GAS ARABIA SUMMIT, 5th annual meetingSour Gas Meeting Liquid Sulphur H andling Facilities and Long D istance Pipelines Rolf Szczepanek, 31/01/2010 Liquid Sulphur Handling Facilities and Long Distance Pipelines Table of Contents Physical Properties Heating Station Systems facilities • Pumps • Loading / Unloading Facilities • Tanks • Solidification units • Silo Pipelines Main Project Risks N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 2 heating and insulation N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 3 .Liquid Sulphur Handling Facilities and Long Distance Pipelines Physical Properties of λ-Sulphur 9 1800 7 1790 6 5 1780 density / kg/m 2 viscosity / mm/s 8 3 viscosity density 4 3 120 130 140 150 1770 160 temperature / °C narrow operating range (125°C to 150°C) → special demands on redundancy. valves and pumps • Jacketing or tracing Pipelines • Electrical • Steam • Conventional Heating Cables • Hot Water • Skin Effect Heating System • Thermal Oil • Hot water • Electrical heating cables N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 4 .Liquid Sulphur Handling Facilities and Long Distance Pipelines Heating Systems Station piping. 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 Pipe in Pipe System for heating by Thermo-Oil. 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. Hot Water. jacketed Pumps and Valves N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 7 .Liquid Sulphur Handling Facilities and Long Distance Pipelines Heating Systems. Pumps • Centrifugal Pumps • • conventional coupled • magnetically coupled Screw Pumps N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 8 .Liquid Sulphur Handling Facilities and Long Distance Pipelines Station facilities. Loading / Unloading Facilities Railway 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. 6 m → Screw pumps N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 10 . Loading / Unloading Facilities NPSHA = 1.Liquid Sulphur Handling Facilities and Long Distance Pipelines Station facilities. 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 10.000 to. Tanks Insulation N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 12 .Liquid Sulphur Handling Facilities and Long Distance Pipelines Station Facilities. 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 Granulation N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 14 .Liquid Sulphur Handling Facilities and Long Distance Pipelines Station Facilities. Liquid Sulphur Handling Facilities and Long Distance Pipelines Station Facilities. Solidification Pastilation Flaking N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 15 . 35° (concrete) N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation bottom plate (concrete) supporting wall (concrete) page 16 . Sulphur Plant Brake / Germany spiral slide conveyor emptying tube discharge opening air in-/outlet emptying tube discharge opening swelling (Beton) gangway ridged roof.000 to. Silo 10.Liquid Sulphur Handling Facilities and Long Distance Pipelines Station facilities. and supports • SCADA • 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 . 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.Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines Special Design Criteria • Decision on heating system. Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines solid density ~2000 kg/m3 → re-melting is critical due to ~10 % volume increase N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 18 . Heating Systems Electrical/C onventional.Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines. 4. 3” Line.5 km N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 19 . Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines. Heating Systems N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation Electrical/Skin Effect page 20 . 6“-return line) • Max.Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines. existing: appr. distance of Heater stations. 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 Advantages: • Increased heat capacity → more time in case of failure • Remelting from the end → reduced risk of bursting • Long heating sections Hot Water Heating System N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 21 . Heating Systems • Heat loss: ~ 90 W/m (8“/12“-Pipeline. Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines. Underground. Supports 4 “ Line. Pipe in Pipe System Voigtei – Barenburg. 7 km N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 22 . 5 km N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 23 . 4. Supports and Expansion Elbows 3 “ Sulphur Pipeline. Buschhaus – Alversdorf.Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines. Liquid Sulphur Handling Facilities and Long Distance Pipelines Pipelines. supports sliding support N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation ILF design fixed-point support page 24 . displacement system.Liquid Sulphur Handling Facilities and Long Distance Pipelines Main Project Risks • Insulation → No cold bridges • 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. energy) N:\GB-S\sp-proj\+Präsentation GB-S\Schwefelpraesentation page 25 . Liquid Sulphur H andling Facilities and Long D istance Pipelines Thank you for your attention! .