High performance processing solutions from SPX

The international oil and gas exploration, development and downstream processing industries make substantial demands on the designers and manufacturers of processing equipment. Not only must equipment meet exacting health and safety standards, it must deliver the highest performance at all times. Reliability and engineering support throughout the working life of equipment is all-important.

SPX Process Equipment has made it its business to develop individual fluid and gas handling products. Together these many and varied technologies create integrated solutions for both the offshore and onshore oil and gas markets. Comprising a number of international companies SPX PE’s core business activities encompass the design and manufacture pumps, valves, mixers, pipe closures and filtration equipment.

Pumps and mixers lie at the centre of oil and gas exploration, recovery and processing, but they rely on many other technologies to optimise their functionality. Solids both in liquids and gas need to be removed from pipelines, valves are required to control media flow and delivery, whilst safe and secure access to vessels and pipelines are issues that can never be overlooked.

Pumps for hydrocarbon environments
The hydrocarbon environment presents one of the more arduous ranges of pumping applications with corrosive compounds that are commonly encountered including CO 2, H 20, Methanol and Glycol (MEG). Then there are other factors that have to be taken into consideration, such as sand particles, slurries, high viscosity fluids and highly compressed fluids. The types of critical applications that have to be addressed encompass high flow, high differential pressure, and high suction pressure in cryogenic duties.

All these require a high performance pump that provides high levels of operating safety, coupled with efficiency and reliability. Reciprocating fixed stroke positive displacement, high speed and multi-stage type centrifugal pumps have been the historical choice for most end-users, but they do have a number of recognised limitations. The most frequently highlighted are product leakage, high running costs and an ongoing requirement for expensive maintenance.

Over the past few years SPX Process Equipment has been recommending its ATEX certified Bran + Luebbe Novaplex pump for hydrocarbon condensate pumping duties and the levels of take up have been highly encouraging. Novaplex units have been specified for, amongst others, the Clipper PR Platform, the Leman Alpha Platform and the Sean PP Platform, all located in the UK sector of the North Sea.

Integrated processing packages
Many of the technologies available from SPX Process Equipment are brought together in the design of its chemical injection and produced water packages. Each component, whether it is a pump, valve, mixer, end-closure or gas filter, has a particular part to play within the complete package, but equally, they have an importance in their own right. The most recent example of SPX PE bringing several of its individual technologies together has been a multi-unit package purpose-designed to provide chemical dosing for a Produced Water treatment facility and the contaminated Open Drains Treatment plant for an onshore based production location in Azerbaijan.

Due to the physical size of the PWCI (Produced Water Chemical Injection) package, the Company’s engineers in the UK divided the construction into three separate units, these being the main chemical package, a Biocide package and a chemical unloading package. In addition, a Ferric Chloride package was also supplied as part of the contract.

By far the largest unit, weighing in at 42 tonnes dry weight, was the main chemical injection package containing 11 stainless steel multi-compartment tanks and 32 Bran + Luebbe Novados P API double diaphragm pumpheads. These pumpheads will handle Corrosion, Scale, Reverse Demulsifier, Oxygen Scavenger, Filter Aid, Flotation Aid, Coagulant, Dewatering and Flocculent. Novados pumps are also a feature of the Biocide package, but in order to suit this duty H4 and H5 types were supplied. With Novados pumps, users have a choice of plunger or hydraulically actuated diaphragm pumpheads. Accurate capacity adjustment can be performed by manual, pneumatic or electric stroke length control with the added option of variable speed drive via a frequency inverter that can be integrated into the motor if required.

The Chemical Unloading unit was designed for offloading chemicals from road tankers to the multi-compartment tanks of the main chemical injection package and contains 12 air operated double diaphragm pumps (AODD) with stainless steel pumpheads and pipework. The Ferric Chloride unit features a mix of Novados P API pumps with titanium pumpheads and pipework and an OADD pump to unload chemical from road tankers into the cylindrical GRP holding tank.

According to Oil and Gas Manager Harish Mistry, the Novados pumps were a critical element for these types of chemical injection packages as they are suitable for use in desert conditions and in environments where extremely low temperature levels are encountered. “In harsh environments it is essential that pumps are capable of withstanding both difficult conditions and aggressive fluids,” comments Harish Mistry. The Novados single-piece gearbox is easy to maintain and offers improved life cycle costs through the reduced number of components. The robust internal gear housing uses state-of-the-art sealing technology, thereby removing any chance of corrosion, whilst fail-safe immersion lubrication reduces thermal load.”

Valves
Many critical applications in fluid handling demand control valves that can withstand the most severe operating conditions. The one style of valve that is among the first to be considered is the Copes-Vulcan SD-1000 as it is a proven technology worldwide. The rugged and highly dependable SD-1000 valve assembly features a straight through globe style body design with a single web internal construction. The high structural integrity, large interior flow passageways and large capacity bowl accommodate an extensive variety of trim designs, while allowing maximum recovery within the valve. Combining a massive amount of body and bonnet material with thick cross-sectional areas ensures that the SD-1000 valve can withstand the most severe conditions.

Applications for which the SD-1000 valve is suitable include: pump recirculation, feed water control, feed water start-up, flashing or cavitation and any potentially noisy or vibration prone service. It is also widely used for nuclear “N” stamp and seismic applications. Offering a quick disconnect between valve stem and actuator yoke to simplify service and inspection, the SD-1000 is fast becoming the industry standard for severe duties and critical conditions.

Closures
Gaining access to horizontal or vertical access to pipeline pig traps, filters, coalescers, strainers, separators, meter skid systems, hydrocyclones or any pressure vessel in seconds is almost a basic necessity, and it is a technology that SPX has not overlooked. The GD Bandlock™ 2 is the benchmark design for global high-pressure applications and it can be operated safely at a remarkable speed – any size of unit can be opened or closed in less than a minute, with no special tools required.

The main pressure-loaded sections are designed to save weight by employing finite element analytical techniques and proof testing by strain gauges. The tried and tested locking band mechanism, which gives the range its name, is a duplex stainless steel conical thrust ring fitted between the door and hub. This transmits loads uniformly around the full 360° circumference of the hub.

Safety has been engineered into the Bandlock™ 2 at every stage of its design and manufacture. A hand-operated pressure warning screw integrated into the mechanism prevents the door being unlocked until it is confirmed that the vessel's internal pressure has been relieved. Standard units meet ASME VIII Div.1 and other pressure vessel codes, such as ASME VIII Div. 2 and PD5500 can be accommodated. ASME Code Stamp with U-2A partial data report can be furnished as an option.

To give a completely pressure-tight seal, the purpose-designed servo acting lip seal energises at zero pressure. It is housed in the door face away from the working area for protection and long life, and is easily fitted without tools.
The one-piece moulding is available in a range of elastomers and incorporates a stainless steel spring to prevent extrusion and provide a full vacuum capability.

Mixing applications
High performance mixing is an essential processing element in oil recovery and production. Top entry mixers are internationally recognised as providing the best possible solution for the mixing applications within this industry and SPX Lightnin Mixers offers the most comprehensive range of equipment available. Within the oil and gas industry, the most common mixer requirement is for the make down and suspension of Drilling Mud, this arduous duty demanding rugged and reliable top entry mixers. Lightnin recommends the employment of its Series ECL 10 and Series 70/780 models for these applications as they are designed specifically to carry the high shaft and gear box loadings resulting with these high specific gravity drilling muds and varying liquid levels. All Lightnin models come with a range of high efficiency impellers optimised to suit these specific applications and a choice of beam mounted open tank mixers with lip seals designs or replaceable cartridge seals where required.

Rugged construction and easy maintenance are prime considerations for tough operating conditions. To satisfy these requirements the Lightnin Series 10 and 70/780 units use a gearbox housing that is simple to install and maintain, employ a drywell output shaft design (to eliminate lubricant leakage) together with bearings that are sized far in excess of AGMA requirements for minimum maintenance and long service life. Heavy duty motors ranging from 0.5 to 450kW and with speeds up to280rpm provide a positive direct drive for these applications. All mixers can be supplied in either standard Lightnin design or specifically to meet the needs of the exacting local and international standards such as CE, ATEX, GOST-R, Norsok, VIK or Promatomnadzor etc.

Summary
The real issues that have to be addressed in the oil and gas industries are the safe handling and containment of potential hazardous media through the employment of technologies that make recovery and processing efficient and environmentally acceptable. SPX PE has developed, and continues to advance technologies for blending, metering and transporting fluids as well as gas and air filtration and dehydration products. These technologies address the immediate and future requirements of producers looking to find the most cost-effective, safe and environmentally acceptable methods of exploiting oil and gas reserves.

For further product details, contact:
Mary Anne Johnson
SPX 351
SPX Process Equipment
Ironstone Way
Brixworth
Northants NN6 9UD, UK
T: 01604 889921
E: maryanne.johnson@.spx.com

Media contact:
Bryan Orchard
T/F: 01420 588194
E: orchard@primex.co.uk