Pi li P Pipeline Pumps
Presenter Ralph Dickau Enbridge Pipelines Inc. Inc
Calgary Pump Symposium 2013
PresenterName Bio RalphDickau RalphDickauisaSeniorEngineeringSpecialistatEnbridgePipelines. RalphhasworkedforEnbridgeforalmost30yearsinavarietyofroles and dh hasbeen b involved i l di inpumpstation i d design, i pumpselection, l i installation,writingcompanyspecificationsandstandardsforpumps, troubleshootingpumpoperatingproblems,andvibrationanalysis. Ralph p hasp presentedcoursesonp pipeline p p pumps p forEnbridge g Internationaltocompaniesfrommanypartsoftheworld. RalphhaspresentedattheASMEInternationalPipelineConference, andTexasA&MInternationalPumpUsersSymposium. RalphcurrentlysitsonthePRCIPumpandCompressorTechnical CommitteeandtheAPI61012theditiontaskforce.
Calgary Pump Symposium 2013
Pi li Pumps Pipeline P
Calgary Pump Symposium 2013
WhatMakesPipelinePumpsUnique
Calgary Pump Symposium 2013
WhatMakesPipelinePumpsUnique
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
USACrudeOilSupply
AlbertaOilsands
FortMcMurray
Trans Mountain 10%
Edmonton Hardisty
WCorridor 6%
Express 13%
Enbridge 71%
Chicago
~12%TotalUSImports
2009
Calgary Pump Symposium 2013
WhatMakesPipelinePumpsUnique
Pumpstationsareunmanned Helpcanbe100sofkmaway Controlofthep pumps p canbe1000sofkm awayatacontrolcenterinanothercountry Pumpsmayberunstop/start Largeflowvariability Rely R l oninstrumentation i i f forcontrol land d protection Calgary Pump Symposium 2013
WhatMakesPipelinePumpsUnique
Frequentlymultiproductsinthepipe Pumpefficiencyisveryimportant Electric l i powercostsarehigh hi h
Eg.24pipe,1000milelong,300kbpd heavy crude d @$0.08 $ /kwh /k h $100,000,000peryear
Calgary Pump Symposium 2013
WhatMakesPipelinePumpsUnique
PipelinesandPumpStationsarebuiltto:
CSAZ662inCanada(GasandLiquid) ASMEB31.4inUSA
RegulatorycodesbyFederalandStateor ProvincialGovernments
NEBActandRegulationsinCanada DOTCFR49Part105inUSA
Currentpoliticalandenvironmentclimatee.g. y andGateway y Keystone Calgary Pump Symposium 2013
PipelineHydraulics
2000
Maximum Allowable Station Discharge
Maximum Allowable Pressure Profile
Elev vation / Pr ressure H Head (ft)
1500
Pressure Profile at Maximum Flow
1000
PLOSS
sg f LQ 5 Did
2
500
Ground Elevation Profile Minimum Station Holding g Pressure
55 60 65 70
0 0 10 15 20 25 30 35
Single 30 30 Pipe
40 45 50
Kilometers
Calgary Pump Symposium 2013
PipelineHydraulics HowtoIncreasePipeline l Capacity
Replacepipewithlargerpipeorhigherstrength Addap parallelline( (looping) p g) Rehydro(pressure)testunderratedpipe Addpumpstations Addorreplacepumps UseDragReducingAgent(DRA)
Calgary Pump Symposium 2013
PipelineHydraulics Add ddaStation
2000
E le v a tio n / P re s s u re e H e a d (ft )
Maximum Allowable Station Discharge g Pressure Profile at Maximum Flow
M i Maximum All Allowable bl P Pressure P Profile fil
1500
1000
Pressure Profile at Maximum Flow + X
500
Ground Elevation Profile Intermediate Station Minimum Station Holding Pressure
65 70
0 0
Single 30 Pipe
10
15
20
25
30
35
40
45
50
55
60
Kilometers
Calgary Pump Symposium 2013
PipelineHydraulics Batched Operation
Calgary Pump Symposium 2013
PipelineHydraulics Batched Operation LaminarFlow l
Calgary Pump Symposium 2013
PipelineHydraulics Batched Operation Turbulent b l Flow l
Calgary Pump Symposium 2013
PipelinePumpFluidProperties
EthylenetoBitumen(density) VaporPressure SolidsContent
Commodity Ethylene y NGL LightCrude HeavyCrude Density(SG) 0.37 0.5 0.6 0.8 0.87 0.9 0.94 Viscosity(cSt) 0 0 0.4 2 20 150 350
Calgary Pump Symposium 2013
Seriesvs ParallelPumpStation
Parallel Pump Station
Series Se es Pump u p Station Stat o
Calgary Pump Symposium 2013
PumpsinSeries
2500
Efficiency
2000
Head & BH H HP/10
Efficiency y %
Head
System Curve
1500 1000 500 0 0 10000 20000 Flow (usgpm)
100 90 80 70 60 50 40 30 20 10 0 30000
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
Calgary Pump Symposium 2013
PumpsinParallel
2000 1500 Head (ft) )
3pumps 1p pump p 2pumps
1000
FlatSystemCurve SteepSystemCurve
500
0 0 10000 20000 Flow (usgpm) 30000
Calgary Pump Symposium 2013
Head&Efficiencyvs PumpRPM
SystemCurve MaximumEfficiency
Calgary Pump Symposium 2013
VariableFrequencyDriveEffects 1VFDperPump
1200 1000 Pres ssureHead( (meter) 800 600 400 200 0 0 1000 2000 Three Pumps Maximum EfficiencyLine
SystemCurve
Two Pumps One Pump
Maximum Speed1780rpm MinimumSpeed1200rpm 3000 4000 Flow Rate (m3/hr) 5000 6000
Calgary Pump Symposium 2013
VariableFrequencyDriveEffects 1 Shared VFD 1200
1000 Pres ssureHead( (meter) 800 600 400 200 0 0 1000 2000 3000 4000 (m3/hr) ) Flow Rate ( 5000 6000 One Pump Three Pumps
SystemCurve
Two Pumps Maximum M i Speed1780
MinimumSpeed1200rpm(Example)
Calgary Pump Symposium 2013
PipelinePumpTypes Single l StageAPI610TypeBB1
LowHead HighFlow
CourtesyFlowserve
Calgary Pump Symposium 2013
PipelinePumpTypes Multistage l API610TypeBB3
High g Head LowFlow
CourtesyFlowserve
Calgary Pump Symposium 2013
MechanicalSealType
HardfacesSConSC orTC forwear resistance Stationarypusher springdesign Flushthroughseal chamber Highsuction pressureson2nd, 3rd,4th pumps Segmentalcarbon bushing Setscrewcollar
Seal Leakage
CourtesyFlowserve
Calgary Pump Symposium 2013
MechanicalSealFlush
APIPlan11
CourtesyFluidSealingAssociation
Calgary Pump Symposium 2013
SealLeakageDetection
APIPlan 65A Typical Gravity Drainage toSump Vessel withLevel Detector
CourtesyFluidSealingAssociation
Calgary Pump Symposium 2013
PipelinePumpInstrumentation
Monitorfor
BearingVibration
UseTransmitter(Velocity)
BearingTemperature
InboardandOutboardinsertionRTD
PumpCaseTemperature
InsertionThermowell andRTD
Calgary Pump Symposium 2013
PumpRerating
Pumpistoolarge
Toomuchcontingency Higher g flowratesinthefuture Flowrateshavedroppedoff
Pumptoosmall Benefitsofrerating
Higher Hi h efficiency ffi i Smootherrunning
Calgary Pump Symposium 2013
PumpRerating
1000 900
Total D Differential Head in Feet
800 700 600 500 400 300 200 100 0
CurrentFlow
Original Design
2000
4000
6000
8000 10000 12000 14000 16000 18000 20000 22000
Gallons Per Minute
Calgary Pump Symposium 2013
PumpRerating
Changethespeed(VFD) Trimtheimpeller Volute l modifications difi i
Weldinnewvolutelips Weldinnewconeinserts Newdiffuserring(diffuserpumps)
Calgary Pump Symposium 2013
PumpRerating
Calgary Pump Symposium 2013
ReplacementVoluteLips
Calgary Pump Symposium 2013
Conclusions
Pipelinesarelikerailroads railroads,pumpslikeengine Pipelinepumpsmustrunreliably(remote) Pumpstypically i ll operatein i series i VFDaddsflexibility TypicallypushersealtypeandPlan11/65 /drainplan p flush/ Pumpreratingoptionforchangingpump curve
Calgary Pump Symposium 2013
Questions?
Calgary Pump Symposium 2013
