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บทความ เกจวัดแรงดัน

KSB’s slurry dealing with success in oil sands

Alberta, Canada has the world’s third largest oil reserves within the type of oil sands. Extracting and processing the oil from the sands and bedrock is a challenging process and requires the most important slurry pump in the oil sands industry.
When it involves pumping slurry, there can be very few purposes which would possibly be more challenging than the hydro-transport of heavy-duty slurries in oil sands manufacturing. Not solely do the pumps need to contend with the extremely aggressive nature of the fluid being pumped, they’re also expected to operate in a few of the harshest environments in the world.
In January 2020, GIW Industries, Inc., a KSB firm, commissioned its largest ever heavy-duty centrifugal slurry pump for operation in Canada’s oil sands, namely the Tie Bolt Construction (TBC-92). Named after its 92 in (2337 mm) impeller, the TBC-92 is the most important and heaviest slurry pump obtainable in the oil sands trade and the most recent in a line of powerful high-pressure pumps provided by GIW.
Slurry transportation Slurry transport covers a considerable range of industry sectors, starting from food and beverage to mining. What is frequent to all, is that the pumps used should be succesful of transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and oil sands production, the largest problem is to accommodate excessive density slurry and extremely abrasive grits.
It is essential that the slurry passes by way of the pump with the minimal quantity of wear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump must be able to delivering high flows and in a position to face up to harsh operating environments.
Alberta in Canada has in depth oil reserves and these are in the form of oil sands. Extracting and processing the oil from the sands and bedrock is difficult, involving the removal of bituminous ore which is transported to a crushing plant. The crushed ore is then mixed with warm water to kind a dense slurry that might be transported within the pipeline in direction of extraction, where the bitumen is separated from the sand and rock. After extraction, the remaining solids (or tailings) are sometimes transported via different pumps to settling ponds.
The processes require extensive use of slurry and water transportation pumps able to dealing with vast portions of liquids at high pressures and high temp- eratures. Drawing on its lengthy expertise of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that mix advanced materials, hydraulics and patented mechanical designs, the latest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW business growth supervisor, explains extra: “Our client wanted a higher capability pump which was able to 10,000–11,000 m3 per hour of output at nearly forty m of developed head and a most working stress of 4000 kPa. The pump additionally wanted to have the flexibility to move rocks of approximately one hundred thirty mm in diameter with a complete passage measurement requirement of 10 in (or 254 mm) and handle slurry densities in extra of 1.5 SG.
In addition, the customer was concentrating on a upkeep interval (operational time between planned maintenance) of around 3,000 hours. They had expressed an curiosity in maximising the maintenance intervals and based mostly on initial put on indications, they are currently hoping to attain round 6,000 hours between pump overhauls (i.e. 6–8 months).”
The instant software for the first batch of GIW’s TBC-92 pumps in Alberta is in hydro-transport service the place they are used to maneuver bitu- minous ore from the crusher to the extraction plant. The liquid pumped is a combination of water, bitumen, sand, and enormous rocks. Screens are in place to maintain these rocks to a manageable measurement for the method, but the high measurement can nonetheless usually reach as a lot as a hundred thirty mm in diameter or larger.
The abrasive nature of the slurry is what separates a slurry pump from other pumps used within the industry. Wear and erosion are details of life, and GIW has many years of expertise in the design of slurry pumps and the event of materials to assist lengthen the service life of those critical components to match the planned upkeep cycles within the plant.
“GIW already had a pump able to the output requirement, this being the MDX-750, which has been a popular measurement in mill duties for practically 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s application required a pump with higher stress capabilities and the aptitude of handling larger rocks so we responded with the development of the TBC-92 which provided the most effective solution for maximised manufacturing.”
The TBC collection The building type of GIW’s TBC pump vary options large, ribbed plates held together with tie bolts for very high-pressure service and maximum put on performance. First developed for dredge service, then later introduced into the oil sands within the Nineties, the TBC pump collection has grown into a completely developed vary of pumps serving the oil sands, phosphate, dredging and onerous rock mining industries for tailings and hydrotransport applications.
The pumps are often grouped together in booster stations to construct stress as high as 750 psi (5171 kPa) to account for the pipe losses encountered over such long distances. The strong construction of the TBC pump is nicely suited to do the job, while making certain maximum availability of the gear beneath closely abrasive put on.
Capable of delivering stress up to 37 bar and flows of more than 18,200m³/h and temperatures as a lot as 120o C, the TBC vary is a horizontal, end suction centrifugal pump that offers most resistance to wear. Simple to take care of, the pump’s tie-bolt design transfers stress hundreds away from the damage resistant white iron casing to the non- bearing aspect plates without the utilization of heavy and unwieldy double-wall development.
The TBC-92 combines the most effective elements of earlier TBC fashions, together with the TBC-84 oil sands tailing pump, also called the Super Pump. The pump additionally incorporates features from GIW’s MDX product line, which is used in heavy-duty mining circuits all through the world of exhausting rock mining.
In whole, the TBC-92 weighs about 209,000 lbs (95,000 kg), which is roughly equal to a fully-loaded Airbus A321 aeroplane. The casing alone weighs 34,000 lbs (15,500 kg). Key features of the pump embrace a slurry diverter that dramatically will increase suction liner life by decreasing particle recirculation between the impeller and the liner. The giant diameter impeller permits the pump to run at slower speeds so that put on life is enhanced. The decrease pace additionally provides the pump the ability to function over a wider range of flows to have the ability to accommodate fluctuating circulate circumstances.
To make upkeep easier, the pump is fitted with a particular two-piece suction plate design which helps to reduce software time and provide safer lifting. Customers obtain pump-specific lifting units to facilitate the protected removal and set up of wear comp- onents. The pump also contains a longlasting suction liner that may be adjusted while not having to shut the pump down.
New milestone The commissioning of the TBC-92 marks an necessary milestone for GIW, which now has pumps in service in any respect working Canadian oil sands crops for hydrotransport applications. The TBC-92 has been designed to tackle heavy-duty slurry transport while offering a low total value of ownership. Minimal labour and maintenance time assist to maximise manufacturing and revenue.
เกจวัดแรงดันเครื่องกรองน้ำ incorporates the teachings realized from operating in the oil sands over a few years, and features our newest hydraulic and put on applied sciences,” says Mollie Timmerman. “Because this is the heaviest TBC pump we’ve ever designed, particular attention was given to maintainability, in addition to materials selection and building of the pressure-containing components.”
That GIW has established itself as a significant drive in pumping solutions for the oil sands trade is far from stunning given that it has been creating pumping technologies and wear resistant supplies in the international mining trade for the reason that Forties.
These pumps have had a considerable impression on the means in which that excavated sand, rock and bitumen are transported to the upgrader plant. By adding water to the excavated materials it turns into highly environment friendly to pump the slurry alongside a pipeline to the upgrader. The pipeline agitation assists in separating the bitumen from the sand as it is transported, plus there might be the additional good factor about eradicating the usage of vehicles.
GIW has estimated that the value of moving oil sand on this method can reduce prices by US$2 a barrel, and it’s much more environmentally pleasant. These pumps additionally play a significant function in transporting the coarse tailings to the tailings ponds. GIW provides pumps used within the extraction process and other areas of manufacturing (HVF, MDX, LSA).
Understanding slurries Understanding the nature of slurries and how they behave when being pumped has been fundamental to the event of those products. GIW has been obtaining slurry samples from prospects over many years for testing hydraulics and supplies both for pumps and pipelines. Research & Development facilities include multiple slurry test beds on the campus, together with a hydraulics laboratory that is devoted to pump efficiency testing.
These activities are central to the company’s pump improvement programmes. If corporations are experiencing problems the GIW R&D personnel can see the place the problem lies and offer advice for remedial action. Experience does indicate that in many instances the issue lies not with the pump nevertheless, but within the interaction between the pipeline and the pump.
Feedback from prospects about appli- cations helps within the growth of latest tools and pump designs. By bringing to- gether customers and academics from all around the world to share their expertise and analysis with in-house experts, the large funding in analysis, improvement and manufacturing has advanced the design of all of the GIW pump products,materials and wear-resistant components.
The future “There is a transparent pattern toward larger pumps in mining and dredging and oil sands aren’t any exception,” comments Leo Perry, GIW lead product manager. “The first TBC pump within the oil sands business was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their services for larger and higher manufacturing and demanding the identical of the tools that keeps their manufacturing transferring. While these larger pumps demand more power, additionally they enable for greater production with less downtime required for maintenance. Overall, the efficiency improves when in comparability with the same output from a bigger quantity of smaller pumps. “
In conclusion, he says: “Larger pumps go hand-in-hand with bigger services, bigger pipelines, and increased production, all of which proceed to trend greater 12 months after yr. Other clients and industries have also shown an interest on this dimension, and it might be no surprise at all to see extra of these pumps constructed within the close to future for comparable purposes.”
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