4.12 Pumping liquefied gases 4.12.

1 General The term liquefied gas is a general description applied to gases which can be changed from the gas to liquid state at near ambient temperatures and at relatively low pressures. A stricter definition as in standard DIN 51622 identifies hydrocarbon gases such as propane, propene, butane, butene and mixtures which are produced as byproducts of oil refineries and natural gas plants. The liquefied gases propane, butane and their mixtures are primarily used as household, vehicle and industrial fuels. Propene and butene are raw ingredients used in the plastics industry. In order to utilise the liquefied gases for household and industrial purposes distribution systems requiring pumps are set up as typically shown in Fig. 4.12.01.

Fig. 4.12.01

Distribution system for LPG

Special regulations apply for the safe handling and storage of liquefied gases, which also put special requirements on the pumps to ensure the media is kept below its boiling point. Important are: A good NPSH performance Gas/liquid mixture handling ability Reliable shaft sealing

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To satisfy these requirements so called combination pumps with side channel and centrifugal stages were developed. 4.12.2 Construction of liquefied gas pumps 4.12.2.1 Side channel combination pumps The most common construction of side channel combination pumps is the horizontal ring section pump with axial suction. The side channel stages are located at the discharge side in series after a centrifugal stage. This side channel combination uses the best pumping characteristics of each type of impeller to complement the other. The primary centrifugal stage allows low (NPSHR) values to be achieved (Fig. 4.12.02). The following side channel stages enable considerable gas/liquid mixture flows to be handled and for the pump to be self priming.

3 2 1

Side channel pump Centrifugal pump Side channel pump with low NPSH primary stage

Fig. 4.12.02

(NPSHR) - comparison of different pump constructions.

Unlike other types of pump construction, the side channel combination pump requires a suction head of less than 0.5m for flow rates up to Q=35 m3/h. This makes the plant installation much simpler and requires lower capital investment. The combination with side channel stages at the discharge ensures that the flow does not collapse even when gas is evolved. Multi-stage side channel combination pumps are used for flow rates Q up to 35 m3/h and total heads up to H= 350 m, in accordance with DIN 24 254. The steps in the performance grid are so close that a pump can be selected very close to the required data. The number of stages required in the pump is determined by the operating point. The steep Q/H characteristic has advantages for control purposes.

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Fig. 4.12.03

Side channel pump with internally flushed mechanical seal

4.12.2.2 Side channel combination pumps with retaining stage A variation on the side channel combination pump is the incorporation of a retaining stage. This is normally positioned between the primary centrifugal stage and the first side channel stage. Its function is to ensure that when stopped the pump retains sufficient volume of liquid to enable it to be restarted at any time. Furthermore the connections on the housing, enable the installation of a level control device to prevent running of the pump with insufficient liquid (dry running protection). 4.12.2.3 Centrifugal combination pumps For economical pumping of larger flows, without giving up the self priming and gas handling abilities, the centrifugal combination pump was created. This features a main flow centrifugal stage with an integral side channel stage. The axial suction and special (NPSH) impeller at the first stage, ensures that the lowest suction head when handling liquefied gases can be met. The performance range extends to capacities up to Q = 220 m3/h and heads up to H = 250 m.

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Fig. 4.12.04

Centrifugal combination pump with single mechanical seal

4.12.3 Pumping liquefied gases in suction lift operation 4.12.3.1 Pumping with partial flow - bypass Liquefied gases are mainly stored in permanent storage tanks, the size of which is dependent on the usage and serviceability requirements. With safety in mind, these are mostly in earth mounds or underground. Extraction from the base of the tank to provide a flooded suction for the pump operation is possible, but in practice not adopted for safety reasons. The only possible extraction position from the upper dome of the tank, presents special problems for pumps in suction operation with a volatile medium. A possible solution without having to install moving devices in the pressurised container is shown by the vehicle-LPG filling station example, see Fig. 4.12.0.5.

Fig. 4.12.0.5.

Vehicle-LPG filling station

The installation comprises the underground storage tank, the ground level side channel combination pump, a gas separator, the main pumping line and the by-pass line with partial return flow. The advantage of this system lies in its simplicity.
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This is made possible by the characteristic ability of the side channel combination pump to handle large quantities of vapour and their low (NPSH). By exhausting the vapour and the re-evaporation in the suction line, heat is drawn from the liquid. The resulting pressure difference compared to the constant pressure in the storage tank causes the liquid to rise up the pump suction pipe and the pumping commences. At the same time the high energy of the partial flow returned to the tank in the vapour phase produces a differential pressure, sufficient to overcome the initial suction lift and stabilise the pumping operation. The optimum parameters for, as far as possible bubble free pumping are for butane Hs < 4m and a tank capacity V < 20 m3. When handling propane or propane/butane mixtures, the tank capacity can be increased to V < 200 m3. The larger the storage tank capacity, the more significant the gas content in the liquid flow. 4.12.3.2 Pumping with vertical tank pumps For storage tanks with diameters not exceeding 6m, vertical tank pumps with externally mounted motors can be installed. These pumps are mounted in the domed flange of the tank. The first stage, preferably a low (NPSH) stage, is located at the bottom of the tank on an extension designed for the tank, so that it operates with the suction immersed in the liquid. See Fig. 4.12.06. Depending on the performance range, the following pump constructions can be considered: Side channel combination pumps for flows up to Q = 35 m3/h Centrifugal pumps with a low (NPSH) first stage for flows up to 100 m3/h Booster pumps to increase the inlet pressure.

All pumps are driven with magnetic couplings and are therefore totally leak-free. They are designed to meet the latest safety regulations and environmental considerations. With booster pumps a prime consideration is to have as few moving and, where possible, wear resistant parts inside the storage tank, to extend the time intervals between routine maintenance. The low (NPSH) stage is mounted inside the storage tank. The main pressure increase is achieved by an externally mounted pump.
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Fig. 4.12.06 Vertical tank pump

4.12.3 Shaft seals Pumps for liquefied gas can be fitted with various types of shaft seals dependent on the safety standards for the installation: single balanced mechanical seal single balanced mechanical seal with throttle bush double mechanical seals in tandem or back to back construction seal free design with magnetic coupling The most frequently used are pumps with single balanced mechanical seal or pumps with seal free design with magnetic coupling.

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