Proceedings of the 8th International Pipeline Conference

IPC2010
September27-
September 27-October
October 1, 2010, Calgary, Alberta, Canada

IPC2010-
IPC2010-31142

PIPELINE BATCH PLANNING TO OPTIMIZE STORAGE REQUIREMENTS

Bill Ma Alan Zhou Jim Steeves

WorleyParsons Canada WorleyParsons Canada WorleyParsons Canada
Calgary, Alberta, Canada Calgary, Alberta, Canada Calgary, Alberta, Canada

ABSTRACT per annum (MMTPA) of product initially and increase to 4.755

Pipeline batch delivery is a common practice in the MMTPA in full capacity. In this paper, only the initial phase is
industry to transport multiple products in the same pipeline. used to demonstrate the batch planning analysis. The
Proper batch planning can minimize the product storage objectives are to calculate interface volume between adjacent
requirement in operating a pipeline system. Transporting fluids batches of products in the pipeline, and determine the batch
in batches without using separation pigs can result in interface volume, sequence, schedule and the tank storage volumes.
contamination between two different fluids in the pipeline. The There are eight different petroleum products that will be
volume of interfaces is closely related to the diffusion and transported in the pipeline system.
dispersions occurred on the interface, which are dependent on  Product-1
product properties such as density and viscosity, fluid flow  Product-2
velocity, flow regime, pipeline mechanical configuration, pipe  Product-3
diameter and roughness, and travelling distance. In general, a  Product-4
turbulent flow is preferred to minimize the boundary viscous  Product-5
layer, thus, reducing the interface volume. The batching  Product-5a
sequence is typically arranged so as to achieve the minimum  Product-6
batch interface contamination with the distance travelled.
 Product-7
Normally, this is done by arranging the adjacent batches in
Table 1 lists the primary fluid properties of these products.
descending or ascending order of the product quality or density.
In this paper, a batch delivery analysis is performed on a Table 1: Product Properties
proposed multiproduct pipeline to transport eight refined
products from a refinery to a delivery terminal through a Products
240 km NPS 18 pipeline. The minimum volume of each Properties
product making up a batch will be sized to allow for reinjection 1 and 2 3 and 4 5 and 5a 6 7
of the interfaces back into the corresponding product tanks at
the delivery terminal according to a set of contamination Density,
740 830 800 800 680
criteria. The proposed batch sequence is to minimize the (kg/m3)
required tank storage volume.
0.5 @ 5.0 @ 1.0 @ 1.2 @ 0.5 @
A dynamic hydraulic flow simulator is utilized in this study to
confirm the batch planning of the delivery system. The model Viscosity, 40 °C 40 °C 100 °C 40 °C 40 °C
is developed with the optimized batch plan and the dynamic net (cSt) 0.7 @ 8.0 @ 1.6 @ 1.5 @ 0.7 @
tank storage requirement for each product is determined. This
paper will detail the methodology for batching design and tank 20 °C 20 °C 40 °C 20 °C 20 °C
storage calculations.
The throughput of different products is provided in million
1 INTRODUCTION metric tones per annum (MMTPA) as shown in ANNEX A.
The pipeline is an NPS 18 with 240 km in length, which will The volumetric conversion is based on the total operating time
deliver eight petroleum products from a refinery to the existing of 8000 hours per annum. The pipeline suction pressure and
terminals. The pipeline will transport 4.0 million metric tones

1 Copyright © 2010 by ASME

1 Copyright © 2010 by ASME
delivery pressure are all assumed as 350 kPag. The product
injection temperature is about 25°C.
3 METHODOLOGY
The batching sequence is arranged in such a way that it will
result in the least batch interface contamination and the
minimum storage volume for different products. Products that
are most closely related in quality and have the least difference
in density tend to form a shorter length of interfaces. Normally,
the sequencing of batches is arranged in such a way that
products closely related are adjacent in descending or
ascending order of quality or density to minimize batch
interfaces.
As a consequence of batching, interface occurs between
batches. This interface is a mixture which occurs between
adjacent batches of products having different specifications.
Each interface volume will contain a 50/50 mix of the adjacent
batches. The volume of interfaces depends on product
properties such as density and viscosity, fluid velocity, pipe
diameter, and travelling distance. If the pipeline is kept in
turbulent flow at all times, a smaller volume of interface is
formed. The extent to which a product can be safely thrown off
specification determines how much adjacent product can be
blended with it. An allowance factor of 1.1 is provided for the
maximum interface volume to account for operational
uncertainty during interface switching.
The minimum volume of each product making up a batch will
be sized to allow reinjection of the interfaces back into the
corresponding product tanks at the delivery terminal. The
minimum batch size and maximum interface volumes shall
meet the contamination criteria provided by the client.
A dynamic hydraulic flow simulator is used in this project. The
models are set up based on the batch design including the
recommended batch cycles and batch sizes in this study. The
batch schedule and tank storage volume are determined based
on the simulation result.
4 BATCH STUDY
4.1 CONTAMINATION ANALYSIS
The allowable contamination is provided in ANNEX B. The
contamination analysis can be summarized as follows.
 In all cases, Product-6 is the heart cut. Only Product-5
or Product-5a is compatible with Product-6 because
the accepted contamination level of Product-5 or
Product-5a by Product-6 is 100%; therefore, the
preceding and the following batches of Product-6
must be Product-5 or Product-5a and one of the only
accepted batch subsequence is as the form of “5 or 5a
– 6 – 5”. The interface between Product-5/5a 5 and
Product-6 can be injected into the Product-5 or 5a
tanks.
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2 Copyright © 2010 by ASME
 The contamination criteria table indicates that
Product-3 can allow 100% contaminant from Product-
4 and Product-1 can allow 100% contaminant from
Product-2. The interfaces of Product-3/4 and Product-
1/2 can be fully cut into the Product-3 and Product-1
tanks respectively. The conclusion is Product-3 and 4
or Product-1 and 2 can be transported adjacently
without violating the contamination criteria. On the
other hand, this kind of batch sequence will cause the
losses of Product-4 or Product-2 because the whole
interfaces are cut into the Product-3 or Product-1
tanks.
 The sulphur content is given to be less than 50 ppm
for Product-5a and less than 2500 ppm for Product-5.
The main purpose of product-5a is batched as a buffer
to separate product-3 and 4 or product-1 and 2. One of
the advantages is that the interface between product-4
or Product-2 and Product-5a can be injected into the
Product-4 or Product-2 tanks thereby eliminating the
losses of the Product-4 or Product-2. The
recommended batch subsequences are as the forms of
“5a – 4 – 5a” and “5a – 2 – 5a”.
 The allowable contamination level of Product-5 in
Product-7 is 1.5%; therefore, Product-7 can be
transported in the form of “5 – 7 – 5”. The interface
shall be injected into the Product-7 tank and small
portion of the interface can also be injected into the
Product-1 tank.
The resultant interfaces are injected into the corresponding
product tanks as summarized in Table 2. The reinjection
volume of the interface and the pure product volume in the tank
must meet the contamination criteria.
Table 2: Interface and Product Tank
Interface Product Tank
4 / 5a 4
3 / 5 or 5a 3
5/ 6 5
5a / 6 5a
5 / 5a 5
1 / 5 or 5a 1
2 / 5a 2
7/5 7
435-JH0902-00-PR-REP-0002 Rev.C
4.2 INTERFACE PREDICTIONS
The method for calculating the interface length and volume
Table 4: The Blended Viscosity at 25°C
between two products is based on the Austin and Palfrey
equation [1]. The following describes the steps for the Viscosity (cSt)
calculation of the interface length and volumes. Interface A B
@ 25 °C
1) Use the ASTM correlation to calculate A and B for
3 4 8.1 3.3 7.0
each product based on viscosity values at two different
temperatures listed in Table 3. 3 or 4 5 or 5a 7.9 3.3 3.4
LogLog   0.7   A  B logT  5 or 5a 6 8.5 3.6 1.7
Where 5 or 5a 1 11.6 4.9 1.4
 = viscosity of liquid, cSt 1 2 22.9 9.6 0.6
T = absolute temperature, °K
A, B = constants 1 or 2 7 21.9 9.2 0.6
5 or 5a 7 11.3 4.8 1.3
Table 3: Product Viscosity and Constants A&B
3) The Reynolds number and the critical Reynolds
Viscosity (cSt) Constants
Products number for the blended product
20°C 40°C 100°C A B Vd
Re   106
6 1.5 1.2 - 9.6 4.1 b
3 8.0 5.0 - 8.1 3.3 Where  b = viscosity of blended product, cSt
4 8.0 5.0 - 8.1 3.3 V= fluid velocity, m/s
1 0.70 0.5 - 22.9 9.6 d = inside pipe diameter, m
2 The critical Reynolds number is found from
 
0.70 0.5 - 22.9 9.6
7 0.70 0.5 - 21.0 8.8 Rec  10,000  Exp 2.75  d
5/5a - 1.6 0.90 7.7 3.3 Where Rec = critical Reynolds number
4) The interface length ( LC )
2) Calculate the blended viscosity for a 50/50 mix at 0.3716 L.d
interface (see Table 4) If Re  Rec , LC  0.1
The blended coefficients in the ASTM viscosity correlation are Re
as follows:
 Rec , LC 
582.49 L.d Exp 2.19 d  
 AQ  If Re
  Bi i 
0.9
Re
Ab   i  Bb   Q  i Where LC = length of interface (50%/50% mix), km
Q  Q 
  Bi    B i L = Length of travel, km
 i  i  5) The interface volume
VC  250  d 2 .LC
The blended viscosity can be derived from the following
Where VC = interface volume, m3
equation: LogLog  b  0.7   Ab  Bb logT 
d = inside pipe diameter, m
Where
 b = viscosity of blended product, cSt Considering the switch of the preceding and following
T = absolute temperature, °K batches results in the initial interface and the ground
elevation difference along the pipeline increases the
Ab , Bb = constants of blended product commingling of products, an allowance factor of 1.1 is
Qi = volume fraction of product i at interface, 50% is provided for the maximum interface volume. ANNEX C
includes the detailed calculations of the interface volume.
assumed

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3 Copyright © 2010 by ASME

4.3 BATCH VOLUME
In order to allow reinjection of the interfaces back into the
corresponding product tanks at the delivery terminal, the
minimum batch size and maximum interface volumes must
meet the contamination criteria.
The minimum batch size equals the total volume of
contaminant divided by the allowable contamination
percentage. ANNEX D presents the results of the minimum
batch size.
For the heart cut products, the minimum batch size is
approximately 1.5 times the interface volume on each side of
the heart cut.
To ensure there is sufficient heat cut buffer between Product-3
and 4 or between Product-1 and 2, the minimum batch size of
the Product-5a equals 1.5 times the interface volume between
2/4(or 1/3) and 5a; therefore, a batch size of 300 m3 is selected
for the Product-5a.
It can be found that the Product-1 base is the controlling
minimum batch size for all cases. Batch volumes of other
products are based on the minimum batch size of Product-1 and
the volume ratio of the scheduled product throughput (volume
fraction).
The proposed product batch volumes are listed in Table 5.
4.4 BATCH SEQUENCE
Based on the analyses and the calculation results in previous
sections, the recommended batch cycle is as the following:
“3 – 5 – 6 – 5 – 5a – 4 – 5a – 3 – 5 – 6 – 5 – 5a – 4 – 5a – 3 –
5 – 6 – 5 – 7 – 5 – 1 – 5a – 2 – 5a – 6 – 5 – 7 – 5”
Table 5: Proposed Batch Volume
Batch Volume
Products
(m3)
1 18,000 × 1
2 19,500 × 1
3 20,200 × 3
4 22,200 × 2
5 1,500 × 9
5a 300 × 6
6 5,800 × 4
7 13,400 × 2
Days/cycle 13.7
Pipeline capacity, m3/hr 633
Pipeline capacity, MMTPA 4 recommended storage volume for each product can be derived
4.5 BATCH SCHEDULE
The recommended batch sequences and batch sizes were used
in the dynamic simulation for the pipeline system. The batch
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4 Copyright © 2010 by ASME
start and arrival time are recorded while the model is running.
ANNEX E presents one cycle of batch schedule.
4.6 RECOMMENDED STORAGE VOLUME
At the refinery terminal, the inlet flow rate for each product
storage tank is the product annual throughput divided by 8000
hrs assuming each product flows into the tank continuously.
The outlet flow rate for each product tank is assumed to be
identical as the pipeline capacity, and each product flows out of
the tank discontinuously based on the batch plan.
At the delivery terminal, the inlet flow rate for each product
storage tank is assumed to be identical as the pipeline capacity,
and each product flows into the tank discontinuously based on
the batch plan. The outlet flow rate for each product tank is the
product annual throughput divided by 8000 hrs assuming each
product flows out of the tank continuously.
During the normal operations, the product tank inventory
should change as showed in Figure 1 based on the batch plan.
The required net storage volume is the difference between the
maximum and the minimum tank inventory in the model.
40,000
35,000
30,000
Pro d u ct tan k in ven to ry (m 3 )
N et Storage
25,000
20,000
15,000
10,000
5,000
Cycle
0
0 500 1000 1500 2000 2500
Time (hrs)
FIGURE 1: A SAMPLE OF TANK INVENTORY CHANGE
Based on the simulation results indicated in ANNEX F, the net
storage requirements and the recommended storage volume for
each product are calculated and summarized in ANNEX G. The
from the following equation:
Recommended storage volume = net storage × 1.1 + 5 days
Storage
5 days storage = 5 × 24 × (product throughput)/8000
Where 1.1 is the allowance factor
435-JH0902-00-PR-REP-0002 Rev.C
 REFERENCES
Based on the scheduled batch size, the estimated interface
volume, the actual single tank storage and accepted
contamination levels, the interface of Product-5 / 6(or 5a) and
5a / 6 can be directly cut into the Product-5 and 5a tanks
respectively as the batches arrive at the destination. Others
have to be diverted into the slop tank or intermix tank, and then
are re-injected back into the corresponding product tanks for
blending. The reinjection volume of the interface and the pure
product volume in the tank must meet the contamination
criteria.
[1] Mohitpour, M., Golshan, H. and Murray, A., 2000,
Pipeline Design & Construction, ASME Press (2006),
Chap.6.
[2] Yoon, M.S., Warren, B.C., Adam, S., 2005, Pipeline
Systems Automation and Control, ASME, Chap.5.
[3] Sang, G.S., Sun, Y., Zhu, K.F. and Fu, M., 2000,
“Batch Sizing and Storage Calculation for Refinery
Products”, Oil & Gas Storage and Transportation, Vol. 2.

DISCUSSIONS
The proposed batch and tank storage design method can be
used as a reference in the actual operation. When the proposed
batch sequence is not followed due to some un-planned events
(e.g. un-scheduled maintenance caused by pipeline leak), the
operator should understand and anticipate the possible impact
to the tank storage through simulations, and adjust the actual
production to balance the batch size and tank capacity.

DEFINITIONS
Critical Reynolds number – A critical value for the Reynolds
Number (Re) at which the rate of intermixing shows a sharp
decrease.
Interface – The mixture of adjacent products in a multiproduct
pipeline.
Heart cut – Product withdrawn from the middle of a batch is
referred as a heart cut. When a heart cut batch is delivered to a
terminal, the interfaces at its batch head and tail are cut.

NOMENCLATURE
A, B Viscosity Constants
Ab , Bb Viscosity Constants of blended products
d Inside Pipe Diameter
L Length of Interface Travel
LC Length of Interface
NPS Normal Pipe Size
Qi Volume Fraction of Product i at Interface
Re Reynolds Number
Rec Critical Reynolds Number
T Absolute Temperature
 Viscosity
b Viscosity of Blended Products
VC Interface Volume, m3

ACKNOWLEDGMENTS
We thank WorleyParsons resource & energy for supporting
this work and for the permission to publish this paper.

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5 Copyright © 2010 by ASME

 ANNEX A

PRODUCT THROUGHPUT

Products
Properties Total
1 2 3 4 5 5a 6 7

Throughput
323,000 351,000 1,234,000 902,000 261,000 35,000 450,000 444,000 4,000,000
(TPA)
Density (kg/m3) 740 740 830 830 800 800 800 680 -
Volume (m3) 437,600 475,600 1,480,600 1,082,100 327,400 44,000 565,000 653,000 5,065,000
Capacity (m3/hr) 55 59 185 135 41 5 71 82 633

ANNEX B

CONTAMINATION CRITERIA
Contaminant Percentage of Contamination in Product
Products 6 3 4 1 2 7 5 5a
6 - 0.0 0.0 0.0 0.0 0.0 0.0 0.0
3 0.0 - 100.0 0.0 0.0 0.0 1.0 1.0
4 0.0 0.0 - 0.0 0.0 0.0 0.0 1.0
1 0.0 0.0 0.0 - 100.0 0.25 1.0 1.0
2 0.0 0.0 0.0 0.0 - 0.0 0.0 1.0
7 0.0 0.0 0.0 1.5 1.5 - 1.5 1.5
5 100.0 0.0 0.0 0.0 0.0 0.0 - 100
5a 100.0 0.0 0.0 0.0 0.0 0.0 100 -

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6 Copyright © 2010 by ASME

 ANNEX C

INTERFACE CALCULATION
Interfaces
Properties
3/4 3 or 4 / 5 or 5a 5 or 5a / 6 5 or 5a / 1 or 2 1/2 2/7 5/7 1/7 5 / 5a
Pipeline length (km) 240 240 240 240 240 240 240 240 240
Flow rate (m3/hr) 630 630 630 630 630 630 630 630 630
OD (inch) 18 18 18 18 18 18 18 18 18
WT (mm) 7.9 7.9 7.9 7.9 7.9 7.9 7.9 7.9 7.9
Blended viscosity (cSt) 7.0 3.4 1.7 1.4 0.6 0.6 1.3 0.6 2.0
Velocity (m/s) 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Re 72,000 149,000 301,500 376,700 804,000 800,700 383,500 800,700 259,100
Rec 62,000 62,000 62,000 62,000 62,000 62,000 62,000 62,000 62,000
Interface length (km) 1.3 1.2 1.1 1.1 1.0 1.0 1.1 1.0 1.1
Interface volume (m3) 190 180 170 160 150 150 160 150 170
Maximum interface volume (m3) 210 200 185 180 165 165 180 165 190

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7 Copyright © 2010 by ASME

 ANNEX D

BATCH SIZE CALCULATION

Minimum Batch
Batch
Volume Batch Volume (based on interface bases) Size (based on Selected Batch Calculated
Products Frequencies per
Fraction contamination Frequencies Batch Size
Cycle1
4 / 5a 3/5 1/5 2 / 5a 5/7 criteria)

1 0.086 8,000 6,000 18,000 16,500 8,000 18,000 1.00 1 18,000

2 0.094 8,600 6,300 19,500 18,000 8,700 18,000 1.1 1 19,500
3 0.290 26,900 19,700 60,700 56,000 27,000 19,700 3.1 3 20,200
4 0.210 19,700 14,400 44,400 40,800 19,800 19,700 2.3 2 22,200
5 0.065 6,000 4,400 13,400 12,300 6,000 300 44.7 9 1,500
5a 0.009 800 600 1,800 1,700 800 300 6.0 6 300
6 0.110 10,000 7,500 23,200 21,300 10,300 275 84.2 4 5,800
7 0.130 12,000 8,700 26,800 24,600 12,000 12,000 2.2 2 13,400
Notes: 1. Batch frequencies per cycle = (batch volume based on Product-1) / (minimum batch size based on contamination criteria)

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8 Copyright © 2010 by ASME

 ANNEX E

BATCH SCHEDULE
Scheduled Volume Scheduled Start Estimated Arrival
Cycles Batch Products
(m3) (hrs) (hrs)
3 20,200 0.0 58.9
5 1,500 31.9 90.9
6 5,800 34.3 93.4
5 1,500 43.4 102.6
5a 300 45.8 104.8
4 22,200 46.2 105.2
5a 300 81.3 140.2
3 20,200 81.7 140.7
5 1,500 113.7 172.6
6 5,800 116.0 175.2
5 1,500 125.2 184.3
5a 300 127.5 186.6
4 22,200 128.0 187.0
Cycle 1 5a 300 163.0 222.1
3 20,200 163.5 222.5
5 1,500 195.5 254.4
6 5,800 197.8 256.8
5 1,500 207.0 265.9
7 13,400 209.3 268.2
5 1,500 230.5 289.3
1 18,000 232.8 291.7
5a 300 261.1 320.1
2 19,500 261.6 320.6
5a 300 292.4 351.4
6 5,800 292.9 351.9
5 1,500 302.1 361.0
7 13,400 304.4 363.4
5 1,500 325.6 384.5

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9 Copyright © 2010 by ASME

 ANNEX F

TANK STORAGE SIMULATION

50,000 Product-1

Product-2
40,000
Product tank inventory (m3)

Product-3

30,000
Product-4

20,000 Product-5

Product-5a
10,000

Product-6

0
Product-7
0 250 500 750 1000
Time (hrs)

FIGURE 2: PRODUCT TANK INVENTORY CHANGE AT TERMINALS

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 ANNEX G

RECOMMENDED TANK STORAGE

Products Net storage (m3) Recommended storage* (m3)

6 6,000 15,000
3 24,500 49,000
4 28,500 47,600
1 16,400 24,600
2 17,700 26,600
7 17,300 28,900
5 3,300 8,500
5a 800 1,500
Days per cycle 13.7
Pipeline capacity, m3/hr 633
Pipeline capacity,
4
MMTPA
Notes:
* The recommended storage volume at the refinery terminal is same as that in the delivery terminal.

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11 Copyright © 2010 by ASME