Pipeline Pumps
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Pi li P Pipeline Pumps Presenter Ralph Dickau Enbridge Pipelines Inc. Inc
Calgary Pump Symposium 2013
Presenter Name Bio Ralph Dickau Ralph Dickau is a Senior Engineering Specialist at Enbridge Pipelines. Ralph has worked for Enbridge for almost 30 years in a variety of roles and has been involved in pump station design, pump selection, dh b i l di i d i l i installation, writing company specifications and standards for pumps, trouble shooting pump operating problems, and vibration analysis. Ralph has presented courses on pipeline pumps for Enbridge p p pp p p g International to companies from many parts of the world. Ralph has presented at the ASME International Pipeline Conference, and Texas A&M International Pump Users Symposium. Ralph currently sits on the PRCI Pump and Compressor Technical Ralph currently sits on the PRCI Pump and Compressor Technical Committee and the API 610 12th edition taskforce.
Calgary Pump Symposium 2013
Pi li Pumps Pipeline P
Calgary Pump Symposium 2013
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique
Calgary Pump Symposium 2013
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
USA Crude Oil Supply
Alberta Oilsands Fort McMurray
Trans Mountain 10%
Edmonton Hardisty
W Corridor 6%
Express 13%
Enbridge 71%
~ 12% Total US Imports
2009
Calgary Pump Symposium 2013
Chicago
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique • Pump stations are unmanned • Help can be 100s of km away • Control of the pumps can be 1000s of km p p away at a control center in another country • Pumps may be run stop/start Pumps may be run stop/start • Large flow variability • Rely on instrumentation for control and R l i i f l d protection Calgary Pump Symposium 2013
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique • Frequently multi Frequently multi‐products products in the pipe in the pipe • Pump efficiency is very important • Electric power costs are high l i hi h – Eg. 24” pipe, 1000 mile long, 300 kbpd heavy crude @ $0.08 /kwh d $ /k h – $100,000,000 per year
Calgary Pump Symposium 2013
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique • Pipelines and Pump Stations are built to: Pipelines and Pump Stations are built to: – CSA Z662 in Canada (Gas and Liquid) – ASME B31.4 in USA
• Regulatory codes by Federal and State or Provincial Governments – NEB Act and Regulations in Canada – DOT CFR 49 Part 105 in USA
• Current political and environment climate e.g. y y Keystone and Gateway Calgary Pump Symposium 2013
Pipeline Hydraulics Pipeline Hydraulics Elev vation / Prressure H Head (ft)
2000
Maximum Allowable Station Discharge
Maximum Allowable Pressure Profile
1500
Pressure Profile at Maximum Flow 1000
PLOSS
sg f LQ 5 Did 2
Ground Elevation Profile
500
Minimum Station Holding g Pressure
Single 30” 30 Pipe
0 0
10
15
20
25
30
35
40
45
Kilometers
Calgary Pump Symposium 2013
50
55
60
65
70
Pipeline Hydraulics How to Increase Pipeline Capacity l • • • • • •
Replace pipe with larger pipe or higher strength Add a parallel line (looping) p ( p g) Re‐hydro (pressure) test under‐rated pipe Add pump stations Add pump stations Add or replace pumps Use Drag Reducing Agent (DRA)
Calgary Pump Symposium 2013
Pipeline Hydraulics Add a Station dd E le v a tio n / P re s s u re e H e a d (ft )
2000
Maximum Allowable Station Discharge g
M i Maximum All Allowable bl P Pressure P Profile fil
Pressure Profile at Maximum Flow
1500
Pressure Profile at Maximum Flow + X
1000
Ground Elevation Profile
500
Intermediate Station
Minimum Station Holding Pressure
Single 30” Pipe
0 0
10
15
20
25
30
35
40
45
Kilometers
Calgary Pump Symposium 2013
50
55
60
65
70
Pipeline Hydraulics – Batched Operation
Calgary Pump Symposium 2013
Pipeline Hydraulics – Batched Operation – Laminar Flow l
Calgary Pump Symposium 2013
Pipeline Hydraulics – Batched Operation – Turbulent Flow b l l
Calgary Pump Symposium 2013
Pipeline Pump Fluid Properties Pipeline Pump Fluid Properties • Ethylene to Bitumen (density) • Vapor Pressure Vapor Pressure • Solids Content Commodity Ethylene y NGL Light Crude Heavy Crude
Density (SG) 0.37 0.5 – 0.6 0.8 – 0.87 0.9 – 0.94
Calgary Pump Symposium 2013
Viscosity (cSt) 0 0 – 0.4 2 ‐ 20 150 – 350
Series vs Parallel Pump Station Series vs Parallel Pump Station
Parallel Pump Station
Calgary Pump Symposium 2013
Series Se es Pump u p Station Stat o
2500 Efficiency Head & BH H HP/10
2000 Head
System Curve
1500 1000 500 0 0
10000
20000
Flow (usgpm)
Calgary Pump Symposium 2013
100 90 80 70 60 50 40 30 20 10 0 30000
Efficiency y %
Pumps in Series Pumps in Series Full, 3/4 & 1/2 Head Full & 3/4 Head 1/2 & 3/4 Head half and full head Full Head 3/4 Head Half Head System Curve Efficiency
Pumps in Parallel Pumps in Parallel 2000
3 pumps
Head (ft))
1500
1 pump p p 2 pumps Flat System Curve
1000
Steep System Curve 500
0 0
10000
20000 Flow (usgpm)
Calgary Pump Symposium 2013
30000
Head & Efficiency vs Pump RPM Head & Efficiency vs Pump RPM System Curve Maximum Efficiency
Calgary Pump Symposium 2013
Variable Frequency Drive Effects 1 VFD per Pump 1 VFD per Pump 1200
Presssure Head ((meter)
1000 Maximum Efficiency Line
800 Three Three Pumps
600 400
System Curve System Curve
Two Pumps
200
Maximum Speed‐1780 rpm
One Pump
Minimum Speed‐1200 rpm
0 0
1000
2000
3000 4000 Flow Rate (m3/hr)
Calgary Pump Symposium 2013
5000
6000
Variable Frequency Drive Effects 1 1 Shared VFD Shared VFD 1200 Presssure Head ((meter)
1000 Three Pumps
800
System Curve System Curve Two Pumps
600 400
Maximum M i Speed‐1780
One Pump
200
Minimum Speed‐1200 rpm (Example) 0 0
1000
2000
3000 4000 Flow Rate ((m3/hr))
Calgary Pump Symposium 2013
5000
6000
Pipeline Pump Types Single Stage API 610 Type BB1 l Low Head – High Flow
Courtesy Flowserve
Calgary Pump Symposium 2013
Pipeline Pump Types Multistage API 610 Type BB3 l High Head – g Low Flow
Courtesy Flowserve
Calgary Pump Symposium 2013
Mechanical Seal Type Mechanical Seal Type • • • • • •
Hard faces SC on SC or TC – for wear resistance Stationary pusher spring design Flush through seal Flush through seal chamber High suction pressures on 2nd, 3rd, 4th pumps Segmental carbon Segmental carbon bushing Set screw collar
Courtesy Flowserve
Calgary Pump Symposium 2013
Seal Leakage
Mechanical Seal Flush Mechanical Seal Flush API Plan 11
Courtesy Fluid Sealing Association Courtesy Fluid Sealing Association
Calgary Pump Symposium 2013
Seal Leakage Detection Seal Leakage Detection • API Plan 65A Typical • Gravity Drainage to Sump • Vessel with Level Detector Courtesy Fluid Sealing Association
Calgary Pump Symposium 2013
Pipeline Pump Instrumentation Pipeline Pump Instrumentation • Monitor for Monitor for – Bearing Vibration • Use Transmitter (Velocity) Use Transmitter (Velocity)
– Bearing Temperature • Inboard and Outboard insertion RTD Inboard and Outboard insertion RTD
– Pump Case Temperature • Insertion Thermowell Insertion Thermowell and RTD and RTD
Calgary Pump Symposium 2013
Pump Rerating Pump Rerating • Pump is too large – Too much contingency – Higher flow rates in the future g – Flow rates have dropped off
• Pump too small Pump too small • Benefits of rerating – Higher efficiency Hi h ffi i – Smoother running
Calgary Pump Symposium 2013
Pump Rerating Pump Rerating 1000
Total D Differential Head in Feet
900 800 700 600 500 400 300
Current Flow
200
Original Design
100 0
0
2000
4000
6000
8000 10000 12000 14000 16000 18000 20000 22000 Gallons Per Minute
Calgary Pump Symposium 2013
Pump Rerating Pump Rerating • Change the speed (VFD) Change the speed (VFD) • Trim the impeller • Volute modifications l difi i – Weld in new volute lips – Weld in new cone inserts – New diffuser ring (diffuser pumps)
Calgary Pump Symposium 2013
Pump Rerating Pump Rerating
Calgary Pump Symposium 2013
Replacement Volute Lips Replacement Volute Lips
Calgary Pump Symposium 2013
Conclusions Pipelines are like railroads, pumps like engine Pipelines are like railroads pumps like engine Pipeline pumps must run reliably (remote) Pumps typically operate in series i ll i i VFD adds flexibility Typically pusher seal type and Plan 11 / 65 / p flush/ drain plan • Pump rerating option for changing pump curve
• • • • •
Calgary Pump Symposium 2013
Questions?
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
Presenter Name Bio Ralph Dickau Ralph Dickau is a Senior Engineering Specialist at Enbridge Pipelines. Ralph has worked for Enbridge for almost 30 years in a variety of roles and has been involved in pump station design, pump selection, dh b i l di i d i l i installation, writing company specifications and standards for pumps, trouble shooting pump operating problems, and vibration analysis. Ralph has presented courses on pipeline pumps for Enbridge p p pp p p g International to companies from many parts of the world. Ralph has presented at the ASME International Pipeline Conference, and Texas A&M International Pump Users Symposium. Ralph currently sits on the PRCI Pump and Compressor Technical Ralph currently sits on the PRCI Pump and Compressor Technical Committee and the API 610 12th edition taskforce.
Calgary Pump Symposium 2013
Pi li Pumps Pipeline P
Calgary Pump Symposium 2013
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique
Calgary Pump Symposium 2013
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
USA Crude Oil Supply
Alberta Oilsands Fort McMurray
Trans Mountain 10%
Edmonton Hardisty
W Corridor 6%
Express 13%
Enbridge 71%
~ 12% Total US Imports
2009
Calgary Pump Symposium 2013
Chicago
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique • Pump stations are unmanned • Help can be 100s of km away • Control of the pumps can be 1000s of km p p away at a control center in another country • Pumps may be run stop/start Pumps may be run stop/start • Large flow variability • Rely on instrumentation for control and R l i i f l d protection Calgary Pump Symposium 2013
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique • Frequently multi Frequently multi‐products products in the pipe in the pipe • Pump efficiency is very important • Electric power costs are high l i hi h – Eg. 24” pipe, 1000 mile long, 300 kbpd heavy crude @ $0.08 /kwh d $ /k h – $100,000,000 per year
Calgary Pump Symposium 2013
What Makes Pipeline Pumps Unique What Makes Pipeline Pumps Unique • Pipelines and Pump Stations are built to: Pipelines and Pump Stations are built to: – CSA Z662 in Canada (Gas and Liquid) – ASME B31.4 in USA
• Regulatory codes by Federal and State or Provincial Governments – NEB Act and Regulations in Canada – DOT CFR 49 Part 105 in USA
• Current political and environment climate e.g. y y Keystone and Gateway Calgary Pump Symposium 2013
Pipeline Hydraulics Pipeline Hydraulics Elev vation / Prressure H Head (ft)
2000
Maximum Allowable Station Discharge
Maximum Allowable Pressure Profile
1500
Pressure Profile at Maximum Flow 1000
PLOSS
sg f LQ 5 Did 2
Ground Elevation Profile
500
Minimum Station Holding g Pressure
Single 30” 30 Pipe
0 0
10
15
20
25
30
35
40
45
Kilometers
Calgary Pump Symposium 2013
50
55
60
65
70
Pipeline Hydraulics How to Increase Pipeline Capacity l • • • • • •
Replace pipe with larger pipe or higher strength Add a parallel line (looping) p ( p g) Re‐hydro (pressure) test under‐rated pipe Add pump stations Add pump stations Add or replace pumps Use Drag Reducing Agent (DRA)
Calgary Pump Symposium 2013
Pipeline Hydraulics Add a Station dd E le v a tio n / P re s s u re e H e a d (ft )
2000
Maximum Allowable Station Discharge g
M i Maximum All Allowable bl P Pressure P Profile fil
Pressure Profile at Maximum Flow
1500
Pressure Profile at Maximum Flow + X
1000
Ground Elevation Profile
500
Intermediate Station
Minimum Station Holding Pressure
Single 30” Pipe
0 0
10
15
20
25
30
35
40
45
Kilometers
Calgary Pump Symposium 2013
50
55
60
65
70
Pipeline Hydraulics – Batched Operation
Calgary Pump Symposium 2013
Pipeline Hydraulics – Batched Operation – Laminar Flow l
Calgary Pump Symposium 2013
Pipeline Hydraulics – Batched Operation – Turbulent Flow b l l
Calgary Pump Symposium 2013
Pipeline Pump Fluid Properties Pipeline Pump Fluid Properties • Ethylene to Bitumen (density) • Vapor Pressure Vapor Pressure • Solids Content Commodity Ethylene y NGL Light Crude Heavy Crude
Density (SG) 0.37 0.5 – 0.6 0.8 – 0.87 0.9 – 0.94
Calgary Pump Symposium 2013
Viscosity (cSt) 0 0 – 0.4 2 ‐ 20 150 – 350
Series vs Parallel Pump Station Series vs Parallel Pump Station
Parallel Pump Station
Calgary Pump Symposium 2013
Series Se es Pump u p Station Stat o
2500 Efficiency Head & BH H HP/10
2000 Head
System Curve
1500 1000 500 0 0
10000
20000
Flow (usgpm)
Calgary Pump Symposium 2013
100 90 80 70 60 50 40 30 20 10 0 30000
Efficiency y %
Pumps in Series Pumps in Series Full, 3/4 & 1/2 Head Full & 3/4 Head 1/2 & 3/4 Head half and full head Full Head 3/4 Head Half Head System Curve Efficiency
Pumps in Parallel Pumps in Parallel 2000
3 pumps
Head (ft))
1500
1 pump p p 2 pumps Flat System Curve
1000
Steep System Curve 500
0 0
10000
20000 Flow (usgpm)
Calgary Pump Symposium 2013
30000
Head & Efficiency vs Pump RPM Head & Efficiency vs Pump RPM System Curve Maximum Efficiency
Calgary Pump Symposium 2013
Variable Frequency Drive Effects 1 VFD per Pump 1 VFD per Pump 1200
Presssure Head ((meter)
1000 Maximum Efficiency Line
800 Three Three Pumps
600 400
System Curve System Curve
Two Pumps
200
Maximum Speed‐1780 rpm
One Pump
Minimum Speed‐1200 rpm
0 0
1000
2000
3000 4000 Flow Rate (m3/hr)
Calgary Pump Symposium 2013
5000
6000
Variable Frequency Drive Effects 1 1 Shared VFD Shared VFD 1200 Presssure Head ((meter)
1000 Three Pumps
800
System Curve System Curve Two Pumps
600 400
Maximum M i Speed‐1780
One Pump
200
Minimum Speed‐1200 rpm (Example) 0 0
1000
2000
3000 4000 Flow Rate ((m3/hr))
Calgary Pump Symposium 2013
5000
6000
Pipeline Pump Types Single Stage API 610 Type BB1 l Low Head – High Flow
Courtesy Flowserve
Calgary Pump Symposium 2013
Pipeline Pump Types Multistage API 610 Type BB3 l High Head – g Low Flow
Courtesy Flowserve
Calgary Pump Symposium 2013
Mechanical Seal Type Mechanical Seal Type • • • • • •
Hard faces SC on SC or TC – for wear resistance Stationary pusher spring design Flush through seal Flush through seal chamber High suction pressures on 2nd, 3rd, 4th pumps Segmental carbon Segmental carbon bushing Set screw collar
Courtesy Flowserve
Calgary Pump Symposium 2013
Seal Leakage
Mechanical Seal Flush Mechanical Seal Flush API Plan 11
Courtesy Fluid Sealing Association Courtesy Fluid Sealing Association
Calgary Pump Symposium 2013
Seal Leakage Detection Seal Leakage Detection • API Plan 65A Typical • Gravity Drainage to Sump • Vessel with Level Detector Courtesy Fluid Sealing Association
Calgary Pump Symposium 2013
Pipeline Pump Instrumentation Pipeline Pump Instrumentation • Monitor for Monitor for – Bearing Vibration • Use Transmitter (Velocity) Use Transmitter (Velocity)
– Bearing Temperature • Inboard and Outboard insertion RTD Inboard and Outboard insertion RTD
– Pump Case Temperature • Insertion Thermowell Insertion Thermowell and RTD and RTD
Calgary Pump Symposium 2013
Pump Rerating Pump Rerating • Pump is too large – Too much contingency – Higher flow rates in the future g – Flow rates have dropped off
• Pump too small Pump too small • Benefits of rerating – Higher efficiency Hi h ffi i – Smoother running
Calgary Pump Symposium 2013
Pump Rerating Pump Rerating 1000
Total D Differential Head in Feet
900 800 700 600 500 400 300
Current Flow
200
Original Design
100 0
0
2000
4000
6000
8000 10000 12000 14000 16000 18000 20000 22000 Gallons Per Minute
Calgary Pump Symposium 2013
Pump Rerating Pump Rerating • Change the speed (VFD) Change the speed (VFD) • Trim the impeller • Volute modifications l difi i – Weld in new volute lips – Weld in new cone inserts – New diffuser ring (diffuser pumps)
Calgary Pump Symposium 2013
Pump Rerating Pump Rerating
Calgary Pump Symposium 2013
Replacement Volute Lips Replacement Volute Lips
Calgary Pump Symposium 2013
Conclusions Pipelines are like railroads, pumps like engine Pipelines are like railroads pumps like engine Pipeline pumps must run reliably (remote) Pumps typically operate in series i ll i i VFD adds flexibility Typically pusher seal type and Plan 11 / 65 / p flush/ drain plan • Pump rerating option for changing pump curve
• • • • •
Calgary Pump Symposium 2013
Questions?
Calgary Pump Symposium 2013
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