Microsoft PowerPoint - Ramesh Krishnappan presentation.pptxRamesh Krishnappan AESSEAL
ICEPIM 2015 I t ti l C f Pi li I t it tInternational Conference on Pipeline Integrity management
Introduction
This presentation will focus on the application ofThis presentation will focus on the application of mechanical seals in pipeline pumps, covering the transmission of crude oil and refined products such as fuel oils, gasoline's and natural gas liquids (NGL), for example propane and ethaneexample propane and ethane.
Included in this discussion will be pipeline systems that transport multiple products through the same pipeline as well as mixtures of NGL. These batched product pipelines present difficult sealing applications because the pumped products can range from light NGL products to heavier gasoline products. Additionally, some of these same pipeline systems can also be used to transport crude oils.
Pipeline Categories
In general, pipelines can be classified in three categories depending on purpose:
Gathering pipelines Group of smaller interconnected pipelines forming complex networks with the purpose of bringing crude oil or natural gas from several nearby wells to a treatment plant or processing facility. In this group, pipelines are usually short a couple of hundred metres and with small diameters. Also subsea pipelines for collecting product from deep water production platforms are considered gathering systems.
Transportation pipelines Mainly long pipes with large diameters, moving products (oil, gas, refined products) between cities, countries and even continents. These transportation networks include several compressor stations in gas lines or pump stations for crude and multiproduct pipelines.
Distribution pipelines Composed of several interconnected pipelines with small diameters, used to take the products to the final consumer. Feeder lines to distribute gas to homes and businesses downstream. Pipelines at terminals for distributing products to tanks and storage facilities are included in this group.
Pipeline Types  Gas Gas production and in particular Liquefied NaturalGas production, and in particular Liquefied Natural Gas (LNG), is expanding at a rapid rate. With a range of cryogenic pumps suitable for pumping LNG, Pump OEM’s specialize in building ultra large high pressure send out pumps for the latesthigh pressure send out pumps for the latest generation of LNG terminals.
Multiphase Multiphase pumping is increasingly used to boostMultiphase pumping is increasingly used to boost well production. Latest developments include a subsea version of the pump for direct boosting at the well head.
CO2CO Capture, transportation and storage of CO2 is a developing market with CO2 being used as an injection medium or stored in depleted wells. Pump OEM’s are active in this field supplying CO2 pipeline transportation and high pressure injection pumps.
Crude Oil / NGL Transporting crude oil or refined products in pipelines across continents from production centers to market is a key part of the modern world’s energy distribution infrastructure.
Pipeline Lay out
Desired material throughput values as well as circumstantial factors along the pipeline route are considered in designing and l ti t ti B th ltit d f i hi h th d i d ti diti b bt i d dlocating pump stations. Because there are a multitude of ways in which the desired operating conditions can be obtained and sustained, the outfitting and location of pump stations are also often influenced by economics, typically representing a compromise between few largecapacity pump stations and a greater number of smallercapacity stations.
Pumping Stations
At a minimum, pump stations include pumps (components that actually contact the fluids in the pipeline and provide kinetic energy) and prime movers (power sources that provide power, typically some form of mechanical energy) to the pumps.
To facilitate maintenance and to prevent disruptions of pipeline operation as a result of equipment failure, most pump stations use several pumps arranged in parallel fashion. Typically, all but one of the pumps isfashion. Typically, all but one of the pumps is capable of producing the desired operating pressures and throughputs, so some pump is constantly offline and in standby.
Typical pump station configurations involve at least three pumps connected to the pipeline in parallel. Two of the three pumps operate while the third remains available, if needed, or in the event of a failure of oneof the three pumps operate while the third remains available, if needed, or in the event of a failure of one of the operating pumps. Such a configuration also allows pumps to be taken offline for maintenance or replacement without affecting the operating status of the pipeline.
Pump Designs
Pumps of various designs are used in crude oil and petroleum product pipelines. Two fundamental pump designs are in common use: centrifugal pumps and positive displacement pumps.
Centrifugal pumps are preferred for moving large volumes of material at moderate pressure, while positive displacement pumps are selected for movingpositive displacement pumps are selected for moving small volumes of material at higher line pressures.
Centrifugal pumps consist of two main components: the impeller and the volute. The impeller, the only rotating component of the pump, converts the energyg p p p, gy it receives from the force that causes its rotation into kinetic energy in the fluid being pumped, while the volute converts the kinetic energy of the fluid into pressure.
d l b f dPositive displacement pumps can be of various designs; however, two designs predominate in pipeline applications: reciprocating and rotating pumps. Rotating pumps are often the pump design of choice for viscous fluids such as crude oils. Unlike a centrifugal pump where power demands rise sharply withpump where power demands rise sharply with increasing fluid viscosity, the performance of rotating pumps is generally unaffected by variations in either fluid viscosity or line pressure.
1. Pipeline Seal Designs 
CFC / CFFC up to 60 barg / 60 m/s 64% to 69% Face balance
HPVS/HPVD up to 90 barg / 60 m/s 80/70 Face balance, Hydro pads
2. Demanding Applications
60 bar plus Pressures Bigger Shafts / high velocity Reverse pressure capability
Dry running possibility High Viscous (Crude) Volatile fluids (Ethane & Propane)p
Sand Particles, Abrasive Pipe Rouge Start/Stop operations Cooling Water availability at remote locations.g y
Remote Locations Complex Supply Systems Poor Equipment Conditions Small Seal Chamber
2a. Seal Arrangements
• Single Seals Containment Secondary
• Face to Face
– Gas PressurizedGas Pressurized  • Face to Face
• Back to Back
• Face to Back
3. Pump Types Crude Oil and Refined Product Pipeline  Pumps Mainline/Booster Pumps • Single and twostage between bearings
Water Pipeline Pumps • Single and multistage overhung • Axially split, singlestage between bearings • Vertical turbine Single and two stage between bearings
• Multistage, horizontal split case • Multistage, radially split double case • Multistage vertical canned
l h
l l• Twin screw multiphase
Auxiliary Pumps • Singlestage overhung
Slurry Pipeline Pumps • Singlestage overhung ––Hard metal ––Metallic and nonmetallic linedg g g
• Vertical inline  • Submersible motor • Singlestage and multistage  vertical wet pit Si l t d lti t
• Reciprocating positive displacement
CO2 Pipeline Pumps Si l t b t b i di ll lit• Singlestage and multistage 
vertical canned • Servicespecific specialty designs
• Singlestage, between bearings, radially split • Multistage, horizontal split case • Multistage, radially split doublecase
3a. Pump Types and Models  Sulzer Sulzer Single and two Stage Pumps
3b. Pump Types and Models  Sulzer Sulzer Axially Split Pumps
3c. Pump Types and Models  Sulzer
Pumping Stations at remote locations Horizontal Split Diffuser Pumps of Sulzer Bingham
3d. Pump Types and Models H C d Oil i B & L i t itHeavy Crude Oil pumping : Bornemann & Leistritz
Screw pumps used in pipeline applications are of two types:
1) T i hi h d d i tl t i li b ti1) Twin-screw pumps which are used predominantly at pipeline boosting stations and Terminals.
2) Three-screw pumps to boost pressure from laterals to the main i lipipeline.
4x Seals per  Pump...
Tight Space!
3e. Pump Types and Models : Flowserve DVSH/LPN/LPLD (BB1) Axially Split, SingleStage • Flows to 15 000 m3/h (65 000 gpm) • Heads to 565 m (1854 ft)• Heads to 565 m (1854 ft) • Pressures to 150 bar (2175 psi) • Speeds to 6000 rpm
DMX (BB3) A i ll S lit M lti tAxially Split, Multistage • Flows to 2950 m3/h (13 000 gpm) • Heads to 2130 m (7000 ft) • Pressures to 275 bar (4000 psi)( p ) • Speeds to 6000 rpm
Design Features
Some of CFFC seals working satisfactorily in Pipeline Applications ranging from 65mm to 100mm size. These l h b fitt d i St k P E i l M t P d OLMX G i d P f iseals have been fitted in Stork Pumps, Ensival Moret Pumps and OLMX Guinard Pumps for pressures ranging
from 23 bar to 65 bar. The pumped fluids include Mineral Oil, Crude Oil & Naphtha
Typical API Plans in Pipelines
Research has proven that the best way to prevent mechanical seal failure is inResearch has proven that the best way to prevent mechanical seal failure is in using effective Seal Support Systems. This means that no matter how well designed your mechanical seals are, without a reliable Seal Support System there is still the possibility of your mechanical seal failing.
Because sealing applications on product pipeline pumps are critical to pipelineg pp p p p p p p p operation, the use of dual (tandem, double or dry running secondary) seals should be considered. Dual seals can maintain low leakage rates while providing improved safety.
A tandem seal is two seals operating in series with the secondary seal ll f h f h l d lusually of the same configuration as the primary seal. An unpressurized seal
reservoir, Plan 52, is required to support the operation of the secondary seal.
A double seal is usually two seals sealing in opposite directions. This seal is usually supported with a pressurized seal reservoir, Plan 53A or 53B or 54.
Dry running secondary seals operate in tandem arrangement without the seal reservoir required for liquid tandem arrangements.
The innovative and reliable Seal Support System Range at AESSEAL® gives customers the confidence to remove this root cause of mechanical seal failure.
Typical API Plans in PipelinesAPI Plan 53B
Pressurized barrier fluid circulation in outboard seal of dual seal configuration. Circulation is maintained by using pumping ring in running condition and with thermosyphon effect in stand still condition. The pressure is maintained in the seal circuit by a bladder acc m latoraccumulator.
1. Keeps barrier fluid and pressurized gas (N2) separate by using a bladder. 2. Heat is removed from the circulation system by an aircooled orcirculation system by an air cooled or watercooled heat exchanger. 3. Being a standalone system does not rely upon a central pressure source. Hence much more reliable than a Plan 53A. 4. In no case media leakage to atmosphere.
Sample System
opportunities
4. Opportunities – Asia
Enterprise Products Partners L.P. provides midstream energy services to producers andmidstream energy services to producers and consumers of natural gas, natural gas liquids (NGLs), crude oil, refined products, and petrochemicals in the United States and internationally
Pipeline Operators
Sunoco Logistics Partners L.P. engages in the transport, terminalling, and storage of crude oil and refined products in the United States.
Pipeline Operators
Enbridge Inc. operates as an energy transportation and distribution company inp p y the United States and Canada. Its Liquids Pipelines segment operates common carrier and contract crude oil, natural gas liquids (NGL), and refined products pipelines and terminals.
Pipeline Operators
ONEOK Partners, L.P. engages in the gathering, processing, storage, and
i f l i h U i dtransportation of natural gas in the United States. It operates in three segments: Natural Gas Gathering and Processing, Natural Gas Pipelines, and Natural Gas Liquids.
h kThank you.