. Blend
parameters may be received from other computing devices or controllers or, in
another
embodiment, from a user interface 314.
[0054] At block 404, the controller 302 may determine whether the blend is a
single component
blend or, in other words, whether the desired end product includes a single
type of fluid. Such a
determination may be made based on the blend parameters received or based on
input received at
a user interface 314.
21
Date Recue/Date Received 2022-07-06
[0055] At block 406, if the blend operation includes a single tank, the
controller may transmit a
signal to a corresponding main isolation valve to open. As no other tanks may
be utilized in such
an operation, the corresponding main isolation valve may receive the signal,
rather than all main
isolation valves.
[0056] At block 408, after the main isolation valve is open, the controller
302 may transmit a
signal to the jumper isolation valve to close. The controller 302 may transmit
such a signal to the
corresponding jumper isolation valve, rather than all jumper isolation valves.
At block 410,
controller 302 may wait until such an operation is finished. Once the
operation is finished, the
controller 302 may wait until new blend parameters are received.
[0057] At block 412, if the blend includes two or more tanks, the controller
302 may transmit a
signal to corresponding jumper isolation valves to open. At block 414, the
controller 302 may
transmit a signal to corresponding main isolation valves to close.
[0058] At block 416, after the blending operation has been initiated, the
controller 302 may
measure a fluid pressure, fluid flow, fluid density, and/or a tank level for
each tank utilized. Such
received characteristics or measurements may depend on the type of meters
and/or sensors
included in the in-line mixing system.
[0059] At block 418, based on the received characteristics, the controller 302
may determine a
current mix ratio (e.g., the current blend ratio of the blending operation).
At block 420, the
controller may determine whether the mix ratio is correct or within a
percentage of error (e.g.,
0.1%, 0.2%, 0.3%, or up to 1%). If the mix ratio is not correct, the
controller 302 may move to
block 422. If the mix ratio is correct, the controller 302 may move to block
426.
[0060] At block 422, the controller 302 may determine a corrected ratio. The
correct ratio may
be based on the received blend parameters and the current mix ratio. At block
424, the controller
302, based on the corrected ratio, may adjust corresponding control valves. At
block 426, the
controller 302 may determine whether the blend operation is finished. If the
operation is not
finished, the controller 302 may continue to check measurements and adjust
accordingly,
otherwise the controller 302 may wait to receive new blend parameters.
[0061] FIG. 5 is another flow diagram, such as implemented in a controller, of
a method 500 for
managing a multi-component in-line mixing system according to an embodiment of
the
disclosure, according to an embodiment of the disclosure. The method 500 is
detailed with
reference to the controller 302 and in-line mixing system 300 of FIG. 3.
Unless otherwise
22
Date Recue/Date Received 2022-07-06
specified, the actions of method 500 may be completed within the controller
300, for example,
but it also may be implemented in other systems and/or computing devices as
will be understood
by those skilled in the art. Specifically, method 500 may be included in one
or more programs,
protocols, or instructions loaded into the memory 306 of the controller 302
and executed on the
processor 304 or one or more processors of the controller 302. The order in
which the operations
are described is not intended to be construed as a limitation, and any number
of the described
blocks may be combined in any order and/or in parallel to implement the method
500.
[0062] At block 502, a controller 302 may initiate a hydrocarbon liquid
process (e.g., a blend
operation or blend process). The controller 302 may determine that the
hydrocarbon liquid
process is to be initiated based on one or more of reception of blend
parameters or an input from
a user, another controller, or other computing device. Such an input may
include a signal
indicating that the hydrocarbon liquid process is to begin. The blend
parameters may include a
ratio of one or more different liquids from one or more corresponding tanks.
The blend
parameters may additionally include a length of time of the hydrocarbon liquid
process. Other
factors or variables may be included in the blend parameters, including type
of fluids, gravity or
density of the fluids, and/or other relevant information. Blend parameters may
be received from
other computing devices or controllers or, in another embodiment, from a user
interface 314.
[0063] At block 504, the controller 302 may transmit a signal to main valves
(e.g., main valves
of tanks to be utilized or corresponding to a hydrocarbon liquid in the
hydrocarbon liquid
process) to close. At block 506, the controller 302 may transmit a signal to
corresponding jumper
valves (e.g., jumper valves of tanks to be utilized or corresponding to a
hydrocarbon liquid in the
hydrocarbon liquid process) to open. Once the jumper valves are open and the
main valves are
closed, the controller 302 may begin the hydrocarbon liquid process (e.g., the
controller 302 or a
user opening a port or valve (via manual actuation or based on a signal
received from the
controller 302) on a tank to allow a hydrocarbon liquid to flow from the tank
to the jumper
valves).
[0064] At block 508, after the hydrocarbon liquid process has begun, the
controller 302 may
measure a flow rate of each hydrocarbon liquid flowing to a mixing pipe or
pipeline or header.
The controller 302 may additionally measure fluid pressure, fluid density,
and/or a tank level for
each tank utilized. Such received characteristics or measurements may depend
on the type of
meters and/or sensors included in the in-line mixing system.
23
Date Recue/Date Received 2022-07-06
[0065] At block 510, based on the received flow rate and/or other
characteristics, the controller
302 may determine a current mix ratio (e.g., the current blend ratio of the
blending operation)
and determine whether the current mix ratio is different (e.g., within a
percentage of error, such
as within 0. 1%, 0.2%, 0.3%, or up to 1%) than a selected or pre-set mix ratio
(e.g., the selected
or pre-set mix ratio, for example, included in the blend parameters). If the
mix ratio is not
different or is within a percentage of error, the controller 302 may move to
block 516 and
determine whether the hydrocarbon liquid process is finished or complete. If
the mix ratio is
different or not within a percentage of error, the controller 302 may move to
block 512 to
determine a corrected ratio.
[0066] At block 512, the controller 302 may determine a corrected ratio. The
correct ratio may
be based on the received blend parameters and the current mix ratio. At block
514, the controller
302, based on the corrected ratio, may adjust corresponding control valves. At
block 516, the
controller 302 may determine whether the hydrocarbon liquid process is
finished. If the operation
is not finished, the controller 302 may continue to check measurements and
adjust accordingly,
otherwise the controller 302 may wait to receive new blend parameters or
initiate another
hydrocarbon liquid process.
[0067] In the drawings and specification, several embodiments of systems and
methods to
provide in-line mixing of hydrocarbon liquids have been disclosed, and
although specific terms
are employed, the terms are used in a descriptive sense only and not for
purposes of limitation.
Embodiments of systems and methods have been described in considerable detail
with specific
reference to the illustrated embodiments. However, it will be apparent that
various modifications
and changes may be made within the spirit and scope of the embodiments of
systems and
methods as described in the foregoing specification, and such modifications
and changes are to
be considered equivalents and part of this disclosure.
24
Date Recue/Date Received 2022-07-06
