For more than six decades, a Canadian energy company has been delivering energy, including oil and gas, across North America. A large part of the company’s business is the operation of the world’s longest crude oil and liquids transportation system, conveying crude oil and other liquid hydrocarbons from the point of supply to refining markets in the midwestern U.S. and eastern Canada. This company had two goals for its pumping system. First, it wanted to streamline the system for its waste oil storage tanks. Second, the company needed a system to improve its diluent blend into heavy crude before the product joins the main pipeline for distribution. The energy pipeline company asked a pump manufacturer to design and build customized pumping solutions for greater operational efficiencies and lower maintenance.
Customized equipment helped an energy company achieve greater operational efficiencies, lower maintenance and improved diluent injection control.
04/14/2015
Image 1. The need to reduce maintenance and simplify the transfer of oil from an underground tank back into the pipeline required a pump manufacturer to design and build a custom, 10-stage vertical progressing cavity sump pump to satisfy customer requirements. (Images courtesy of NETZSCH Pumps North America, LLC)
Image 2. Large progressing cavity pumps are required to work outdoors in sub-zero temperatures.
The energy company conducted an in-depth evaluation of pumping systems. It originally settled on a multi-stage canned pump for this application but still had reservations about viscosity and injection control. For this pump type to work, it would need to operate at full speed and capacity and modulate the injection flow through a control valve. The irregular viscosity of the product through the drawdown of the storage tank could cause problems.
As the crude oil sits in storage tanks, lighter product moves to the top, and the heavier product moves to the bottom.
“Crude oil is drawn off the bottom of the tanks first, which is where most of diluent injection is required,” said Luke Bauer, a senior application engineer with the pump manufacturer. “As the product’s viscosity changes, the amount of diluent being used must be adjusted. We approached the design of this system with progressing cavity pumps to take care of operating issues associated with constantly changing viscosity.”
The extremely cold operating temperatures during the winter months was a critical design issue. With ambient conditions of -22 to -40 F (-30 to -40 C) and diluent temperatures as cold as -8 to -13 F (-22 to -25 C), the pump manufacturer’s engineers carefully considered the elastomer selection for this application. Because the progressive cavity pumps would operate outdoors, a patented reduced wall stator was selected with heat tracing to ensure that a 23 to 32 F (-5 to 0 C) operating temperature was maintained within the elastomer. Additionally, three resistance temperature detectors (RTD) were mounted in each pump to provide feedback data to the control system.
The chemical compatibility of the diluent also presented a design challenge. “Two different diluent samples were given to us, and we did a lengthy immersion test with several elastomers at different temperatures to provide a better picture of how our elastomers would react,” Bauer said. “After extensive evaluation and swell testing, a special blend of Viton was designed and produced for the stator and seals that would be used.”
To compensate for the cold temperatures, the pump manufacturer designed a slightly oversized rotor to maintain the interference fit at sub-zero temperatures. This presented an additional hurdle at assembly time. The stators were packed with ice to fit the oversize rotors during fabrication.
Other custom design features were required as well. The energy company requested that the pumps be mounted on a metal grid platform because the standard baseplate for these pumps would not provide enough support. The pump manufacturer designed a new baseplate incorporating a reinforced 8-inch I-beam with a drip pan and lifting supports. The energy company also wanted a pump housing with added connections for a relief valve return and other monitoring equipment to be installed on-site. The pump manufacturer designed a spool piece to attach to the pump housing inlet, providing the extra connection.
By using four custom-designed progressing cavity pumps piped to a common header, the pump manufacturer provided the energy company with the required level of diluent injection control. The energy company can run any combination of the pumps and, with the use of variable frequency drives, they have complete control over diluent injection. The large pump size also allows the energy company to run the pumps slower for a longer life cycle.