Methods and systems for spillback control of in-line mixing of hydrocarbon liquids
Methods and systems of admixing hydrocarbon liquids from two or more sets of tanks into a single pipeline to provide in-line mixing thereof. In an embodiment of the in-line mixing system, hydrocarbon liquids stored in at least one tank of each of two or more sets of tanks positioned at a tank farm are blended into a blend flow pipe via in-line mixing and the blended mixture is pumped through a single pipeline. In one or more embodiments, the in-line mixing system employs a separate spillback or recirculation loop that is fluidly connected to each set of the two or more sets of tanks to control the flow of the hydrocarbon fluid/liquid from each set of tanks to the blend flow pipe. Associated methods of operating one or more embodiments of the system include regulation of spillback or recirculation loop flow rate and/or pressure to drive the actual blend ratio towards a desired blend ratio.
1 . An in-line liquid mixing system comprising:
a first set of tanks, one or more tanks of the first set of tanks containing a first liquid of one or more hydrocarbon liquids, petroleum liquids, or renewable liquids therein, each tank in the first set of tanks connected to and in liquid flow communication with a first header;
a second set of tanks, one or more tanks containing a second liquid of one or more hydrocarbon liquids, petroleum liquids, or renewable liquids therein, each tank in the second set of tanks connected to and in liquid flow communication with a second header;
one or more first pumps positioned to increase pressure of liquid flow therethrough;
one or more flow meters positioned to measure a flow rate;
one or more spillback pipes each comprising a spillback loop in fluid communication with the first header or the second header, the spillback loop comprising a control valve configured to adjust a flow rate of liquid flow therethrough;
one or more blend pipes configured to admix liquid that flows from one or more first booster pipes downstream of the one or more flow meters with liquid that flows through one or more second booster pipes to create a blend flow; and
one or more blend meters connected to the one or more blend pipes to measure a flow rate of the blend flow through the one or more blend pipes.
2 . The in-line liquid mixing system of claim 1 , wherein the one or more spillback pipes comprise:
a first spillback pipe having a first connection to the one or more first booster pipes positioned between a first flow meter of the one or more flow meters and the one or more first pumps and a second connection to the first header upstream of the first set of tanks, the first spillback pipe including a first control valve of the one or more control valves, the first control valve configured to adjust a flow rate of liquid flow through the first spillback pipe between the one or more first booster pipes and the first header; and
a second spillback pipe having a first connection to the second booster pipe downstream of a second pump and a second connection to the second header upstream of the second set of tanks, the second spillback pipe including a second control valve of the one or more control valves, the second control valve configured to adjust a flow rate of liquid flow through the second spillback pipe between the one or more second booster pipes and the second header.
3 . The in-line liquid mixing system of claim 2 , wherein the first spillback pipe includes a first differential pressure transmitter (DPIT) positioned to measure differential pressure of liquid flow upstream and downstream of the first control valve and the second spillback pipe includes a second DPIT positioned to measure differential pressure of liquid flow upstream and downstream of the second control valve.
4 . The in-line liquid mixing system of claim 3 , further comprising one or more controllers in signal communication with each of the first control valve and the second control valve, wherein the one or more controllers controls an open percentage of the first control valve to adjust the flow rate of the liquid flow through the first spillback pipe.
5 . The in-line liquid mixing system of claim 4 , wherein the one or more controllers is positioned in signal communication with the one or more flow meters, the first DPIT, and the second DPIT, wherein the one or more controllers determines the flow rate of liquid through the first spillback pipe based on the differential pressure measured by the first DPIT, wherein the one or more controllers determines the flow rate of liquid through the second spillback pipe based on the differential pressure measured by the second DPIT.
6 . The in-line liquid mixing system of claim 2 , further comprising one or more controllers in signal communication with each of the first control valve and the second control valve, wherein the one or more controllers controls an open percentage of the first control valve to adjust the flow rate of the liquid flow through the first spillback pipe.
7 . The in-line liquid mixing system of claim 2 , further comprising one or more controllers in signal communication with each of the first control valve and the second control valve, wherein the one or more controllers controls an open percentage of the second control valve to adjust the flow rate of liquid flow through the second spillback pipe and a ratio of first flow rate to a flow rate of the blend flow.
8 . The in-line liquid mixing system of claim 2 , further comprising one or more controllers in signal communication with each of the first control valve and the second control valve, wherein the one or more controllers adjusts the first control valve to drive the flow rate of the liquid flow through the first spillback pipe toward a first set point flow rate.
9 . The in-line liquid mixing system of claim 8 , further comprising one or more controllers in signal communication with each of the first control valve and the second control valve, wherein the one or more controllers adjusts the second control valve to drive the flow rate of the liquid flow through the first spillback pipe toward a second set point flow rate.
10 . The in-line liquid mixing system of claim 2 , further comprising one or more controllers in signal communication with each of the first control valve and the second control valve, wherein the one or more controllers adjusts at least one of the first control valve or the second control valve to drive a ratio of first flow rate to a flow rate of the blend flow toward a set point.
11 . A method of admixing one or more hydrocarbon liquids, petroleum liquids, or renewable liquids, the method comprising:
blending two or more liquids of the one or more of the hydrocarbon liquids, petroleum liquids, or renewable liquids, at least one of the two or more liquids being stored in a tank of a first set of tanks and at least another of the two or more liquids being stored in a tank of a second set of tanks, each tank of the first and second sets of tanks being connected to one or more blend pipes to blend the two or more liquids into a blended liquid;
determining or measuring a first flow rate of the one or more liquids flowing from the first set of tanks into the one or more blend pipes;
determining or measuring a blend flow rate of the blended liquid in the one or more blend pipes;
determining a second flow rate of the one or more liquids flowing from the second set of tanks into the one or more blend pipes; and
in response to a difference between a target ratio and a ratio of the first flow rate to the second flow rate:
determining ratio adjustments for the first flow rate relative to the second flow rate, and
adjusting one or more control valves based on the ratio adjustments, to modify a first spillback flow rate of a flow of the one or more liquids from the first set of tanks recirculated in a first spillback loop and the first flow rate to drive the ratio towards the target ratio.
12 . The method of claim 11 , further comprising:
determining a first spillback flow rate based on a function of at least density of the one or more liquids that flow from the first set of tanks and a differential pressure upstream and downstream of one or more flow control valves connected to the first spillback loop; and
the determining a second spillback flow rate based on a function of at least density of the one or more liquids that flow from the second set of tanks and a differential pressure upstream and downstream of one or more control valves connected to a second spillback loop positioned upstream of the one or more blend pipes.
13 . The method of claim 11 , wherein at least one of first flow rate or the second flow rate is determined based on the blend flow rate.
14 . The method of claim 11 , wherein the flow of the one or more hydrocarbon liquids from the first set of tanks that is recirculated in the first spillback loop enters the first spillback loop downstream of a first pump and upstream of the blend pipe, and wherein a flow of the one or more liquids from the second set of tanks that is recirculated in a second spillback loop enters the second spillback loop downstream of a second pump and upstream of the blend pipe.
15 . The method of claim 12 , wherein a differential pressure upstream and downstream of the one or more control valves connected to the first spillback loop is determined by a first DPIT, and wherein a differential pressure upstream and downstream of the one or more control valves connected to a second spillback loop is determined by a second DPIT.
16 . The method of claim 12 , further comprising adjusting a control valve in a second spillback loop to drive a second spillback flow rate towards a set point.
17 . A method of admixing one or more hydrocarbon liquids or renewable liquids, the method comprising:
blending two or more liquids of the one or more of the hydrocarbon liquids or renewable liquids, at least one of the two or more liquids being stored in a tank of a first set of tanks and at least another of the two or more liquids being stored in a tank of a second set of tanks, each tank of the first and second sets of tanks being connected to one or more blend pipes to blend the two or more liquids into a blended liquid;
determining a target blend ratio of one or more liquids flowing from the first set of tanks into the one or more blend pipes and one or more liquids flowing from the second set of tanks into the one or more blend pipes;
measuring a first flow rate of the one or more liquids flowing from the first set of tanks into the one or more blend pipes;
measuring a blend flow rate of the blended liquid in the one or more blend pipes;
determining a second flow rate of the one or more liquids flowing from the second set of tanks into the one or more blend pipes;
determining a first spillback flow rate of a flow of the one or more liquids from the first set of tanks when recirculated in a first spillback loop positioned upstream of the one or more blend pipes; and
adjusting the first flow rate based on the first flow rate, a target first flow rate, and the first spillback flow rate.
18 . The method of claim 17 , wherein the determining the first spillback flow rate is based on a function of at least density of the one or more liquids that flow from the first set of tanks and a differential pressure upstream and downstream of one or more flow control valves connected to the first spillback loop, the method further comprising determining a second spillback flow rate based on a function of at least density of the one or more liquids that flow from the second set of tanks and a differential pressure upstream and downstream of one or more control valves connected to the second spillback loop.
19 . The method of claim 17 , wherein at least one of first flow rate or the second flow rate is determined based on the blend flow rate, wherein the flow of the one or more liquids from the first set of tanks that is recirculated in the first spillback loop enters the first spillback loop downstream of a first pump and upstream of the blend pipe.
20 . The method of claim 18 , wherein the differential pressure upstream and downstream of the one or more control valves connected to the first spillback loop is determined by a first DPIT, and wherein the differential pressure upstream and downstream of the one or more control valves connected to the second spillback loop is determined by a second DPIT, and the method further comprising adjusting the one or more control valves to drive the second spillback flow rate towards a set point.