A STUDY AIR DRIVEN DIAPHRAGM PUMPS FOUND IN THE LOGBABA GAS PLANT

TO DETERMINE REASONS FOR FAILURE AND PROVIDE SOLUTIONS (Case study

P102A/B CONDENSATE OFFLOADING PUMPS)

CHAPTER 2: BACKGROUND OF STUDIES

2.1 INTRODUCTION

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical
action.

Pumps operate by some mechanism (typically reciprocating or rotary), and consume energy to
perform mechanical work by moving the fluid. Pumps operate via many energy sources, including
manual operation, motors (electricity), engines (diesel).

Mechanical pumps serve in a wide range of applications in industry such as pumping water from
wells, for water-cooling and fuel injection systems on engines, for pumping oil.

Pumps can be classified into three major groups according to the method they use to move the fluid:
- direct lift
- displacement
- gravity pumps

Other classification is:

- Single stage pump (when in a casing only one impeller is revolving then it is called single
stage pump)
- Double/ Multi stage pump (when in a casing two or more than two impellers are revolving
then it is called double or multi stage pump)

Mechanical pumps may be submerged in the fluid they are pumping or be placed external to the
fluid.

In oil and gas industry are mostly used two types of pumps: positive displacement and centrifugal.

2.2 POSITIVE DISPLACEMENT PUMPS

A positive displacement pump makes a fluid move by trapping a fixed amount and forcing
(displacing) that trapped volume into the discharge pipe.

Some positive displacement pumps use an expanding cavity on the suction side and a decreasing
cavity on the discharge side. Liquid flows into the pump as the cavity on the suction side expands
and the liquid flows out of the discharge as the cavity collapses. The volume is constant through
each cycle of operation.

Positive displacement pumps theoretically can produce the same flow at a given speed (RPM) no
matter what the discharge pressure. Thus, positive displacement pumps are constant flow machines.

A positive displacement pump can be further classified according to the mechanism used to move
the fluid:
 - Rotary-type positive displacement: internal gear, screw, shuttle block, flexible vane or
sliding vane, circumferential piston, flexible impeller, helical twisted roots or liquid-ring
pumps
- Reciprocating-type positive displacement: piston or diaphragm pumps
- Linear-type positive displacement: rope pumps and chain pumps

2.3 COMPRESSED-AIR-POWERED DOUBLE-DIAPHRAGM PUMPS

One modern application of positive displacement pumps is compressed-air-powered double-

diaphragm pumps.

A diaphragm pump (also known as a membrane pump) is a positive displacement pump that uses a
combination of the reciprocating action of a rubber, thermoplastic or Teflon diaphragm and suitable
valves on either side of the diaphragm (check valve, butterfly valves, flap valves, or any other form
of shut-off valves) to pump a fluid.

Run on compressed air these pumps are intrinsically safe by design, although all manufacturers
offer ATEX certified models to comply with industry regulation (suitable for work in explosive
areas).

These pumps are relatively inexpensive and can perform a wide variety of duties, from pumping
water out of bunds, to pumping hydrochloric acid from secure storage (dependent on how the pump
is manufactured – elastomers / body construction).

There are three main types of diaphragm pumps:

- Those in which the diaphragm is sealed with one side in the fluid to be pumped, and the
other in air or hydraulic fluid. The diaphragm is flexed, causing the volume of the pump
chamber to increase and decrease. A pair of non-return check valves prevents reverse flow
of the fluid.
- Those employing volumetric positive displacement where the prime mover of the diaphragm
is electro-mechanical, working through a crank or geared motor drive, or purely mechanical,
such as with a lever or handle. This method flexes the diaphragm through simple mechanical
action, and one side of the diaphragm is open to air.
- Those employing one or more unsealed diaphragms with the fluid to be pumped on both
sides. The diaphragm(s) again are flexed, causing the volume to change.
2.4 PRINCIPLE OF OPERATION
Air-Operated Double Diaphragm (AODD) pumps are
powered by compressed air or nitrogen. The main
directional (air) control valve ① distributes compressed
air to an air chamber, exerting uniform pressure over the
inner surface of the diaphragm ②. At the same time, the
exhausting air ③ from behind the opposite diaphragm is
directed through the air valve assembly(s) to an exhaust
port ④. As inner chamber pressure (P1) exceeds liquid
chamber pressure (P2), the rod ⑤ connected diaphragms
shift together creating discharge on one side and suction
on the opposite side. The discharged and primed liquid’s
directions are controlled by the check valves (ball or
flap)⑥ orientation. The pump primes as a result of the
suction stroke. The suction stroke lowers the chamber
pressure (P3) increasing the chamber volume. This results
in a pressure differential necessary for atmospheric
pressure (P4) to push the fluid through the suction piping
and across the suction side check valve and into the outer
fluid chamber ⑦. Suction (side) stroking also initiates
the reciprocating (shifting, stroking or cycling) action of
the pump. The suction diaphragm’s movement is
mechanically pulled through its stroke. The diaphragm’s
inner plate makes contact with an actuator plunger
aligned to shift the pilot signaling valve. Once actuated,
the pilot valve sends a pressure signal to the opposite end
of the main directional air valve, redirecting the
compressed air to the opposite inner chamber.

2.5 LOGBABA GAS PLANT PUMPING SYSTEM

In Logbaba Gas Plant are used compressed-air-powered double-diaphragm pumps.

All pumps are used to moves liquids. The liquids transferred with the pumps in Logbaba Gas Plant
are:
- condensate
- water.

All the pumps are manufactured by Versa-Matic.

The pumps used in Logbaba Gas Plant are:

- P101A condensate transfer from stabilizer to condensate storage tanks
 - P101B condensate transfer from stabilizer to condensate storage tanks
- P102A condensate offload from condensate storage tanks to loading station on road tanker
- P102B condensate offload from condensate storage tanks to loading station on road tanker
- P103A water transfer from stabilizer to water storage tank
- P103B water transfer from stabilizer to water storage tank
- P104A water offload from water storage tank to loading station on road tanker
- P104B water offload from water storage tank to loading station on road tanker
- P702 water recirculation from condensate storage tanks to stabilizer

2.6 CASE STUDY: P102A/B CONDENSATE OFFLOAD FROM CONDENSATE STORAGE

TANKS TO LOADING STATION INTO ROAD TANKERP

102A/B are the pumps used for condensate offloading have been having series of failure and all the
failures that have occurred in the other pipes have occurred as well making P102A/B a suitable case
study

Description of the process

Gas condensate is a by-product of the Logbaba natural gas plant is used as a cleaner and solvent,
lantern and stove fuel and as a premium product in heavy oil production. Condensate is taken by
road tanker to its customers. There are 3 condensate storage tanks T-101A, T-101B, T-101C. the
condensate is transferred to the offloading station through pump 102AB. A sequence of activity
need to be followed for effective and safe condensate offloading. In normal operation, only one
tank will be lined up for filling while the other two will be kept isolated and LOTO applied. This is
because T-101C being a vertical tank, will have a higher liquid level than T-101 A&B which are
horizontal and, if equalized, the condensate will overflow from the horizontal tanks. The storage
tanks are provided with blanket gas that is vented to atmosphere through a breathing valve and
flame arrestor. The blanket gas is supplied from the fuel gas system via pressure regulator PCV-
121. The blanket gas pressure is set to 15 mbar g. The purpose of the blanket gas is to prevent air
ingress while offloading the tanks or during quick cooling due to heavy rainfall.
Individual transmitters monitor the liquid level in the tanks as follows:T-101A with LT-121; T-
101B with LT-122; T-101C with LT-123.

The level for each tank is indicated in the Control Room and is provided with high alarm
setting in order to avoid overfilling by alerting the operator whose first action is to close the
corresponding inlet valve.

The total condensate storage (3 x 270 = 810 bbl) is adequate for one and a half days
production at maximum output. In order to prevent a halt in production, tanks must be regularly
emptied by road tanker.

Each tank is provided with a water removal connection, allowing any separated water to be
removed from the tank and manually transferred to the Condensate Stabiliser V-102 using the
portable air driven pump P-105. Water accumulation is checked visually through dedicated nozzles
fitted with 1” gate valves GT-105/108/111.

The condensate from the storage tanks is being pumped into road tanker by the Condensate
Pumps P-102A/B (duty/standby) and it is measured by FT-121 Vortex Flowmeter located on the
common discharge line of the pumps. The connection to the road tanker is provided by quick
connect flexible hose approved for hydrocarbon service at the pumps maximum discharge pressure
of 95 psig.

The frequency of the condensate offloading depends of the accumulation rate that is
determined by the gas output.

2,6 CONDENSATE OFFLOADING PROCEDURE

Preliminary Checks and Job Preparation

1. Produced water accumulated in the bottom of the Condensate Storage Tanks scheduled for
offloading has to be returned to Condensate Stabilizer via produced water draining pump
prior to commence the offloading;
2. Check valve alignment on storage tanks inlet/outlet and ensure correct status of valves in
order to prevent liquid transfer from one tank to other:

WARNING! It is NOT allowed to open inlet or outlet valves on T-101 A or B horizontal

tanks while the corresponding valve on T-101 C vertical tank is open! Major spill hazard!

3. Confirm functionality of the blanketing gas system provided for the Condensate Storage
Tanks;
The status indicator of pressure regulator PCV-121 must be on GREEN colour. If the
indicator is RED the valve is tripped and blanket gas is not available so the offloading shall
NOT start at all or will be stopped immediately until the blanketing is restored.
4. Confirm the availability of the offloading pumps;
5. Check the integrity of air supply to the offloading pumps;
6. Visually check the integrity of the offloading system consisting of storage tanks outlet-
pump’s suction – pumps and pump’s discharge line till the Loading Station – the latest is
manned by GdC Loading Operators;
7. Confirm level indication on the storage tanks available and functional;
8. Confirm with the Control Room Operator that the FT-121 Totalizer is reset.
9. Confirm P-102 A/B, 2’’ suction/discharge lines are pressure free, by operating the ½’’
pressure blow down ball valve (upstream check valve) to Condensate Stabilizer.
10. Attend Toolbox Talk in joint with Loading Operator

Overpressure is an existing hazard in the offloading line between pumps and LTS counter
inclusive. Pressure can increase above operational limit due to thermal dilatation when liquid is
trapped inside or at sudden closure of the shut off valve downstream LTS counter.
The thermal dilatation can cause an increase of pressure as much as 8 bar / °C (reference
document 6) which may have a devastating impact on the pumps if those are not protected. The
driving element of the thermal dilatation is the rising temperature in the offloading line exposed to
sunlight while the pumps are idling and the LTS is closed. This happens when the loading operator
moves to the next compartment or changes the tankers. The phenomenon is extremely severe during
the dry season and less severe but not negligible during rainy weather.
Sudden closure of the shut off valve downstream LTS counter when the target volume is met
causes a sharp rise in the discharge pressure usually up to 8 bar when the PRV upstream LTS
counter opens for short time and releases the extra pressure.
 Possible failures are:
- discharge valve ball being stuffed into fluid chamber;
- early wearing of discharge valve seats;
- rupture of discharge elbow
The present operating instructions has took into consideration the increase of pressure due to
thermal dilatation as well as the sharp pressure rise caused by the shut off valve and contains steps
meant to eliminate and/or reduce the risk of equipment failure.. Following the correct operating
sequence as described below, provides smooth operation, prevents equipment failure and, more
important, protect personnel.

Sequence of Operation

Record preliminary checks on the check sheet provided in the Appendix and sign it off.
NOTE: STANDBY MODE will be considered as follow:

 3” outlet valves from the storage tanks: CLOSE

 2” suction valve of the pumps: OPEN
 2” discharge valve of the pumps: OPEN
 1/2” vent discharge line of the pumps: OPEN
 1/2” SS tube for depressurisation lined-up to Condensate Stabilizer V-102
 Offloading valves at TLS: CLOSE
 ½” discharge valve at recycle pump P-702 CLOSE
This set up eliminates the overpressure hazard while the pumps are idling waiting for
compartment or tanker change over since the gain in volume due to thermal dilatation is routed
away from the system to a safe recipient, the Condensate Stabilizer which works at atmospheric
pressure.

1. Control Room Operator to reset the flow totalizer FT-121;

2. OPEN 3” outlet valve from the tank chosen for the offload;
3. CLOSE 2” discharge valve at the pump that will remain in standby;
4. CLOSE ½” vent valve at the pump that will remain in standby;
5. CLOSE ½” ball valve to Stabilizer (upstream check valve)
6. Confirm with Loading Operator that all valves (3 off) on the Loading Station are open and the
tanker is ready to receive hydrocarbon;
7. Confirm with Loading Operator the quantity going to be loaded in the current compartment of
the road tanker, then state the intention of starting the pump;
8. OPEN air isolation valves downstream air regulator;
9. Progressively OPEN air isolation valve upstream air regulator.
10. Although the air pressure regulator setting should be found at the value used during previous
offload, adjust the air pressure between 3 and 4 barg (do not exceed 4 barg) as required by the
current circumstances (simultaneous offload of produced water, compressor availability etc.);
11. Inform GdC LT that the pump is now delivering at normal rate;
12. Be alert to stop pump if required;
13. When the quantity loaded reaches the value set at the LTS counter, stop the pump at the
Loading Operator’s signal by closing the air isolation valve upstream of regulator before the
shut off valve closes – the pump will stop smoothly and the discharge line will remain without
pressure, other than at the hydrostatic pressure;
14. OPEN ½” ball valve (upstream check valve) to line up the pump’s discharge to Condensate
Stabilizer. Confirm on the pressure gauge the offloading system pressure decreases close to zero
barg and the air pressure should drop to zero as well;
15. While the Loading Operator moves the loading arm to the next compartment, monitor the
pressure on the pump discharge just to be sure there is not any omission on operating activities.
16. Loading Operator will move the loading arm into the next compartment and will open again the
shut off valve by setting a new value on the counter – wait to receive his confirmation;
17. Repeat steps no. 5 to 16 for the second compartment then again until all available compartments
are filled;
18. Confirm with Loading Operator that the loading into the current tanker is completed;
19. CLOSE drive air isolation valve upstream/downstream of the regulator;
20. OPEN 1/2” ball valve (upstream check valve) to depressurise offloading system;
21. OPEN 2” discharge valve at standby offloading pump;
22. OPEN ½” vent valve at the pump that was in standby;
23. CLOSE the 3” outlet valve from the tank just been emptied;
NOTE: If two tanks are scheduled for offload, resume the operation as described above once the
Loading Operator confirms the availability of the second road tanker.
24. At the end of offloading operation set the valves alignment to match the configuration as
described for STANDBY MODE.
25. Field Operator to perform periodical checks, 4 hourly as a minimum, on valve’s status within
his mandatory routine operating and maintenance checks.
2.7 CHYARATERISTICS OF CONDENSATE PUMPS P-102 A/B

Type Air Driven Diaphragm Pump

Flow Rate Adjustable to 0 – 230 gpm (870 lpm)

Max. Discharge Pressure 95 psig (6.6 bar)

Suction Lift 25’ (7.62m)

Max. Particle Size 0.75” (19.1 mm)

Suction Connection 3” ANSI 150# (DIN 80)

Discharge Connection 3” ANSI 150# (DIN 80)

Air Inlet 0.50” NPT

Air Exhaust 0.50” NPT

Weight 275 lbs (125 kg)

Model Elima-Matic

Pump size 3“

Wetted Parts Aluminum

Non-Wetted part Aluminum

Diaphragm Material Nitrile (Nitrile)

 Diaphragm Series Dome

Nitrile
Valve Ball Material Valve
Nitrile
Seat/Valve Seat O-Ring Material
Bolted
Construction Design

Operating Parameters Formula Value

1
2
3
4
5
6

CHAPTER 3: FAILURE ANALYSIS

3.1 HISTORY OF FAILURE AND SUCCESIVE MAINTENANCE

P102A

P-102A CONDENSATE
OFFLOADIND PUMP
DATE CAUSE RESOLUTION
5/3/2016 Diaphragm damage Replace diaphragm
10/2/2016 Diaphragm damage Replace diaphragm
Replace piston
Replace pilot air valve unit
26/10/15 Diaphragm damage Replace diaphragm
13/09/15 Broken elbow Replace discharge elbow
8/6/2015 broken elbow Replace broken elbow
2/6/2014 Broken elbow Replace broken elbow
11/1/2014 Replace suction end seal
Replace discharge line ball
valve
20/07/13 Air leakage in the air exhaust
12/2/2013 Diaphragm damage Replace diaphragm
Replace suction check valves
P102B

P-102B CONDENSATE
OFFLOADIND PUMP
DATE CAUSE RESOLUTION
Pumped fluid in air exhaust
2/1/2016 muffler Tighten diaphragm
Pump leakage
Loose diaphragm
Condensate leak at air
31/12/2015 muffler Replace diaphragm
28/04/15 Diaphragm damage Replace diaphragm
Replace pilot Valve kit
Adjustment on the base of the
pump by putting some plates on
22/09/15 Malfunction its base
Replace the broken bow on the
21/10/13 discharge side
14/03/13 Replace Teflon valve
Replace viton valve seat
28/12/2012 Replace valve balls

3.2 STATISTICS OF FAILURE

FREQUENCY OF DAMAGE P102AB

(72 MONTHS PERIOD)
BROKEN
ELBOW
20%
SHAFT DIAPHRAGM
5% 35%

GASKET
10%

AIR VALVE KIT

5%
CHECK VALVE
25%
3.3 POSSIBLE REASONS FOR FAILURE

Parts that fail Possible reasons for failure

1 Diaphragm Air pressure not evenly applied on the diaphragm
Pumping liquid too far from the pump
Unbalance condition due to high discharge head
Air pressure above limit
Suction line length too long
High cycle rate
CENDENSATE CONTAINS highly polar solvents like
acetone and MEK, ozone, chlorinated hydrocarbons and
nitro hydrocarbons.
Excessive flooded suction pressure
Diaphragm plate installed incorrectly

2 Check Valve, ball, seat Poor priming

Unstable cycling
Reduced performance of the pump cycling
Cavitation on the suction side
Suction line is blocked
High pressure
Cendensate contains highly polar solvents like acetone
and MEK, ozone, chlorinatedhydrocarbons and nitro
hydrocarbons.

3 Elbows Misalignment of parts

High pressure

3.4 ANALYSIS

1. Ozone Cracking

Cracks can be formed in many different elastomers such as Buna Nitrile by ozone attack, and the
characteristic form of attack of vulnerable rubbers is known as ozone cracking. The problem was
formerly very common, especially in tires, but is now rarely seen in those products owing to
preventive measures.
However, it does occur in many other safety-critical items such as fuel lines and rubber seals, such
as diaphragm, gaskets and O-rings, where ozone attack is considered unlikely. Only a trace amount
of the gas is needed to initiate cracking, and so these items can also succumb to the problem.
Tiny traces of ozone in the air will attack double bonds in rubber chains, with natural
rubber, polybutadiene, styrene-butadiene rubber and nitrile rubber being most sensitive to
degradation.[1] Every repeat unit in the first three materials has a double bond, so every unit can be
degraded by ozone. Nitrile rubber is a copolymer of butadiene and acrylonitrile units, but the
proportion of acrylonitrile is usually lower than butadiene, so attack occurs. Butyl rubber is more
resistant but still has a small number of double bonds in its chains, so attack is possible. Exposed
surfaces are attacked first, the density of cracks varying with ozone gas concentration. The higher
the concentration, the greater the number of cracks formed.

2. Thermal Expansion
Thermal expansion is the tendency of matter to change in shape, area, and volume in response to a
change in temperature,[2] through heat transfer. Temperature is a monotonic function of the average
molecular kinetic energy of a substance. When a substance is heated, the kinetic energy of its
molecules increases, leading to an increase in pressure.
As with most liquids, they will expand and contract with temperature. In any system where there is
a chance for liquid to be captured between closed valves without relief, thermal expansion will
likely occur and create dangerously high pressures within the system.. When product is trapped
within the system, the pressure will increase by 126 PSI (8.69 BAR) for every one (1) temperature
degree increase. Possible failures are:
- discharge valve ball being stuffed into fluid chamber;
- early wearing of discharge valve seats;
- rupture of discharge elbow

3. Misalignment
Misalignment occurs when one surface or shaft is forced to deviate from its desired position.
Excessive forces and moments can lead to misalignment in several sections of a pumping system.
Equally, misalignment can lead to an increase in resultant forces and moments by altering mating
surfaces, thereby changing angles and orientations such that new resultant load directions are
established.
4. Cycle rate
Cycle is the primary factor that determines both the capacity of a reciprocating pump and its
maintenance costs. Running at high speeds shortens packing life and increases acceleration and
deceleration forces on all moving components. Operating below the maximum “rated” speed may
be advantageous when the pump is operated unattended, when there are no spares and no standby,
when there is a high penalty for down time, when unit maintenance is poor, when long life is
desired, and when the NPSH margin is low. Operating at the maximum rated speeds requires:

 Clean, cool fluids

 Excellent piping layout with rigidly fixed piping
 Good NPSH margin
 Solid foundation
 Well-designed suction and discharge pulsation dampeners
 Good maintenance

Whenever it becomes necessary to operate above the maximum rated speeds, very close attention
should be given to all design, operation, and maintenance details.
Ozone-resistant elastomers include EPDM, fluoroelastomers like Viton and polychloroprene rubbers
like Neoprene. Attack is less likely because double bonds form a very small proportion of the chains, and with the
latter, the chlorination reduces the electron density in the double bonds, therefore lowering their propensity to
react with ozone. Silicone rubber, Hypalon and polyurethanes are also ozone-resistant.

References
1. Layer, R. W., & Lattimer, R. P. (1990). Protection of rubber against ozone. Rubber Chemistry and
Technology, 63(3), 426-450.
2. when the body is heated its dimension(size) increase.This increase in dimension is called thermal
expansion . Paul A., Tipler; Gene Mosca (2008). Physics for Scientists and Engineers, Volume 1 (6th
ed.). New York, NY: Worth Publishers. pp. 666–670.ISBN 1-4292-0132-0.