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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.
Calgary Pump Symposium 2013Calgary Pump Symposium 2013
Pi li PPipeline Pumps
Calgary Pump Symposium 2013Calgary Pump Symposium 2013
What Makes Pipeline Pumps UniqueWhat Makes Pipeline Pumps Unique
Calgary Pump Symposium 2013
What Makes Pipeline Pumps UniqueWhat Makes Pipeline Pumps Unique
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
What Makes Pipeline Pumps UniqueWhat Makes Pipeline Pumps Unique
• 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
Calgary Pump Symposium 2013
What Makes Pipeline Pumps UniqueWhat 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. Keystone and Gateway
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
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)
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
Kilometers
Pipeline Hydraulics – Batched Operation
Calgary Pump Symposium 2013
Pipeline Hydraulics – Batched lOperation – Laminar Flow
Calgary Pump Symposium 2013
Pipeline Hydraulics – Batched b l lOperation – Turbulent Flow
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
Series vs Parallel Pump StationSeries vs Parallel Pump Station
Parallel Pump Station Series Pump Station
Calgary Pump Symposium 2013
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)
Calgary Pump Symposium 2013
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)
Calgary Pump Symposium 2013
Head & Efficiency vs Pump RPMHead & Efficiency vs Pump RPM
Maximum EfficiencySystem Curve
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
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)
Calgary Pump Symposium 2013
( )
Pipeline Pump TypeslSingle Stage API 610 Type BB1
Low Head – High Flow
Courtesy Flowserve
Calgary Pump Symposium 2013
Pipeline Pump TypeslMultistage API 610 Type BB3
High Head – Low Flowg
Courtesy Flowserve
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
Mechanical Seal FlushMechanical Seal FlushAPI Plan 11
Courtesy Fluid Sealing Association
Calgary Pump Symposium 2013
Courtesy Fluid Sealing Association
Seal Leakage DetectionSeal Leakage Detection• API Plan 65A Typical
• Gravity Drainage to Sump
• Vessel with Level DetectorDetector
Courtesy Fluid Sealing Association
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
Pump ReratingPump Rerating
• 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)
Calgary Pump Symposium 2013
Pump ReratingPump Rerating
Calgary Pump Symposium 2013
Replacement Volute LipsReplacement Volute Lips
Calgary Pump Symposium 2013
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
Calgary Pump Symposium 2013
curve
Questions?Questions?
Calgary Pump Symposium 2013