Pump Replacement at a Key Pump Station · Pump Replacement at a Key Pump Station ... • Pump...
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Pump Replacement at a Key Pump Station • Tom Greaves, P.Eng., PMP 1 Photo by Mitch Cheek
Transcript of Pump Replacement at a Key Pump Station · Pump Replacement at a Key Pump Station ... • Pump...
Pump Replacement at a Key Pump Station
• Tom Greaves, P.Eng., PMP
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Photo by Mitch Cheek
Tom Greaves, P.Eng., PMP
Tom is a civil engineer with 27 years experience in the municipal and crude oil pipeline engineering fields. In 2013 Tom started on a pump performance review that ultimately lead to the replacement of the mainline crude oil pumps in 2015. Tom has worked as project manager and designer on projects as varied as the routing of large watermains through urban environments, crude oil tank inspections, hillside remediations, and pump optimization and replacements.
Presenters
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Problems at the site
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• Vibration issues• Multi‐Stage pumps–Series pumps
• Key Station
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Pump Station: PFD
4 x 2000 Hp multistage pumps
2 x 2000 Hp single stage pumps
2 x 5000 Hp single stage pumps
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• Replace parallel pumps one at a time• Design Principles
• Obsolete parallel pumps will be replaced, maintenance project (not an increase in flow project)
• Existing suction/discharge piping not acceptable, replace
• New station will be built in convenient location• New operating philosophy will be series pumps with dedicated VFD starts
• Pump selection and pump station design will mirror best practices from other pump station projects
• Fit for purpose
Options
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Pump / Motor Selection
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Pump / Motor Selection
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Operating Philosophy• Continuous Operation
– 3 years continuous service
• Series– Like all other pumps in system
• Spare philosophy– 100% redundancy
• Maintenance frequency• Pump control
– VFD starts
– Controlled remotely
• Service conditions
• Previous history– Look to what worked in the past
• Function– Mainline pumps
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Pump / Motor Selection
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Pump / Motor Selection
Fluid Type
• Density• Viscosity• Corrosiveness• Erosiveness• Volatility• Flammability• Toxicity• Temperature
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Gasoline: 720 kg/m3, 0.4 cStDiesel: 840 kg/m3, 4 cStLight/medium crude: 850 kg/m3, 7‐13 cStHeavy crude:925 kg/m3, 250 cSt
Heavy crude: sand particles/ orifice plate
Gasoline: vapour pressure
Crudes: H2S
All products
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Pump / Motor Selection
Pump Analysis
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• FEED:• Spreadsheet
software analysis• Pump
characteristics• 2332 m3/h
(352,000 bpd)• 500 m head
• API 610, Vendor Curves
• Multistage worked, single stage worked
• Detailed Design:• Stoner software
analysis• Boundary
conditions (NPSHa)
• Pipe Geometry• Vendor Pump
Curve• Multiple fluids
Pump Selection
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• Pump: Sulzer 20x 20 x 19B,
• single stage 2332 m3/hr (352,000 bpd) at BEP
• 518 m differential head
• Replaceable volute• Forced oil bearing • ANSI 600 (PN 100)
Transient Analysis:10 runsDifferent products
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Pump / Motor Selection
Electric Motor Selection
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Motor: • Toshiba 5000 Hp
induction motor, 3600 RPM*,
• 3 phase, 60 Hz, 4160 V• SF 1.15 • Class 1, Div. 2• VFD starting
• Forced oil bearing lubrication
Pump & Motor Selection Summary
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API 610: Pump SpecsAPI 541Motor Specs
Design
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Process
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Detailed Design: Changes– Stepped foundations (2014 IPC paper)
– Gabion wall (245 m2)
– Dedicated VFDs for each motor
– Spill containment:• Asphalt base (containment and parking)• Storage chamber and instrumentation/pond
– MCC Room instead of e‐house
– AHUs for cooling VFDs
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Procurement (equipment)
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Procurement (equipment)• Challenges/ Strategies
• Long lead time items (pumps 1 year, motors Japan, VFDs Houston)
• Medium lead time items (Ball Valves: Tuscany Italy…local inspector)
• No tinkering: Sulzer Pumps “custom build”• Shipping, cheaper to handle yourself• Weekly procurement meeting
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Procurement (equipment)– Tom’s Urgency Law
• Urgency of Vendor to Respond = Physical proximity to your project
• Work with Expeditors to keep vendor’s engaged
Vendor PM Vendor
Mngt, BD
Proximity to Your Project
Urgen
cy
Sub‐vendors
FabricatorsDGAD* Line
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ConstructionFall 2014:• Gabion Wall, 20” pipe supports• November 25, 2014: shutdown and re‐route of suction line
200 mm snow
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Pump Station: Testing Inline Pumps2 x 2000 Hp single stage pumps
Temp. bypass• Run temp. bypass
across pump suction/discharge (NPSHa) to reduce cavitation
• Across the line start of inline pumps
Success!!
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ConstructionSpring 2015: • foundation and underground conduitSummer 2015:• 480 V cable trayand communicationcable tray
• Installation ofbuilding (cable tray)
Construction
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“Borrowed” motor for sole plate adjustments
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ConstructionSummer 2015• Mounting motor sole plates (critical), and aligning motors and
pumps• Terminating piping and electrical• Spill management system construction starts
Fall 2015• All trades now in building (congestion)• Spill management system continues• Lube oil system (480 V)• Yard piping (with hydrotests)• PLC programming(critical path)• Energize electrical equipment (480 V)
Dry Commissioning(Fall / Winter 2015)
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• Commissioning manager on board• Equipment and system dry commissioning • Commissioning Lead
• Turn Over Committee
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Design HighlightsLouvres/ Fans= Class 1, Div. 2Expansion Pipes: nozzle loadsCoarse Screens: leave them inStepped FoundationsJack and roll motor removalAir handling unit: snow fall
Project Management
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• Scope Management• Development of pump station ScopeList™• 816 deliverables• Spreadsheet based
Summary & Conclusions
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• List of guiding principles– Fit for purpose, use tested technology– Consider expeditor: just in time contract
• Changes: – spill management system– Canadian economy
