Oil is often found in regions with extreme ambient conditions. This is the case in Kazakhstan, where one of the largest deposits of oil has been found. Ten process metering pumps from ProMinent’s Orlita Mfs product range are in use in the Kazakhstan oil field. Their robust design makes them ideal for reliable operation – even under the toughest conditions. By metering hypochlorite in the Kazakh oil field, they ensure that the various cooling water circuits function efficiently.
The Kazakh oil field is 47 miles x 22 miles in size and is located in the North Caspian Sea around 50 miles away from the Atyrau coast. The Kazakhstan project includes both offshore production and onshore processing. There are plans for the first crude oil to be extracted this year. Once full capacity is reached, it is estimated that the field will provide the second largest production volume anywhere in the world. New estimates indicate that around 1.25 million barrels a day can be extracted.
All the necessary systems and equipment need reliable cooling circuits if smooth oil extraction and production is to be possible. Sea water is used for cooling purposes. The temperature and pH inside the piping provide the ideal conditions for bacteria to grow. Sodium hypochlorite reduces the growth of biological organisms and is added to the cooling water in appropriate volumes. This prevents the biofilm inside the piping from increasing and the pipe cross-section from shrinking. A reduction in the flow of water is thereby prevented. This maintains the good efficiency and performance of the cooling circuit.
Modular design ensure flexibility
Eight process pumps from the Orlita MfS product range, 18/7 pumps and two Duplex MfS 18/7 from ProMinent ensure that the right amount of hypochlorite solution enters the cooling circuits at all times. The metering pumps of the ORLITA MF product range are modular in design and basically comprise drive, crank and liquid end function groups. Their modular construction means that they can adapt flexibly to the real-life conditions. Depending on what is needed, the pumps can also be used at very high pressures of up to 700 bar, in a temperature range of -40 °C to +160 °C and to meter high to very high viscosity liquids. Thanks to their valve-free and virtually wear-free feeding equipment, they ensure smooth operation by means of overfill and diaphragm protection inside the pumps. The hydraulic diaphragm liquid end is equipped with a PTFE dual diaphragm system, as well as an integrated rupture indicator. An integrated relief valve protects the pump against overload. The pumps have an exceptional intake capacity (priming lift of up to 8 m). The titanium dosing head in the pumps used in Kazakhstan is very special. The combination of titanium in the dosing head and PTFE in the dual diaphragm ensures reliable metering of the hypochlorite solution to disinfect the coolant at all times.
Polymer vanes last 3 times as long in vacuum rotary pump
Vanes made of the bearing polymer Hitemp 150 have lasted three times as long as traditional vanes in servicing company Septic Tanks (Pty) Ltd’s vacuum rotary pump, a Broom B35.
The pump is used to create a pressure difference that sucks up the waste liquids from septic tanks.
The pumps involved in such operations should not come into contact with sewage ideally.
However, where septic tank pumping is not monitored continuously, overflow from the transport truck can make its way to the pressure vessel and on to the vacuum rotary pump.
The vanes in these pumps thus need to be cleaned.
In addition, the vanes need to be able to operate at high temperatures, since the pumps can overheat due to operation for long periods.
Armed with information about vane operating requirements, when the original laminate vanes in Septic Tanks (Pty) Ltd’s Broom B35 pump needed replacing as frequently as every 6 months, the waste-sector servicing company turned to Vesconite Bearings, the maker of various polymers, for a solution to this unique operating environment.
Vesconite Bearings technical sales consultant Phillip de Villiers recommended Hitemp 150, an engineered polymer that is wear resistant and can withstand temperatures of up to 150ºC.
This material will not delaminate as does the original-equipment-manufacturer supplied material, a thermosetting phenol formaldehyde resin that impregnates layers of cotton to produce a hard synthetic plastic, he reasoned.
The trial result has been impressive: Hitemp 150 did not delaminate unlike its competitor and it was resistant to overheating.
In addition, the new polymer vanes coped well with the frequent pump cleans that were required when waste material accidentally entered the pump.
Septic Tanks (Pty) Ltd owner Charl Neuhof is also pleased that the Hitemp 150 vanes continue to operate after a year and a half, while the phenolic alternative had to be replaced after six months.
Moreover, he is enthusiastic about the reduced maintenance costs that are associated with the product, which can be cleaned in-situ unlike the previous variety of vanes that had to be removed prior to cleaning because of their high levels of swelling when exposed to water.
Since testing of the B35 vacuum rotary pump vanes has gone well, Neuhoff plans to replace the vanes on its fleet of truck pumps as they fail.
His four trucks are used in the Johannesburg North, Pretoria, Hartebeespoort and Brits areas of South Africa, with three out on the road daily, each carrying six 6000 litre loads of waste material a day.
The five vanes that were employed in the B35 pump measured 35mm by 6mm by 330mm and had chamfered edges, but vanes for the other pump models that will be introducing the Hitemp 150 vanes will have different dimensions.
Sulzer’s innovative engineering solutions
Sulzer will focus on the future of the oil & gas industry in Brazil and presenting its range of solutions for pumping, separation and mixing technology, and services for rotating equipment at the Rio Oil & Gas Expo and Conference. Experts in these areas will be on hand at Stand L16 in Pavilion 4 to demonstrate the latest innovations in upstream, midstream and downstream, digital technologies and industry management. During the event, Sulzer will also be celebrating its 70th anniversary of operations in Brazil, where it has been supporting the growth of local businesses.
At the forefront of innovation and a market leader in separation and mixing technology, Sulzer Chemtech will present the latest developments in processing technology for gas/liquid and liquid/liquid separation. With its customizable, high-quality, durable and reliable columns, column internals, mist eliminators and separator vessels, there is a comprehensive range of products for the oil and gas sector at this year’s expo.
As a leading independent repair specialist and pump manufacturer, Sulzer’s extensive service offering will be represented by a number of displays including compressor rotor blades that feature specialist air spray coatings, which improve the equipment’s durability and performance. Sulzer will also showcase its capabilities in reverse engineering, testing and design improvements on a compressor impeller, resulting in the delivery of a precision-crafted replacement part with an extended service life. Also, members of the experienced field service teams from Sulzer will be present to discuss the turnkey support offered for the maintenance and repair of rotating equipment.
As digital technologies are set to play a key role in the future of the oil and gas industry, Sulzer has developed the BLUE BOX™ platform for predictive maintenance. This solution applies Industry 4.0 to oil pipelines and their pumps, analyzing data from day-to-day pump operations in near real-time and providing actionable insights to improve the performance and reliability of the system.
The company will also be exhibiting its capabilities in high-voltage coil manufacturing and testing. Complete sets of coils, designed to match or exceed original efficiency levels, are manufactured and tested on the shortest lead times in the industry, minimizing downtime and providing a new lease of life for generators and motors.
Thanks to holographic augmented reality technology, visitors to Sulzer’s stand will also be able to experience cutting-edge subsea pumps for offshore applications first hand.
Pump impeller delivers improved suction characteristics
The KSB Group has developed a special impeller for its Movitec multistage high-pressure pumps. This new impeller significantly improves these pumps’ suction characteristics (NPSH value).
It proves its worth particularly in applications with critical inlet conditions (e.g. boiler feed applications) as well as applications in which the pump is required to take in water from low-lying tanks or at higher temperatures. Under these conditions, a pressure drop in the intake area may cause cavitation to occur in the first pump stage. This can result in excessive wear of pump parts or motor bearings as well as a reduced service life of the pump due to damaged parts and an unbalanced hydraulic system.
The new impeller is offered as an alternative to the standard product. When developing the new impeller, KSB’s design engineers went to great lengths to ensure it can be used with a number of Movitec variants without necessitating modifications to the outer pump casing.
The new impeller features a modified inlet diameter, vanes allowing a slightly diagonal throughflow and a newly designed stage casing, all of which serve to substantially improve the pump’s NPSH curve.
The multistage centrifugal pumps from the Movitec range are designed for handling fluids such as water, coolants, condensate and mineral oils. They are ideal for a wide variety of applications ranging from industrial boiler feed installations in steam circuits, recirculation and fire-fighting systems, cooling water circuits and washing plants to pressure boosting in general process applications.
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