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