This document discusses submerged electric motor pumps (SEMPs) used for transferring liquefied natural gas (LNG). SEMPs are uniquely designed for this application with the motor, bearings, and all components submerged in LNG. This inherently safe design eliminates the possibility of gas leakage compared to pumps with shaft seals. SEMPs are used in both onshore LNG storage tanks and send-out systems. Primary pumps in storage tanks are retractable to allow removal for maintenance, while secondary pumps in send-out systems are vessel-mounted and produce higher pressures. Proper venting and system design are important considerations for safe operation of these cryogenic pumps.
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oil and gas
Original Title
2004 Submerged Motor LNG Pumps in Send-Out System Service_S. Rush_Pumps & Systems
This document discusses submerged electric motor pumps (SEMPs) used for transferring liquefied natural gas (LNG). SEMPs are uniquely designed for this application with the motor, bearings, and all components submerged in LNG. This inherently safe design eliminates the possibility of gas leakage compared to pumps with shaft seals. SEMPs are used in both onshore LNG storage tanks and send-out systems. Primary pumps in storage tanks are retractable to allow removal for maintenance, while secondary pumps in send-out systems are vessel-mounted and produce higher pressures. Proper venting and system design are important considerations for safe operation of these cryogenic pumps.
This document discusses submerged electric motor pumps (SEMPs) used for transferring liquefied natural gas (LNG). SEMPs are uniquely designed for this application with the motor, bearings, and all components submerged in LNG. This inherently safe design eliminates the possibility of gas leakage compared to pumps with shaft seals. SEMPs are used in both onshore LNG storage tanks and send-out systems. Primary pumps in storage tanks are retractable to allow removal for maintenance, while secondary pumps in send-out systems are vessel-mounted and produce higher pressures. Proper venting and system design are important considerations for safe operation of these cryogenic pumps.
A pump is a pump, right? Not exactly, given all the variations on the theme. Take, for example those pumps primarily used for trans- fer 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 sys- tem 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. Unique pumps for unique duty. . . Multistage LNG send-out pump after removal from test stand Submerged Motor LNG Pumps In Send-Out System Service Submerged Motor LNG Pumps In Send-Out System Service Along with the rapid growth of the global LNG market has come an escalating demand for additional LNG receiving termi- nals and regasification systems around the world. Such termi- nals, 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 com- pletely flooded with LNG. 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 atmo- sphere in the hazardous area, and no rotating seals are required. The design almost completely eliminates the possibility of leak- age 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 sub- merged in liquid that acts as effective sound insulation, these pumps operate very quietly. Basic Design In a traditional, land-based LNG receiving terminal, the sys- tem consists of a storage tank that contains retractable (remov- able) or in-tank type pumps, and a send-out system, which con- tains vessel-mounted type high- pressure LNG pumps and vapor- izers. 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 sub- merged motor, retractable types, as shown in Figure 1. For a typi- cal receiving terminal, this type pump, sometimes also referred to as a primary pump, will have a flow rate of approximately 200 to over 400 m 3 /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 sys- tem. For vaporizer-feed duty, a relatively high pressure is required due to the high-pressure drop across the vaporizer. For this application, a multistage ves- sel-mounted type pump (see Figure 2) that can produce pres- sures up to approximately 140 kg/cm 2 is used. For primary transfer pumps, the motor voltage is normally 400 to 480 volts, three phase, but also can be made at higher volt- ages, depending on the site power supply. The secondary vaporizer-feed pumps are nor- mally 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 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 dis- charge column. 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 equal- ize 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 liq- uid in the storage tank. The high-pressure secondary pump is installed in its own self- contained suction vessel, with PUMPS & SYSTEMS www.pump-zone.com MAY 2004 33 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. 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 head- plate. Vessels can be made to the ASME Section VIII code or to just about any pressure vessel code, as required. Apart from the piping connec- tions, 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 prima- ry 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 require- ments and the need for backup or redundancy. From a pump design standpoint, there is no particular spacing requirement between the pump columns. Normally, the col- umn spacing will be dictated by the tank design and spacing of the pip- ing, 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 enter- ing 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. PUMPS & SYSTEMS becomes very important at low liquid levels, where two meters of LNG is equal to only 0.09 kg/cm 2 pressure. If the col- umn pressure is too high, the lower section of the column, including the pump, can be com- pletely void of liquid, which can create problems during starting. 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 start- up 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 particu- larly 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 prob- lems with secondary pumps over the years have been attributed to poor vent-system design. In the secondary pump sys- tem, a phase separator, or recon- denser, is normally installed in the suction area. This tank is typ- ically 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 sys- tem in this area should also be treated carefully to ensure that the LNG temperature is still well into the liquid phase as it enters the pump suction. Motors With the recent interest in offshore or remote send-out sys- tems, 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 start- ing system is required. A cryo- genic motor is a unique design, and the starting current required is approximately 6 1 2 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 cur- rent, soft starters, autotransform- ers and variable frequency drives can be used with SEMPsand have been used very successfully in many applications. However, proper set-up of starting parame- ters in any current reduction type starting system is critical. To pre- vent 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 sec- ondary pumps has been dis- cussed. It appears as though the biggest obstacle in this type sys- tem is the venting and boil-off from the send-out system during operation. Using the boil-off gas to feed local gas turbine genera- tors 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 sys- tems installed to trend vibration. These systems typically consist of a piezoelectric type accelerometer PUMPS & SYSTEMS www.pump-zone.com MAY 2004 35 About EIC/Cryodynamics Cryodynamics specializes in the design, manufac- ture and testing of sub- merged, electric motor- powered pumps and power recovery turbine generators. Used in a vari- ety 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 repu- tation 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 bor- der), also is the site of one of the worlds largest and most sophisticated cryo- genic 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. mounted to the outside of the pump casingyes, submerged in the LNG. This is a very difficult type of installation, and the relia- bility 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 dis- tributed control system (DCS). If motor amperage, flow and pres- sure 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-spec- ification, 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 indica- tion of a mechanical problem or a problem in the electrical wiring into the motor. Furthermore, a typical system will contain pro- tection 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 cre- ating acceptable operating para- meters 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 consid- er when seeking to ensure a safe, reliable system. In a review of LNG pump failures over the years, the predominant root caus- es for failure have been as follows: Cavitation due to poor sys- tem design or improper operation. C i r c l e
2 2 6 o n
R e a d e r
S e r v i c e
C a r d MAY 2004 www.pump-zone.com PUMPS & SYSTEMS 36 Operation at flow rates away from the rated or best effi- ciency point for extended periods of time. Debris or contamination in the liquid. Since LNG systems are nor- mally clean, the first two points seem to be the main causes of failure. To ensure reliable send- out 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 ini- tial design or FEED stages, as well as when writing specifica- tions for equipment. As with any application, proper system design should result in a safe, simple, reliable and reasonably priced installation. P&S References 1. D. Cullen, J. Madison, High Pressure Technology, Hydro- carbon 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 Motor- Driven 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, devel- opment, 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 manufac- tured by EIC/Cryodynamics, Rush based this article on a presentation he delivered for the 2004 AIChE Spring National Meeting, Topical Conference on Natural Gas Utili- zation, in New Orleans, LA, April 27th. Contact him directly at: srush@ebaraintl.com PUMPS & SYSTEMS www.pump-zone.com MAY 2004 37 C i r c l e