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GAS ARABIA SUMMIT, 5th annual meeting

Sour Gas Meeting

Liquid Sulphur Handling Facilities and Long D istance Pipelines

meeting Sour Gas Meeting Liquid Sulphur Handling Facilities and Long D istance Pipelines Rolf Szczepanek, 31/01/2010
meeting Sour Gas Meeting Liquid Sulphur Handling Facilities and Long D istance Pipelines Rolf Szczepanek, 31/01/2010

Rolf Szczepanek, 31/01/2010

Liquid Sulphur Handling Facilities and Long Distance Pipelines Table of Contents

Physical Properties

Heating Systems

Station facilities

Properties  Heating Systems  Station facilities p a g e 2 • Pumps • Loading
Properties  Heating Systems  Station facilities p a g e 2 • Pumps • Loading

page 2

 Heating Systems  Station facilities p a g e 2 • Pumps • Loading /

Pumps

Loading / Unloading Facilities

Tanks

Solidification units

Silo

Pipelines

Main Project Risks

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

Liquid Sulphur Handling Facilities and Long Distance Pipelines Physical Properties of λ-Sulphur

Long Distance Pipelines Physical Properties of λ-Sulphur 9 1800 viscosity density 8 7 1790 6 5
9 1800 viscosity density 8 7 1790 6 5 1780 4 3 1770 120 130
9
1800
viscosity
density
8
7
1790
6
5
1780
4
3
1770
120
130
140
150
160
viscosity / mm 2 /s
density / kg/m 3

temperature / °C

narrow operating range (125°C to 150°C) → special demands on redundancy, heating and insulation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 3

→ special demands on redundancy, heating and insulation N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 3

Liquid Sulphur Handling Facilities and Long Distance Pipelines Heating Systems

Station piping, valves and pumps

Pipelines

Systems  Station piping, valves and pumps  Pipelines • Jacketing or tracing • Steam •

• Jacketing or tracing

• Steam

• Hot Water

• Thermal Oil

• Electrical heating cables

• Electrical

• Conventional Heating Cables

• Skin Effect Heating System

• Hot water

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 4

Cables • Skin Effect Heating System • Hot water N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 4

Liquid Sulphur Handling Facilities and Long Distance Pipelines Heating Systems, boiler unit

and Long Distance Pipelines Heating Systems, boiler unit TO-Heaters Brake 2 x 700 kW N:\GB-S\sp-proj\+Präsentation

TO-Heaters

Brake

2 x 700 kW

Heating Systems, boiler unit TO-Heaters Brake 2 x 700 kW N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 5

Heating Systems, boiler unit TO-Heaters Brake 2 x 700 kW N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 5

Liquid Sulphur Handling Facilities and Long Distance Pipelines Heating Systems, Pipes

and Long Distance Pipelines Heating Systems, Pipes Pipe in Pipe System for heating by Thermo-Oil, Hot

Pipe in Pipe System for heating by Thermo-Oil, Hot Water, Steam

Fixed

support

of

jacketed

pipe

Thermo-Oil, Hot Water, Steam Fixed support of jacketed pipe N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

Hot Water, Steam Fixed support of jacketed pipe N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 6

page 6

Hot Water, Steam Fixed support of jacketed pipe N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 6

Liquid Sulphur Handling Facilities and Long Distance Pipelines Heating Systems, jacketed Pumps and Valves

Pipelines Heating Systems, jacketed Pumps and Valves N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation
Pipelines Heating Systems, jacketed Pumps and Valves N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation
Pipelines Heating Systems, jacketed Pumps and Valves N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 7

Pipelines Heating Systems, jacketed Pumps and Valves N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 7

Liquid Sulphur Handling Facilities and Long Distance Pipelines Station facilities, Pumps

and Long Distance Pipelines Station facilities, Pumps • Centrifugal Pumps • conventional coupled •
and Long Distance Pipelines Station facilities, Pumps • Centrifugal Pumps • conventional coupled •

• Centrifugal Pumps

• conventional coupled

• magnetically coupled

Screw Pumps

coupled • magnetically coupled • Screw Pumps N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 8

Liquid Sulphur Handling Facilities and Long Distance Pipelines Station facilities, Loading / Unloading Facilities

Station facilities, Loading / Unloading Facilities Railway Unloading Station, Brake 5 x 60 m³ / h

Railway Unloading Station, Brake 5 x 60 m³ / h Screw pumps

Railway Unloading Station, Brake 5 x 60 m³ / h Screw pumps N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 9

Unloading Station, Brake 5 x 60 m³ / h Screw pumps N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 9

Liquid Sulphur Handling Facilities and Long Distance Pipelines Station facilities, Loading / Unloading Facilities

Station facilities, Loading / Unloading Facilities N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

NPSHA = 1.6 m

→ Screw pumps

/ Unloading Facilities N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation NPSHA = 1.6 m → Screw pumps page 10

page 10

/ Unloading Facilities N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation NPSHA = 1.6 m → Screw pumps page 10

Liquid Sulphur Handling Facilities and Long Distance Pipelines Station facilities, Tanks

and Long Distance Pipelines Station facilities, Tanks 10,000 to, Sulphur Plant Brake / Germany
and Long Distance Pipelines Station facilities, Tanks 10,000 to, Sulphur Plant Brake / Germany

10,000 to, Sulphur Plant Brake / Germany

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 11

Tanks 10,000 to, Sulphur Plant Brake / Germany N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 11

Liquid Sulphur Handling Facilities and Long Distance Pipelines Station Facilities, Tanks

and Long Distance Pipelines Station Facilities, Tanks Insulation N:\GB-S\sp-proj\+Präsentation

Insulation

Distance Pipelines Station Facilities, Tanks Insulation N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation
Distance Pipelines Station Facilities, Tanks Insulation N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 12

Distance Pipelines Station Facilities, Tanks Insulation N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 12

Liquid Sulphur Handling Facilities and Long Distance Pipelines Station Facilities, Tanks

and Long Distance Pipelines Station Facilities, Tanks Heating coils on bottom N:\GB-S\sp-proj\+Präsentation
and Long Distance Pipelines Station Facilities, Tanks Heating coils on bottom N:\GB-S\sp-proj\+Präsentation
and Long Distance Pipelines Station Facilities, Tanks Heating coils on bottom N:\GB-S\sp-proj\+Präsentation

Heating coils on bottom

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

Roof heating system

page 13

Tanks Heating coils on bottom N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation Roof heating system page 13

Liquid Sulphur Handling Facilities and Long Distance Pipelines Station Facilities, Solidification

Long Distance Pipelines Station Facilities, Solidification Granulation N:\GB-S\sp-proj\+Präsentation
Granulation
Granulation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 14

Station Facilities, Solidification Granulation N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 14

Liquid Sulphur Handling Facilities and Long Distance Pipelines Station Facilities, Solidification

Long Distance Pipelines Station Facilities, Solidification Pastilation Flaking N:\GB-S\sp-proj\+Präsentation

Pastilation

Pipelines Station Facilities, Solidification Pastilation Flaking N:\GB-S\sp-proj\+Präsentation

Flaking

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

Station Facilities, Solidification Pastilation Flaking N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 15

page 15

Station Facilities, Solidification Pastilation Flaking N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 15

Liquid Sulphur Handling Facilities and Long Distance Pipelines Station facilities, Silo

and Long Distance Pipelines Station facilities, Silo air in-/outlet 10,000 to, Sulphur Plant Brake / Germany

air in-/outlet

10,000 to, Sulphur Plant Brake / Germany

spiral slide gangway
spiral slide
gangway

supporting wall (concrete)

emptying tube

discharge opening

ridged roof, 35° (concrete)

emptying tube discharge opening ridged roof, 35° (concrete) conveyor emptying tube discharge opening swelling (Beton)

conveyor

emptying tube

discharge opening

swelling (Beton)

bottom plate (concrete)

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 16

opening swelling (Beton) bottom plate (concrete) N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 16

Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines

Special Design Criteria

Distance Pipelines Pipelines  Special Design Criteria • Decision on heating system; Electrical (conventional /

Decision on heating system; Electrical (conventional / skin effect) or hot water

Sectioning: optimization of length and voltage

Redundancy: two independent circuits

Pre-tensioning and/or expansion elbows

Special design of insulation, and supports

SCADA

• Special design of insulation, and supports • SCADA • temperature and viscosity profile • set

temperature and viscosity profile

set point for temperature controllers

calculation of survival time

monitor insulation quality

Displacement system

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 17

• monitor insulation quality • Displacement system N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 17

Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines

solid density ~2000 kg/m 3 → re-melting is critical due to ~10 % volume increase
solid density ~2000 kg/m 3
→ re-melting is critical due to ~10 % volume increase

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

→ re-melting is critical due to ~10 % volume increase N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 18

page 18

→ re-melting is critical due to ~10 % volume increase N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 18

Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines, Heating Systems

and Long Distance Pipelines Pipelines, Heating Systems Electrical/Conventional, 3” Line, 4.5 km

Electrical/Conventional, 3” Line, 4.5 km

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

Systems Electrical/Conventional, 3” Line, 4.5 km N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 19

page 19

Systems Electrical/Conventional, 3” Line, 4.5 km N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 19

Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines, Heating Systems

and Long Distance Pipelines Pipelines, Heating Systems N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation
and Long Distance Pipelines Pipelines, Heating Systems N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

Electrical/Skin Effect

page 20

Pipelines, Heating Systems N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation Electrical/Skin Effect page 20

Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines, Heating Systems

and Long Distance Pipelines Pipelines, Heating Systems • Heat loss: ~ 90 W/m (8“/12“-Pipeline, 6“-return

Heat loss: ~ 90 W/m (8“/12“-Pipeline, 6“-return line)

• Max. distance of Heater stations, existing: appr. 40 km

(Shell’s Caroline-Shantz pipeline, 41 km, world‘s longest sulphur pipeline)

Disadvantages:

• Hot Water return line (6”) → increased heating requirements

• Deaeration

• No redundant heating circuit

Hot Water Heating System

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

Advantages:

• Increased heat capacity

→ more time in case of failure

• Remelting from the end

→ reduced risk of bursting

• Long heating sections

page 21

→ more time in case of failure • Remelting from the end → reduced risk of

Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines, Supports

Facilities and Long Distance Pipelines Pipelines, Supports 4 “ Line, Underground, Pipe in Pipe System Voigtei

4

“ Line, Underground, Pipe in Pipe System Voigtei – Barenburg, 7 km

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

Pipe in Pipe System Voigtei – Barenburg, 7 km N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 22

page 22

Pipe in Pipe System Voigtei – Barenburg, 7 km N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 22

Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines, Supports and Expansion Elbows

Distance Pipelines Pipelines, Supports and Expansion Elbows 3 “ Sulphur Pipeline, Buschhaus – Alversdorf, 4.5 km
Distance Pipelines Pipelines, Supports and Expansion Elbows 3 “ Sulphur Pipeline, Buschhaus – Alversdorf, 4.5 km

3 “ Sulphur Pipeline, Buschhaus – Alversdorf, 4.5 km

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 23

3 “ Sulphur Pipeline, Buschhaus – Alversdorf, 4.5 km N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 23

Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines, supports

Facilities and Long Distance Pipelines Pipelines, supports s l i d i n g s u
Facilities and Long Distance Pipelines Pipelines, supports s l i d i n g s u
Facilities and Long Distance Pipelines Pipelines, supports s l i d i n g s u

sliding support

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

ILF design

fixed-point support

page 24

g s u p p o r t N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation ILF design fixed-point support page 24

Liquid Sulphur Handling Facilities and Long Distance Pipelines Main Project Risks

• Insulation → No cold bridges

Main Project Risks • Insulation → No cold bridges • Efficient heating system → sufficient, but

• Efficient heating system → sufficient, but not too much

• Selection of Pumps → very critical

• Possibility of Pipeline Draining or Displacement → No stop of flow

• Redundancy (flow, displacement system, energy)

N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation

page 25

flow • Redundancy (flow, displacement system, energy) N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 25

Liquid Sulphur Handling Facilities and Long D istance Pipelines

Thank you for your attention!

Liquid Sulphur Handling Facilities and Long D istance Pipelines Thank you for your attention!
Liquid Sulphur Handling Facilities and Long D istance Pipelines Thank you for your attention!