Offshore production technology summit 2014

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Information about Offshore production technology summit 2014
Technology

Published on March 11, 2014

Author: Bronswerk

Source: slideshare.net

Description

Bronswerk participated in the 8th Offshore Technology Summit in London 10-11 March 2014.
Learn more about the 4 steps approach for reducing operational costs on production rigs & FPSO’s.

FACS - 10/3/2014Offshore Production Technology Summit 2014

Dynamic Heat Exchange Solutions Innovative process equipment reducing operational costs on production rigs & FPSO’s Femke Schaëfer London – March 10th, 2014 FACS - 10/3/2014Offshore Production Technology Summit 2014

Topics: • Introduction to Bronswerk Heat Transfer® • Debottlenecking • Case study – Offshore compact cooling • With High Efficiency Air Cooled Cooling • With Compact Header • With Subsea Cooler • Flare gas recovery FACS - 10/3/2014Offshore Production Technology Summit 2014

Introduction FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

Our markets: Sustainability Service & Maintenance Power Oil Gas Chemical Air Handling Food Processing FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

What we do: •Thermal designs: based on:  Aspen/HTFS  HTRI  HEI  Computational Fluid Dynamics  Hysys FACS - 10/3/2014Offshore Production Technology Summit 2014

What we do: •Mechanical designs:  - ASME  - EN13445  - AD2000  - RTOD  - PD5500  - CODAP  - GOST  FEM analysis FACS - 10/3/2014Offshore Production Technology Summit 2014

What we do : •Process design: Process optimization FACS - 10/3/2014Offshore Production Technology Summit 2014

What we do : • Equipment:  Heat exchangers  Air cooled coolers  And other process equipment FACS - 10/3/2014Offshore Production Technology Summit 2014

What we do : •Materials:  Titanium  (Super)Duplex  Nickel-Alloy  Inconel  Other exotics FACS - 10/3/2014Offshore Production Technology Summit 2014

What we do : • Systems:  Incl. controls FACS - 10/3/2014Offshore Production Technology Summit 2014

What we do : •Site work:  Erection  Assembly  Start up  Commissioning  Service FACS - 10/3/2014Offshore Production Technology Summit 2014

What we do : •Service & Maintenance:  Upgrading  Debottlenecking  Inspection  Specialist maintenance for machines operating hazardous materials FACS - 10/3/2014Offshore Production Technology Summit 2014

Our focus on innovation: • Product development • System solutions • New technology  Compact Header®  Radiax®  Whizz-Wheel® fans  Thermo-Acoustic heat pump FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

Reducing operational costs on production rigs & FPSO’s in four steps. FACS - 10/3/2014Offshore Production Technology Summit 2014

+ = Cost reduction! ++ FACS - 10/3/2014Offshore Production Technology Summit 2014

Step one Weight Reduction of Equipment Why?  Reduction in weight of supporting structure  Lower Centre of Gravity on FPSO  Reduction of module weight >> less restrictions on shipyard lifting capacity FACS - 10/3/2014Offshore Production Technology Summit 2014

Step two Size Reduction of Equipment Why?  On FPSO’s more space = more storage  More space for maintenance & repair  Smaller equipment means smaller platforms and FPSO’s FACS - 10/3/2014Offshore Production Technology Summit 2014

Step three Power consumption reduction Why?  Limitation on available power  Less power requirement can result in a smaller power package  Reduction in CO2 emission – save the planet! FACS - 10/3/2014Offshore Production Technology Summit 2014

Step four Easy Maintenance of Equipment Why?  Reduction of HSE risks  Shorter down-time  Space reduction needed for maintenance FACS - 10/3/2014Offshore Production Technology Summit 2014

How can we contribute to weight, size, power and maintenance reduction on platforms & FPSO’s? FACS - 10/3/2014Offshore Production Technology Summit 2014

Debottlenecking FACS - 10/3/2014Offshore Production Technology Summit 2014 • 50% less kW • 35% more cooling air • 10-15% more production • 700 million euro gas production • 70 million euro additional • Debottlenecking investment: 0,5 million euro

Debottlenecking FACS - 10/3/2014Offshore Production Technology Summit 2014

Debottlenecking FACS - 10/3/2014Offshore Production Technology Summit 2014

Compact cooling – three solutions FACS - 10/3/2014Offshore Production Technology Summit 2014

Current situation: •Huge plot space requirement •High power consumption for air coolers •Heavy equipment •Maintenance •Big influence on CAPEX & OPEX Case study – Compact cooling S&T heat exchangers and air-cooled coolers with compact cooling: FACS - 10/3/2014Offshore Production Technology Summit 2014

Case study – Compact cooling Air-cooled coolers with compact cooling: FACS - 10/3/2014Offshore Production Technology Summit 2014 •New fan design based on aerospace technology •Intensified heat transfer through higher air pressure and velocity •Over 30% plot space reduction OR •Over 50% reduction in power consumption

Situation: Offshore air-cooled condensors for Mexican gas production platform Original design based on standard air coolers; • Absorbed electrical power: 390 kW • Plot space used: 582m² • Noise power emission: 90dB(A) Case study – Compact cooling Air-cooled coolers with compact cooling: FACS - 10/3/2014Offshore Production Technology Summit 2014

Improved design based on high efficiency air coolers (with Whizz-Wheel® fans); Old New • Absorbed electrical power: 390kW 308 kW • Plot space used: 582m2 412m² • Noise power emission: 90dB(A) 85dB(A) Case study – Compact cooling Air-cooled coolers with compact cooling: FACS - 10/3/2014Offshore Production Technology Summit 2014

Figure 2: high efficiency designFigure 1: standard design FACS - 10/3/2014Offshore Production Technology Summit 2014 Case study – Compact cooling 1st & 2nd stage gas and recycle air-cooled coolers with compact cooling: Benefits; • Noise reduction: 5 dB(A) • Size reduction: 170 m² = 30% • Power consump. red.: 82 kW = 22% • Opex savings: € 65.600,- / yr Figure 3: comparative

Case study – Compact cooling S&T heat exchangers with compact cooling: Situation: Offshore interstage compression cooling for Australian FPSO FACS - 10/3/2014Offshore Production Technology Summit 2014

Original design based on conventional D-type high pressure shell & tube heat exchangers; Interstage compressor aftercooler • Weight: 17.000 kg • Space used: ~10 m³ Final re-injection compressor aftercooler • Weight: 28.000 kg • Space used: ~15 m³ Case study – Compact cooling S&T heat exchangers with compact cooling: FACS - 10/3/2014Offshore Production Technology Summit 2014

New design based on compact header® high pressure shell & tube heat exchangers; Old New Interstage compressor aftercooler • Weight: 17.000 kg 10.500 kg • Space used: ~10 m3 ~8,5 m³ Final re-injection compressor aftercooler • Weight: 28.000 kg 14.000 kg • Space used: ~15m³ ~ 13 m³ Case study – Compact cooling S&T heat exchangers with compact cooling: FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

• Up to 60% weight reduction • Reduction in weight of supporting steel structure • Reduced plot space • Much higher allowable temperature gradients • High pressure is no issue up to 1000 bar • Easy maintenance Case study – Compact cooling S&T heat exchangers with compact cooling: FACS - 10/3/2014Offshore Production Technology Summit 2014

Benefits: • Volume reduction: ~3,5 m³ = 15% • Weight reduction: 20.500 kg = 46% • Saving on Capex: Cost for 2 Heat Exchangers = € 736.000,- Saving on support structure = € 1.025.000,- (20,5 x € 50.000,-) Case study – Compact cooling S&T heat exchangers with compact cooling: FACS - 10/3/2014Offshore Production Technology Summit 2014

Case study – Compact cooling Cooling with subsea cooling: Situation: Offshore Gas cooler North Sea FACS - 10/3/2014Offshore Production Technology Summit 2014 • Replacement of air coolers • High material grades • High corrosion resistance • Maintenance free operation • Special anti-fouling coating • No power consumption

Conventional air coolers • required plot space: 78 m² • Consumed power: 62 KW • Maintenance on fan drive Bronswerk sub-sea cooler • Required plot space: 0 m² • Consumed power: 0 KW • No maintenance Bronswerk sub-sea cooler •Saving 78 m2 •62 kW •Bonus in OPEX savings : € 49.600,- /yr Case study – Compact cooling Cooling with subsea cooling: FACS - 10/3/2014Offshore Production Technology Summit 2014

Flare gas recovery Flare gas compression with smart-compact Radiax ® compressor: FACS - 10/3/2014Offshore Production Technology Summit 2014 • Several hundreds of millions m3 of flare gas wasted • Gas at atmospheric pressure • Compress to 20-80 Bar

Flare gas recovery Flare gas compression with smart-compact Radiax ® compressor: FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

FACS - 10/3/2014Offshore Production Technology Summit 2014

Flare gas recovery Flare gas compression with smart-compact Radiax ® compressor: FACS - 10/3/2014Offshore Production Technology Summit 2014 • Several hundreds of millions of flare gas wasted • Gas at atmospheric pressure • Compress to 20-80 Bar

Summary Yes, Significant cost saving for platforms & FPSO’s by innovative process equipment is possible! 1. Weight reduction of process equipment;  High efficiency air coolers up to 30%  Compact Header® Heat Exchangers up to 60%  Subsea cooler instead of an air-cooled cooler FACS - 10/3/2014Offshore Production Technology Summit 2014

Summary Yes, Significant cost saving for platforms & FPSO’s by innovative process equipment is possible! 2. Size reduction of process equipment;  High efficiency air coolers up to 30% in plot area  Compact Header® Heat Exchangers up to 40% in length  Subsea cooler 100% in plot area (on deck)  Radiax® pumps up to 95% in space requirement FACS - 10/3/2014Offshore Production Technology Summit 2014

Summary Yes, Significant cost saving for platforms & FPSO’s by innovative process equipment is possible! 3. Energy consumption reduction of process equipment;  High efficiency air coolers up to 50%  Subsea cooler 100% compared to air cooler FACS - 10/3/2014Offshore Production Technology Summit 2014

Summary Yes, Significant cost saving for platforms & FPSO’s by innovative process equipment is possible! 4. Easy maintenance of process equipment;  Compact Header® ; less people, heavy tools and space required  Subsea cooler; no maintenance FACS - 10/3/2014Offshore Production Technology Summit 2014

Thank you for your attention. Questions please FACS - 10/3/2014Offshore Production Technology Summit 2014

How to contact us: www.bronswerk.com facebook.com/bronswerk Linkedin.com/company/bronswerk-heat-transfer twitter.com/bronswerk FACS - 10/3/2014Offshore Production Technology Summit 2014

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