Remote Pipeline Pump Operation A Control Center Perspective · Calgary Pump Symposium 2013 Remote...

Calgary Pump Symposium 2013

Remote Pipeline Pump Operation –

A Control Center Perspective

Michael Dickau P.Eng.

Enbridge Pipelines Inc.

Calgary Pump Symposium 2015 1

Calgary Pump Symposium 2013 Calgary Pump Symposium 2015

Presenters

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Michael Dickau Michael Dickau is a Senior Engineer at Enbridge Pipelines Inc.. He has been working in the Edmonton Control Center for the past 4 years planning work outages, supporting the Control Center operators, and conducting incident investigations. From the Edmonton Control Center, Enbridge directs the transport of over two million barrel of oil a day through a pipeline network stretching from Ft McMurray, Alberta to Cushing, Oklahoma, and Montreal, Quebec. Michael has instructed courses on pipeline operations for company internal training. He also has experience with transient and steady state pipeline and terminal hydraulic modeling. Michael previously worked for Sulzer Turbo Services on turbine and compressor repair projects. Michael graduated in 2008 with a BSc in Mechanical Engineering from the University of Alberta.


Enbridge Basics

• We deliver an average of 2.2 million barrels of crude oil and liquids every day, with a 99.9994% safe delivery record over the past decade while moving more than 15 billion barrels of crude.

• We transport 53 per cent of U.S.-bound Canadian production, a figure that accounts for 15 per cent of total U.S. crude oil imports.

• On any single day, Enbridge is the largest single conduit of oil into the U.S. We move close to 100 separate commodities, including more than 10 types of refined products.

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Enbridge Basics

• Approximately 26,000 km of pipelines

• 225+ pump stations / 1000+ pumping units

• Mainline Line Fill – 5.9 million m³ (37 million bbl)

• Power consumption 391 GWhr per month or 4700 GWhr Per year which is enough to power half of the city Toronto for a year (1.1 Million Homes)

• Power cost is about $39 million/month or about $470 million per year

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Enbridge Basics

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Waupisoo Pipeline

Olympic Pipeline


Pipeline Hydraulics 101

• Flow is caused by a pressure differential

• As the fluid moves it experiences frictional losses. This converts pressure energy to heat

• Frictional losses change based on product type and fluid velocity (and a few other factors)

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Pipeline Hydraulics 101

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Flow

Pre

ssu

re

Distance

Station A Station B


Control Center Video

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What does Enbridge pump?

• Heavy Crude Oil (904 – 940 kg/m³) (25-340 cSt @10°C) – High Tan Dil Bit/Syn Bit – Cracked

• Medium Crude Oil (876 – 903 kg/m³) (18-26 cSt @10°C) • Light Crude Oil (800 – 875 kg/m³) (4-21 cSt @10°C)

– Light Synthetic – Sweet – Sour

• Condensate / Refined Products (600 – 799 kg/m³) (0.5-1 cSt @10°C) – Gas – Diesel, Jet Fuel

• Natural Gas Liquids (NGL) (up to 599 kg/m³) (0.4 cSt @10°C) – Oil and natural gas are often found together in the same reservoir – Most extracted natural gas contain varying degrees of hydrocarbon compounds

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Batching

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Batch Cuts

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A nice “S” shaped interface between two batches Neither batch gains or losses in volume


Product Effect on Pumps

• Pump head

• Pump units need to be started or stopped to maintain line rate

• Change in motor load

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Line Profile

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Column Separation

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Pipe Diameters

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Line 1 Line 1 Line 1

Line 11 Line 7

Line 14 Line 6b

Line 9

Line 19

Line 21

Line 6a

Line 5 Line 10 Line 3 Loops

Line 17

Line 4 Line 2 Line 2

Line 8

Line 13

• Larger pipe has higher capital cost but lower operating cost.

• Turbulent flow is desired for batched lines

• Pressure loss is the square of velocity


Operating Priorities

• Safety: – Adhere to government regulations – Protect the environment (mass balance) – Follow Enbridge procedures – Coordinate communication with field staff

• Reliability: – Quality (minimize degradation) – On-time delivery (track batches and follow pump orders) – Maintain communications with the customers in operations

• Efficiency: – Minimize costs – primarily power (reduce throttle/balanced

line)

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Pumps in Real Life

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What the Operator Sees

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Types of Maneuvers on a Pipeline

• Injections - product being injected from Tankage to a Pipeline

• Receipt - product being received from a customer directly into the pipeline

• Delivery - product being taken off the mainline to a customer for delivery

• Landing - product being landed off a mainline into tankage within a terminal facility

• Even - batch is being pushed even or by a station, none of the above are occurring

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Types of Maneuvers on a Pipeline

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SO CRW

Pipeline Flow SW

Delivery

Pipeline Shutdown

SW

Station Valve

SO CRW

Pipeline

Shutdown SW

Injection

Pipeline Flow

SW

Station Valve

SO SW CRW Pipeline Flow

SW

Delivery

SW

SO SW CRW Pipeline Flow

SW

Injection

SW

SO SW

SYN

SO

CRW

SW

Delivery

Station Valve

Full Stream Delivery

Simultaneous

Delivery/Injection

Full Stream

Injection

Side Stream Delivery Side Stream Injection


Pressure Limits

• Operators keep pipeline pressures under a maximum pressure provided by Engineering.

• The Maximum Operating Pressure (MOP) is based on several factors

– Hydrotest records

– High consequence areas

– Transient Analysis

– Integrity features

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Operational Considerations

• Operating Limits • Low Pressure Limits

• High Pressure Limits

• Line Pressure Protection

• Energy Constraints • Power Allowable: Peak/Off-Peak Hours

• Minimum/Maximum Flow Rates • Keep above laminar flow rate

• Operation concerns with equipment

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Natural Flow Rates

• Efficient pipeline operation considers many factors.

– Pump efficiency

– Pressure control - PCV or VFD

– Pressure limits

– Power contracts

– Operability / Ability to recover from upsets

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Flow


Natural Flow Rates

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Pre

ssu

re

Distance

Station A Station B

Pressure from one pump Maximum

Operating Pressure

Power Wasted


Pump Orders

• The pipeline rates and batch line ups are calculated and provided to the operator.

• Rates are determined based on volumes nominated that month and natural flow rates.

• Each day the operators receive new pump orders for the next day.

• Emergencies/scheduling conflict can impair the operators’ ability to follow pump orders.

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Pump Orders

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Operator’s Display

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How to Start or Stop Pumps

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How to Stop or Start a Pipeline

• It depends

• Generally

– Ensure a clear flow path (open sectionalizing block valves)

– Start units to get the line running at a minimum rate

– Add additional units to achieve scheduled rates

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Bottlenecks

• On a pipeline one station to station segment will be a bottleneck. This is the segment where the upstream discharge pressure is at its maximum and the downstream suction pressure is at its minimum

• Drag Reducing Agent can be used to open the bottleneck

• Additional pumps can be added

• Line MOP can be increased

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Terminals

• Terminal - A facility along the pipeline route that allows the movement of oil to occur in or out of the Pipeline system.

• Many of these Terminals have crude storage tanks that allow the facility to hold these volumes for a two day turn around period.

• These facilities are designed to receive receipt volumes from shippers and store these volumes until a mainline injection is scheduled.

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Terminals

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• 30 Receipt lines

• 56 Receipt Meters

• 37 tanks (7 in production for 2015 in service date)

• 31 booster pumps

• 5 outgoing lines

• 5 pump stations

• 4.3MM barrels

• 20 Mainline pumps totaling 36,000HP


Terminals

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Alarms that cause pump shutdowns

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– Temperature

– Vibration

– Seal fail

– ESD

– Fire detection

– Gas detection

– Pressure allowables

– Sump tank level

– Power Fail

– VFD issue

– Lube oil issue

– Valve position/ flow path


Questions

35

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