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    Pipeline Pumps

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    andrezpipe08
    This document summarizes Ralph Dickau's presentation on pipeline pumps at the 2013 Calgary Pump Symposium. It discusses what makes pipeline pumps unique, including their remote and unmanned operation. It also covers topics like pipeline hydraulics, batched operation, fluid properties, series vs parallel stations, pump types, instrumentation, rerating pumps, and conclusions. Ralph Dickau has over 30 years of experience at Enbridge in roles related to pump selection, design, troubleshooting and presenting courses on pipeline pumps.

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    Pipeline Pumps

    Uploaded by

    andrezpipe08
    135 views38 pages
    This document summarizes Ralph Dickau's presentation on pipeline pumps at the 2013 Calgary Pump Symposium. It discusses what makes pipeline pumps unique, including their remote and unmanned operation. It also covers topics like pipeline hydraulics, batched operation, fluid properties, series vs parallel stations, pump types, instrumentation, rerating pumps, and conclusions. Ralph Dickau has over 30 years of experience at Enbridge in roles related to pump selection, design, troubleshooting and presenting courses on pipeline pumps.

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    This document summarizes Ralph Dickau's presentation on pipeline pumps at the 2013 Calgary Pump Symposium. It discusses what makes pipeline pumps unique, including their remote and unmanned operation. It also covers topics like pipeline hydraulics, batched operation, fluid properties, series vs parallel stations, pump types, instrumentation, rerating pumps, and conclusions. Ralph Dickau has over 30 years of experience at Enbridge in roles related to pump selection, design, troubleshooting and presenting courses on pipeline pumps.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    135 views38 pages

    Pipeline Pumps

    Uploaded by

    andrezpipe08
    This document summarizes Ralph Dickau's presentation on pipeline pumps at the 2013 Calgary Pump Symposium. It discusses what makes pipeline pumps unique, including their remote and unmanned operation. It also covers topics like pipeline hydraulics, batched operation, fluid properties, series vs parallel stations, pump types, instrumentation, rerating pumps, and conclusions. Ralph Dickau has over 30 years of experience at Enbridge in roles related to pump selection, design, troubleshooting and presenting courses on pipeline pumps.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    At a glance
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    Some key takeaways from the presentation are that pipeline pumps must operate reliably remotely, typically in series, and rely on instrumentation for control and protection. Efficiency is also important due to high power costs. Pumps are also frequently handling multiple products.

    Pipeline pumps face unique challenges as the pump stations are unmanned, help can be far away, and control may be located thousands of kilometers away. Pumps may also operate in start/stop mode and see large flow variability.

    Pipeline pumps are monitored using instruments that measure bearing vibration, bearing and pump case temperatures. This instrumentation is used for control and protection of the pumps. Leakage from mechanical seals is also detected.

    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

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