Pipeline Pumps

Pi li PPipeline Pumps

Presenter

Ralph Dickau Enbridge Pipelines IncRalph Dickau Enbridge Pipelines Inc.

Calgary Pump Symposium 2013Calgary Pump Symposium 2013

Presenter NameRalph Dickau

BioRalph Dickau is a Senior Engineering Specialist at Enbridge Pipelines.Ralph has worked for Enbridge for almost 30 years in a variety of roles

d h b i l d i i d i l iand has been involved in pump station design, pump selection, 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 p p p p gInternational 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 TechnicalRalph currently sits on the PRCI Pump and Compressor Technical Committee and the API 610 12th edition taskforce.


Pi li PPipeline Pumps


What Makes Pipeline Pumps UniqueWhat Makes Pipeline Pumps Unique

Calgary Pump Symposium 2013

USA Crude Oil Supply

Edmonton

EnbridgeFort McMurray

Trans Mountain10%

Alberta Oilsands

Hardisty Enbridge71%

10%

Express13%

W Corridor6%

Hardisty

~ 12% Total US Imports Chicago

2009


What Makes Pipeline Pumps UniqueWhat 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 paway at a control center in another country

• Pumps may be run stop/startPumps may be run stop/start

• Large flow variability

R l i i f l d• Rely on instrumentation for control and protection



• Frequently multi‐products in the pipeFrequently multi products in the pipe

• Pump efficiency is very important

l i hi h• Electric power costs are high– Eg. 24” pipe, 1000 mile long, 300 kbpd heavy

d $ /k hcrude @ $0.08 /kwh

– $100,000,000 per year



• 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. Keystone and Gateway


y y

Pipeline HydraulicsPipeline Hydraulics2000 Maximum Allowable

Station DischargeMaximum Allowable Pressure Profile

1500

Hea

d (f

t)

Pressure Profile at Maximum Flow

1000

ress

ure

H

52

idLOSS D

sgQLfP

500

vati

on /

Pr

Ground Elevation Profile

Minimum StationHolding PressureSingle 30” Pipe

0

0 10 15 20 25 30 35 40 45 50 55 60 65 70

Kilometers

Ele

v gSingle 30 Pipe


Kilometers

Pipeline HydraulicslHow to Increase Pipeline Capacity

• 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)


Pipeline HydraulicsddAdd a Station

2000

)

Maximum AllowableStation Discharge

M i All bl P P fil

1500

e H

ead

(ft g

Maximum Allowable Pressure ProfilePressure Profileat Maximum Flow

1000

/ P

ress

ure

Pressure Profile at Maximum Flow + X

500

Ele

vati

on Ground Elevation Profile

Minimum StationIntermediate Station

0

0 10 15 20 25 30 35 40 45 50 55 60 65 70

Kilometers

Holding PressureSingle 30” Pipe


Kilometers

Pipeline Hydraulics – Batched Operation


Pipeline Hydraulics – Batched lOperation – Laminar Flow


Pipeline Hydraulics – Batched b l lOperation – Turbulent Flow


Pipeline Pump Fluid PropertiesPipeline Pump Fluid Properties• Ethylene to Bitumen (density)• Vapor Pressure• Vapor Pressure• Solids Content

Commodity Density (SG) Viscosity (cSt)

Ethylene 0.37 0y

NGL 0.5 – 0.6 0 – 0.4

Light Crude 0.8 – 0.87 2 ‐ 20

Heavy Crude 0.9 – 0.94 150 – 350


Series vs Parallel Pump StationSeries vs Parallel Pump Station

Parallel Pump Station Series Pump Station


Se es u p Stat o

Pumps in SeriesPumps in Series

901002500

Efficiency

60708090

1500

2000

y %

HP

/10

Full, 3/4 & 1/2 HeadFull & 3/4 Head

Head System Curve

30405060

1000

1500

Eff

icie

ncy

Hea

d &

BH

1/2 & 3/4 Head

half and full headFull Head

3/4 Head

0102030

0

500

H

Half HeadSystem Curve

Efficiency

000 10000 20000 30000

Flow (usgpm)


Pumps in ParallelPumps in Parallel2000

1500

) 1 pump

3 pumps

1000

Hea

d (ft

)

Flat System Curve

p p2 pumps

500Steep System Curve

00 10000 20000 30000

Flow (usgpm)


Head & Efficiency vs Pump RPMHead & Efficiency vs Pump RPM

Maximum EfficiencySystem Curve


Variable Frequency Drive Effects1 VFD per Pump1 VFD per Pump

1000

1200

800

1000

(meter)

Maximum Efficiency Line

Three System Curve

400

600

ssure Head ( Three

PumpsSystem Curve

200

400

Pres

Maximum Speed‐1780 rpm

Two Pumps

One Pump

00 1000 2000 3000 4000 5000 6000

Flow Rate (m3/hr)

Minimum Speed‐1200 rpmPump


Variable Frequency Drive Effects1 Shared VFD

1000

12001 Shared VFD

800

1000

(meter) Three

Pumps

System Curve

400

600

ssure Head (

M i

Two Pumps

System Curve

200

400

Pres Maximum

Speed‐1780 One Pump

00 1000 2000 3000 4000 5000 6000

Flow Rate (m3/hr)

Minimum Speed‐1200 rpm (Example)


( )

Pipeline Pump TypeslSingle Stage API 610 Type BB1

Low Head – High Flow

Courtesy Flowserve


Pipeline Pump TypeslMultistage API 610 Type BB3

High Head – Low Flowg

Courtesy Flowserve


Mechanical Seal TypeMechanical Seal Type

• Hard faces SC on SC or TC – for wear resistance

• Stationary pusher spring design

• Flush through seal

Seal Leakage

Flush through seal chamber

• High suction pressures on 2nd, 3rd, 4th pumps

• Segmental carbonSegmental carbon bushing

• Set screw collar

Courtesy Flowserve


Mechanical Seal FlushMechanical Seal FlushAPI Plan 11

Courtesy Fluid Sealing Association



Seal Leakage DetectionSeal Leakage Detection• API Plan 65A Typical

• Gravity Drainage to Sump

• Vessel with Level DetectorDetector



Pipeline Pump InstrumentationPipeline Pump Instrumentation

• Monitor forMonitor for– Bearing Vibration

• Use Transmitter (Velocity)Use Transmitter (Velocity)

– Bearing Temperature• Inboard and Outboard insertion RTDInboard and Outboard insertion RTD

– Pump Case Temperature• Insertion Thermowell and RTDInsertion Thermowell and RTD


Pump ReratingPump Rerating

• Pump is too large– Too much contingency

– Higher flow rates in the futureg

– Flow rates have dropped off

• Pump too smallPump too small

• Benefits of reratingHi h ffi i– Higher efficiency

– Smoother running


Pump ReratingPump Rerating1000

700

800

900

in F

eet

400

500

600

Diff

eren

tial H

ead

100

200

300

Tota

l D

Original Design

Current Flow

00 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000

Gallons Per Minute



• Change the speed (VFD)Change the speed (VFD)

• Trim the impeller

l difi i• Volute modifications– Weld in new volute lips

– Weld in new cone inserts

– New diffuser ring (diffuser pumps)


Replacement Volute LipsReplacement Volute Lips


ConclusionsConclusions

• Pipelines are like railroads pumps like enginePipelines are like railroads, pumps like engine

• Pipeline pumps must run reliably (remote)

i ll i i• Pumps typically operate in series

• VFD adds flexibility

• Typically pusher seal type and Plan 11 / 65 flush/ drain plan/ p

• Pump rerating option for changing pump curve


curve

Questions?Questions?


Pipeline Pumps

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