pump is a pump, right? Not exactly, given all the variations on the theme.

Take, for example those pumps primarily used for transfer of liquefied natural gas (LNG) and other liquefied gases. Theyre really in a class unto themselves. Over the years, various methods of transferring LNG from ship to tank storage for transfer later to a send-out system, or transfer directly from ship into a regasification or send-out system have been studied, and some are already in detailed design or under construction. This article focuses on the use of submerged, electric motor pumps (SEMPs) for these types of services.

Multistage LNG send-out pump after removal from test stand

Submerged Motor LNG Pumps In Send-Out System Service

Unique pumps for unique duty. . .
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By Steve Rush, Cryodynamics Division, Ebara International Corp. Along with the rapid growth of the global LNG market has come an escalating demand for additional LNG receiving terminals and regasification systems around the world. Such terminals, whether on- or offshore, contain gas send-out systems that utilize SEMPs for LNG transfer and pressurization. These pumps typically feature an integral shaft with the entire motor, bearings and all other components completely flooded with LNG. that contains retractable (removable) or in-tank type pumps, and a send-out system, which contains vessel-mounted type highpressure LNG pumps and vaporizers. This type of terminal also includes a jetty where the LNG carrier would dock and discharge its LNG into the onshore storage tanks. The pumps used in the onshore storage tanks are submerged motor, retractable types, as shown in Figure 1. For a typical receiving terminal, this type pump, sometimes also referred to as a primary pump, will have a flow rate of approximately 200 to over 400 m3/h. This pump would normally only require one or two impeller stages, as it only needs to transfer the LNG out of the tank and into the secondary system. For vaporizer-feed duty, a relatively high pressure is required due to the high-pressure drop across the vaporizer. For this application, a multistage vessel-mounted type pump (see Figure 2) that can produce pressures up to approximately 140 kg/cm2 is used. For primary transfer pumps, the motor voltage is normally 400 to 480 volts, three phase, but also can be made at higher voltages, depending on the site power supply. The secondary vaporizer-feed pumps are normally higher power, which require from 4160 to 6600 volts. Both types of pumps can be manufactured for either 50 or 60 Hz power, depending on site requirements. The primary pump is installed into the storage tank through a discharge column mounted inside the tank. At the base of the column is a suction valve that is opened by the pump itself. As the pump is lowered into the tank, the valve opens, allowing the LNG to flow into
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the inlet of the pump. The pump has a seal located near its base, which allows the discharge liquid to be pumped out the top of the pump and out the top of the discharge column.

Safety
Submerged motor pump technology was first applied in LNG applications in the early 1960s. Since that time, SEMPS have been used in almost all LNG receiving terminals. The main reason for their popularity is their inherently safe design compared to that of external motor type pumps with dynamic shaft seals. The motor and hydraulic sections of the SEMP are directly coupled with a common shaft, submerged in the liquid, with no oxygen present. This means the motor is not located in the atmosphere in the hazardous area, and no rotating seals are required. The design almost completely eliminates the possibility of leakage of flammable gas into the atmosphere. In addition to the safety aspects, as no coupling is required between the motor and pump sections, there are no alignment problems normally associated with pumps that use couplings. Furthermore, since the complete assembly is submerged in liquid that acts as effective sound insulation, these pumps operate very quietly.

Along with the rapid growth of the global LNG market has come an escalating demand for additional LNG receiving terminals and regasification systems around the world.
Since the primary pump is installed in the storage tank, which is already provided with a vent system, no other venting connection at the headplate or column is required (although venting of the column to equalize pressure to the main tank area is required prior to start-up). The heat from the pump primarily is transferred to the pumped fluid, with only a small amount of heat being transferred back to the liquid in the storage tank. The high-pressure secondary pump is installed in its own selfcontained suction vessel, with
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Basic Design
In a traditional, land-based LNG receiving terminal, the system consists of a storage tank
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standard flanged inlet and discharge pipe connections. The vessel needs to be vented and is provided with a vent nozzle at the top of the headplate. Vessels can be made to the ASME Section VIII code or to just about any pressure vessel code, as required. Apart from the piping connections, both pump types require power cables to be connected at their junction boxes located on or near the headplate.

Primary Pump: Design Concerns

With a SEMP used for LNG, it is always important to keep in mind that LNG is normally handled close to its boiling point. Even just a small increase in temperature or a drop in pressure can cause the LNG to vaporize. As previously noted, the primary pumps in the storage tank are used simply to transfer the LNG to the send-out system. Normally, two or three primary pumps are used, depending on total flow requirements and the need for backup or redundancy. From a pump design standpoint, there is no particular spacing requirement between the pump columns. Normally, the column spacing will be dictated by the tank design and spacing of the piping, valves, etc, at the tank top. Care should be taken in the tank design for the location of the inlet piping to the tank. If the inlet pipe is placed too close to the pump columns, the warmer liquid entering the tank can affect the NPSHR of the pumps when filling the tanks during lower-level operation. Another requirement is the need for column venting prior to start-up. Most columns will have discharge piping that can be vented to the tank top to equalize pressure between the tank and column; it is crucial to ensure there are no low spots that could trap liquid or prevent proper venting. This

Figure 1. Diagram of submerged motor, retractable (removable) type pump used in onshore storage tanks.

Figure 2. Multistage vessel-mounted pump design for vaporizer-feed duty.

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becomes very important at low liquid levels, where two meters of LNG is equal to only 0.09 kg/cm2 pressure. If the column pressure is too high, the lower section of the column, including the pump, can be completely void of liquid, which can create problems during starting.

About EIC/Cryodynamics
Cryodynamics specializes in the design, manufacture and testing of submerged, electric motorpowered pumps and power recovery turbine generators. Used in a variety of land-based and marine applications, Cryodynamics pumps are designed to handle liquefied gasses with pumping temperatures ranging from ambient to cryogenic. Through its affiliation with Ebara Corporation of Japan, one of the largest pump companies in the world, Cryodynamics has developed a reputation for quality and flexibility, incorporating its own liquefied gas pump engineering know-how with Ebara's centrifugal pump expertise dating back to 1912. The divisions large, modern headquarters and manufacturing plant in Sparks, NV (adjacent to Reno in Northern Nevada on the California border), also is the site of one of the worlds largest and most sophisticated cryogenic liquefied gas pump test facilities. Cryodynamics supports its products with specialist service engineers based in the U.S., Japan and the U.K. It is Quality System Certified to ISO 9001: 2000 with a Current Continuous Registration. For more information on Ebaras Cryodynamics Division, as well as Ebaras Standard Pump Division or its Electric Motor Division, log onto: www.ebaracryo.com. Or, circle Reader Service Number 523.

Secondary Pumps: Design Concerns

The secondary pumps are normally installed in a bank or row, with the suction nozzles all connected to a common suction header. The discharge lines are also normally connected to a common line, but each pump should have its own discharge control valve, as well as a by-pass or kick-back line to allow proper starting and operation. Discharge control is extremely important to allow proper startup when operating several pumps in parallel. With a secondary pump, it also is critical to recognize proper venting. Since the secondary pumps normally have much higher motor power, it is particularly important to take care of any heated LNG or vapor. Vent lines should always be rising as they leave the pump vessel and provide good venting back to a low-pressure space. Many problems with secondary pumps over the years have been attributed to poor vent-system design. In the secondary pump system, a phase separator, or recondenser, is normally installed in the suction area. This tank is typically used to allow the liquid to settle long enough to allow any vapor to be vented, and is also used to introduce LNG from the boil-off gas system to try and recover as much of the LNG as possible. The design of the system in this area should also be treated carefully to ensure that the LNG temperature is still well
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into the liquid phase as it enters the pump suction.

Motors
With the recent interest in offshore or remote send-out systems, an important topic is the electrical supply used to start the high-pressure send-out pumps. Since the motors in these pumps are typically from 1000 to as much as 2300 kW, a large starting system is required. A cryogenic motor is a unique design, and the starting current required is approximately 612 times the full load current. It is difficult to reduce this value because of the amount of torque required for starting a cryogenic motor. To reduce the starting current, soft starters, autotransformers and variable frequency drives can be used with SEMPsand have been used very successfully in many applications. However, proper set-up of starting paramewww.pump-zone.com

ters in any current reduction type starting system is critical. To prevent problems, consult your pump manufacturer. In some offshore or remote locations, using the LNG carrier as the primary system delivering the LNG directly to the secondary pumps has been discussed. It appears as though the biggest obstacle in this type system is the venting and boil-off from the send-out system during operation. Using the boil-off gas to feed local gas turbine generators for power, or pressurizing the gas using compressors and feeding into the downstream gas system appear to be popular alternatives.

Monitor & Protect

Both primary and secondary SEMPs can have monitoring systems installed to trend vibration. These systems typically consist of a piezoelectric type accelerometer
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mounted to the outside of the pump casingyes, submerged in the LNG. This is a very difficult type of installation, and the reliability of these in-tank vibration systems is not very good. For vessel-mounted secondary pumps, the accelerometer can be

mounted outside of the suction vessel, on the headplate. While not as sensitive as a casing mount, it can be effective for trend monitoring, and recently has become the preferred method for mounting. One of the best ways to mon-

itor SEMPs is to simply use the trending capabilities of the distributed control system (DCS). If motor amperage, flow and pressure are checked regularly and trended against one another, the performance of the pump can be verified. Over time, any apparent deterioration in performance is normally an indication that the unit is in need of overhaul. For protection, the pumps should be protected with at least over- and under-current relays in the electrical system out-of-specification, connected to the motor power input. A loss in amperage is an indication of loss of suction pressure (cavitation), and an increase in amperage is an indication of a mechanical problem or a problem in the electrical wiring into the motor. Furthermore, a typical system will contain protection for low suction pressure or low liquid level, and low or out-of-specification flow and/or pressure. Newer DCS systems have excellent capabilities for creating acceptable operating parameters for SEMPs.

Reliability
The reliability of a send-out system is extremely important. Most systems have several pumps operating at all times, with the need for pumps operating 24 hours a day for long periods of time. With LNG systems, mainly because of the fact that the LNG is typically handled close to its boiling point, there are several factors, including system design, that are very important to consider when seeking to ensure a safe, reliable system. In a review of LNG pump failures over the years, the predominant root causes for failure have been as follows:

Circle 226 on Reader Service Card

Cavitation due to poor system design or improper operation.

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Operation at flow rates away from the rated or best efficiency point for extended periods of time. Debris or contamination in the liquid.

tions for equipment. As with any application, proper system design should result in a safe, simple, reliable and reasonably priced installation. P&S

References
Since LNG systems are normally clean, the first two points seem to be the main causes of failure. To ensure reliable sendout systems, the designers and operators of these systems need to be well trained and aware of the important issues surrounding design and operation. Moreover, it is especially important to consult with the SEMP manufacturer during initial design or FEED stages, as well as when writing specifica1. D. Cullen, J. Madison, High Pressure Technology, Hydrocarbon Asia, July/August 2001. 2. G. Louis Weisser, Modern Submersible Pumps for Cryogenic Liquids, World Pumps, January 1994. 3. D. Cullen, S. Rush, J. Madison, Radial and Axial Diffusers for Submerged Electric MotorDriven Pumps, World Pumps, September 2000.

Steve Rush is the Vice President of Sales and Service for the Cryodynamics Division of Ebara International Corp (EIC). Headquartered in Sparks, NV, hes worked with this division for more than 23 years in the design, development, testing, service and sales of submerged motor cryogenic pumps and liquid expanders. The author of several papers and articles on various subjects related to liquefied gas pump equipment manufactured by EIC/Cryodynamics, Rush based this article on a presentation he delivered for the 2004 AIChE Spring National Meeting, Topical Conference on Natural Gas Utilization, in New Orleans, LA, April 27th. Contact him directly at: srush@ebaraintl.com

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Circle 248 on Reader Service Card