Reducing operating costs through pipeline flow optimization

GHD Digital’s client, a pipeline operator located in North America, operates several pipeline systems. At the onset of the project, our client was looking to improve system efficiency and potentially increase pipeline throughput. In addition, they were looking to reduce annual costs through a series of data-driven pipeline analyses.

The client believed that their current flow rate could be increased and improve overall operations. However, as they had a limited internal engineering support team, they were not able to examine potential improvements. And, as client operations are multinational, several challenges were occurring daily, requiring constant attention.

With an adequate partner like GHD Digital, the client could respond to regular operational challenges while also considering new and innovative areas for pipeline optimization.

Our Advance Automation group, along with our Data Analytics team, worked with the client’s IT and Business teams to identify the most useful pipeline operations data available on their network, and to extract the information in useful formats.

The client provided our team with important pipeline data (i.e., pump suction, pressures, flow rates, valve positions, operating conditions, and more). Then, our teams assembled and analyzed the provided data to produce operating trends, identify operational efficiencies, evaluate potential future engineering solutions, and used advanced statistical techniques to provide analytical insights from their operational data.

To provide this solution to our client, we utilized an internal data analytics and machine learning tool called DatAIntel. DatAIntel uses a unique linefill analysis model to accurately model all pipeline flow parameters on a barrel-by-barrel basis. This capability allows the team to uncover operating inefficiencies that are not available to review by standard hydraulic pipeline models. In addition, through advanced statistical techniques and machine learning algorithms, DatAIntel performs offline and real-time analysis to optimize pipeline operation.

The project team also looked at several “What If” scenario analyses for running the system using various DRA injection rates and using Variable Frequency Drives (VFDs) at different pumping stations. This analysis was performed to identify potential electrical cost savings and throughput increases based on DRA injection rates. At the time, the client was reducing flow by closing their control valve, thereby wasting energy. Using a VFD allows the same action to happen, but by running the pump motor at slower speeds, our client can reduce costs.

The linefill analysis extracted highly detailed information from the data, which yielded incredibly useful results for our client. The results uncovered were showed the client that they would be able to reduce operating costs by 46 percent and increase throughput by 40 percent. The savings available to our client, directly because of the analysis, runs into the millions of dollars annually, just on the pipeline segment alone.

Our team also provided flexible options to the client for financing the project. Because we were confident that our solution would deliver significant cost savings, improved operational efficiencies, and increased throughput, we proposed a model where GHD Digital would front the cost of implementation with payback occurring over future years. In this model, we would only be paid for the project when cost savings were realized by our client.