documentc3

Business & Product Centrefor FPSOs, FSOs and rigs

Business Centre for FPSO’s and FSO’s

North Sea Producer (ex Dagmar Maersk)- fitted with HRSG from Aalborg Industries

Boilers etc forBoilers etc forFPSOsFPSOs and and FSOsFSOs


Aalborg Industries ABBusiness & Product Centre

for FPSO’sMarket Coordination

Marketing, Sales & SupportBusiness DevelopmentTechnical Coordination

Project Management

International market & customers

Aalborg Industries KKJapan

Aalborg Industries PteSingapore

Agents

Aalborg IndustriesUSA

Aalborg IndustriesThe Netherlands

Aalborg IndustriesDubai

Aalborg Industries A/SDenmark

Aalborg IndustriesBrazil

Aalborg IndustriesSouth Korea

After SalesBoiler conversions & repairs

Installation, supervision,start-up etc

Aalborg Industries LtdChina / Hong Kong


We can supply the wholeboiler plant

Client’s specification

Design and supply of equipmentTurn-key installation

SupervisionStart-up

System designEquipment supply

Project managementGuarantee

InstallationPlatforms etc


Tanker conversions into FPSO’sConversion of existing boilers

Installation of new boiler system

Client’s specification

AI co-ordination by Business Centre or After Sales

New Boiler SystemPreliminary studiesSteam, hotwater, thermal oilBoilers, burners and controlOther related equipmentIGS, heat exchangers

Boiler ConversionInspection and reportRepair or conversionBoiler body retrofitBurner upgradingInstallation of new burner

By Business Centre… By After Sales…


Boiler plants for oil & gas industry

From a technical point of view the boiler system for an offshore rig or FPSO is very similar to a boiler system for a petrochemical industry

Our combined experience from marine boilers and land based industrial plants gives us an excellent base when working with offshore projects.


Quality and classification

Quality audits by client

ISO 9001 quality certification

All leading classification societies


Engineering Engineering -- basic principlesbasic principles


Basic criteria• Design life length for the FPSO is normally 20 - 25 years• In case the FPSO cannot pump oil the lack of income is 2.5 - 5 MUSD each day, depending on its capacity• The sooner the FPSO can be on the field the sooner the owner can start counting his money• The boilers are normally fired with gas and crude as leading fuels with diesel as back-up• Hazardous area or safe area - On deck or in the engine room


Design life length 20 - 25 yearsNo compromises in system designBest equipment from the most reliable suppliers


In case the FPSO cannot pump oil ….With an oil price of approx 25 USD per barrel the lack of income would be 5 MUSD per day for a200.000 bpd FPSO Essential to have redundancy in terms of importantfunctions onboard the FPSO, for instance boilers,turbines etc


Gas firingHigher temperature from furnace to exhaustDesign the superheater based on higher temperaturesHigher draft lossDe-rate the boiler approx 10%


On deck / engine room? Hazardous / safe area?Even if the area is classified as safe, it gets hazardouswithin 3 metre radius from a potential gas leakage• On deck - hazardous area• On deck - safe area• Engine room - safe area


On deck, exposed to harsh weatherSpecial painting of boilers and FW tankValves and fittings with maker’s painting for offshoreinstallationInsulation with stainless cladding and silicon sealingElectric motors normally IP 56Material must withstand harsh weather


Suggestions

Co-operate with an experienced boiler supplier alreadyfrom the early design phase.

Specify only the real necessary items, let the suppliermake the design and take the responsibility for his system.

The combustion system is a complex part of the boilersystem. In order to reduce the number of interfaces to a realminimum we suggest the whole system to be supplied byone supplier.


A wide range of productsA wide range of productsand servicesand services


Boilers for Steam and Hot waterBoilers for Thermal FluidHeat Recovery after Gas TurbinesHeat recovery after Diesel EnginesInert Gas SystemsHeat ExchangersTurn-key installationBoiler conversions and retrofitsService and spare parts

Aalborg Industries can offer


Control panel• local at boiler• remote

Burner for variousfuels such as Gas,Crude, MDO, HFO

Steam for process

Steam boiler systemOil or gas fired steam boiler type

MISSION™ OMMISSION™ OL

MISSION™ DSingle or multiple boiler system

FW tank

CondensateMake-up water

Temperaturecontrol forFW tank

2 x 100% FW pumpsone pump in operation,one in automatic stand-by

Dosing


Distribution pumps, one pump per boiler in operation, one inautomatic stand-by

Burner for variousfuels such as Gas,Crude, MDO, HFO

Min flow controlControl panel• local at boiler• remote

Expansion tank

Hot water systemOil or gas fired cylindrical hot water

boiler type

SUNROD™ CHS

Single or multiple boiler system

Hot water inlet

Hot water outlet

N2

Dosing

Make-uppump


MISSION™ OMSUNROD™ CHS

Compact and strong design thanks to membrane walls and pin tubes

Easy to inspect and to keep clean

Side fired which makes the boiler easy to ventilate and gives easy access to the burner and its controls

High efficiency, especially on part loads, gives outstanding total fuel economy

Very dry steam (slightly superheated)

This boiler can also be delivered as a hotwater boiler -SunrodTM CHS - up to a capacity of 30 MW


MISSION™ OMup to 45 t/h, 24 bar


SUNROD™ CHS- 30 MW, 24 bar


MISSION™ OL

Compact and strong design thanks to membrane walls and two drums

Top fired



MISSION™ OL12 - 55 t/h, 18 bar


MISSION™ D-type

For capacities above medium range

Design based on our long experience from industrial boilers as well as from boilers for marine steam propulsion systems

Strong and compact design


Quick response to load variations


MISSION™ D-typeUp to 120 t/h


Two MISSION™ D boilers (size 100 t/h)Two MISSION™ D boilers (size 100 t/h)


Our MISSION™ D-typeProbably the best FPSO

boileron the market!


MISSION™ 3-passFor steam or hot water - Pre-assembled unit


THERMAL FLUID BOILERS• CAPACITIES UP TO 20 MW

• VERTICAL OR HORIZONTAL

• MINERAL OIL / SYNTHETIC FLUID


Thermal Fluid Heater


Aalborg Industries can deliver the whole

systemStandard Steam Boilers up to 120 t/h per boiler

Hot Water up to 30 MW per boiler

Thermal Oil up to 20 MW per boiler

Heat Recovery Boilers after Gas Turbines or Diesel Engines

Inert Gas Systems

Heat Exchangers


Gasturbine or Steam?

Typical FPSO: The FPSO needs steam for the process plus power for pump drives, compressors etc. Which is best? Space requirement?Investment cost? Maintenance intervals and costs?Operation cost?


Gasturbine or Steam?

Comparisons have shown that …

Steam boilers with TG’s normally need more spaceSteam systems is less expensive to install Maintenance of GT’s are by far more expensiveOperation cost is much lower for a steam system

The total cost (CAPEX + OPEX) for a system with GT’s with Heat Recovery boilers is often 2 to 4 times the cost for a steam alternative!


Hot Water or Thermal Fluid?

Water above 100 °C needs to be pressurised

Thermal fluids can be heated above 200 °C at atmospheric pressure

Different thermal fluids can be used. Normally mineral oil, but for higher temperatures synthetic fluids must be used.


Hot Water or Thermal Fluid?

A system with thermal fluid cannot corrode. The water in a hot water system needs to be treated to normal boiler water quality. But hot water systems are normally closed systems, so the need of make-up water is very limited.

Thermal fluid cannot freeze. Hot water can be mixed with glycol to avoid freezing and corrosion.

Maintenance costs are low in both cases.


Steam, Hot Water orThermal Fluid?

Regardless if the system shall be designed for steam, hot water or thermal fluid - We can supply the whole heating system!


Combustion systems

Burners for single, dual or triple fuel firing

For gas, condensate, crude, HFO or MDO


We have adopted the steam atomised burner as our

standardEasy to install and to operate

Excellent turn down

Burns a wide range of fuels

Robust design

Limited need of maintenance

Low oxygen content

For hot water boilers air is used to atomise the fuel


KBSD steam atomised burner

for oil firing - top view


KBSD steam atomised burnerfor oil firing - diagram


Dual Fuel BurnersDual Fuel Burners (make: (make: HamworthyHamworthy))

for Daewoo / Terra Novafor Daewoo / Terra Nova2 x 25 t/h, gas and diesel oil2 x 25 t/h, gas and diesel oil


Inert Gas Systems

Risk management during unloading and tank cleaning is crucial on board an FPSO or an FSO.

We offer compact IGS systems using the flue gas from the boilers

Low installation cost

Lowest possible operation cost


Inert Gas Systems

Boilers

To funnel

Scrubber

IGS fans

To funnel

Deckwaterseal

P/V breaker(pressure/vacuum)


Typical O2 content in flue gasClass requires that the O2 content shall be max 5% for IGS operation

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

25 30 40 50 60 70 90 100

GasDiesel

Boiler load (%)

O2 (%)

The IGS can be operated down to approx 30 %load, still having 1 % oxygen as an extra margin!


Advantages by using theflue gas type IGS

Save space and reduceinvestment cost

Reduce the operation cost for the plant

By taking both the boiler system and the IGS from one supplier the co-ordination of these two systems becomes easier and safer

One supplier - one responsible!


Heat Recovery Boilersafter Diesel Engines

PIONEERTM DE-1 AV-6NAV-10DE

Type

Diesel engine output

Diesel engine fuel type

Exhaust gas flow

Exhaust gas temperature

Steam capacity

Horizontal/vertical gas flow water tube

2 - 20 MW

Light fuel oil

Heavy fuel oil

Up to 30 kg/s

<500 °C

Up to ~ 5 t/h

Horizontal gas flowwater tube

0.5 - 20 MW

Light fuel oil

Heavy fuel oil

Up to 30 kg/s

<500 °C

Up to ~ 5 t/h

Vertical gas flow water tube

No limits

Light fuel oil

Heavy fuel oil

No limits

<500 °C

No limits


Heat Recovery Boilers

In a normal Diesel Engine or Gas Turbine there is a lot of energy to save .....

……… and money!


Heat exchangers

We can offer a wide range of heat exchangers for various purposes on board an FPSO, FSO or rig

Tube and shell

Spiral wound tube bundle

Pin tube


Marine - Product RangeHeat exchangers

VESTATM MP-CVESTATM EH VESTATM MX VESTATM MD

Type

Design

Capacity

Design pressure

Installation

Materials

Oil and F.W. Preheater

Shell and Tube

U-Tubes

10 - 5,000 kW

16 or 30 bar (g)

Horizontal

Vertical

Tubes: St. 37.0

Shell: St. 37.0

S.W. Cooler / Condenser

Shell and Tube

Straight Tubes

400 - 6,000 kg/h

16 bar (g)

Horizontal

Vertical

Tubes: CuNi 90/10

Shell: St. 37.0

Oil and F.W. Electrical Heater

FlowTthrough

Out flow

3 - 235 kW

16 bar (g)

Horizontal

Vertical

Tubes: St. 37.0

Shell: St. 37.0

Cargo Heater

Shell and Tube

U-Tubes

300 - 2,000 kW

16 bar (g)

Horizontal

Vertical

Tubes: AISI 316L

Shell: AISI 316L


Offshore plants

We have the resources to offer Boilers, Heat Recovery Boilers, IGS and Heat Exchangers for offshore Installations

RIGS

FPSO’s and FSO’s


Boiler conversions andretrofits

Our engineers have built thousands of boilers, so when a boiler needs to be modified to suit other fuels than it was originally built for, our After Sales organisation is the natural partner.

Boiler repairs and conversionsBoiler retrofits

At any time - anywhere!


Boilers for steam propulsion

We have supplied a large number of boilers for steam propulsion

Babcock & Wilcox

Combustion Engineering


A selection of our international references


Reference plant

Client: FELS / Petrobras, Brasil

Name: Petrobras XVIII

Semi submersible rig, built at FELS, Singapore

2 x CHS hot water boilers each with a capacity of 20 MWHamworthy combustion system for firing gasOn deck / hazardous areaTurn-key installation


Reference plant

Client: Astano / Texaco

Name: Texaco Captain

FPSO, newbuilding, built at Astano shipyard in Ferrol, Spain

3 x CHS hot water boilers each with a capacity of 23 MWHamworthy combustion system for firing gas, crude and diesel3 x Hot water circulation pumps1 x Expansion tankOn deck / hazardous area


Texaco CaptainSupply of 3 x CHS boilers (23 MW) with triple fuel

burners


Reference plant

Client: Mitsui Engineering & Shipbuilding, Japan

FSO, newbuilding, built at Mitsui Chiba shipyard

2 x CPH steam boilers, each with a capacity of 10 t/hHamworthy combustion system for firing gas and dieselBelow deck


Reference plant

Client: ABB Global / Bluewater, The Netherlands

Name: Glas Dowr

FPSO, conversion of a 100,000 DWT tanker

1 x CPH steam boiler with a capacity of 45 t/hHamworthy combustion system for firing gas and dieselOn deck / hazardous area


Reference plant

Client: Daewoo, Korea

Name: Terra Nova

FPSO, newbuilding, built at Daewoo shipyard

2 x CPH steam boilers, each with a capacity of 25 t/hHamworthy combustion system for firing gas and dieselBelow deck


Reference plant

Client: Care Offshore

Name: Armada Perkasa (ex Red Teal)

Conversion of a tanker into an FPSO

Major boiler repair of an Aalborg AT-4 boilerOverhaul / upgrading of existing burner and control systemInstallation of an AQ-9 boiler with a capacity of 20 t/h


Armada PerkasaBoiler repair of AT-4 boiler

Supply of 1 x AQ-9 (20 t/h) boiler with dual fuel burner


The AQ-9 (20 t/h) boiler


Reference plant

Client: Nortrans Offshore, Singapore

Name: Espoir Field FPSO

Conversion of MT White Sea at Keppel Shipyard, Singapore

2 x MISSION D-type steam boilers, each with a capacity of 80 t/hHamworthy combustion system for firing gas and diesel (not AI supply)On deck / hazardous area


Model of Espoir FPSO


Two MISSIONTM D-type boilers during production in our workshop


MISSIONTM D-type boiler ready for delivery


MISSIONTM D-type boilers in Qingdao port


Espoir FPSO

Espoir Ivoirien (ex White Sea)- fitted with two MISSIONTM D from Aalborg Industries

Espoir Ivoirien (ex White Sea)- fitted with two MISSIONTM D from Aalborg Industries


Reference plant

Client: Hyundai Heavy Industries / Elf

Name: Amenam FSO

FSO, newbuilding at HHI shipyard in Ulsan, Korea

2 x CHS hot water boilers each with a capacity of 12 MWHamworthy combustion system for firing gas and diesel3 x Hot water circulation pumpsOn deck / hazardous area


Reference plant

Client: Keppel Fels, Singapore / Vietsovpetro

Name: White Tiger CPP3

3 x MISSIONTM OM steam boilers, each with a capacity of 13.5 t/hHamworthy combustion system for firing gas and dieselFW tank, FW pumps and condensate recovery unitOn deck / hazardous area


Reference plant

2 x MISSIONTM OM steam boilers, each with a capacity of 38.5 t/hHamworthy combustion system for firing gas, crude and dieselFW tank, FW pumps etcOn deck / hazardous area

Client: Vanguard SPC Ltd, Australia / Agip

Name: Woollybutt FPSO

Conversion of MT Four Lakes at Keppel Shipyard, Singapore


Reference plant

Client: Prosafe Production, Singapore

Name: Abo FPSO

Conversion of MT Grey Warrior at Keppel Shipyard,Singapore

2 x MISSION D-type steam boilers, each with a capacity of 90 t/hHamworthy combustion system for firing gas anddiesel (not AI supply)On deck / hazardous area


Knowing the boilers inside and

out - unique experience

We have delivered a large number of quality boilers during the last decades

Regardless if it´s a question of fuel fired boilers or Heat Recovery Systems we have the know-how and organisation to support you


Quality products for marine,offshore and stationary plants


How to reach us…

For personal introduction please contact ourBusiness & Product Centre for FPSOs, FSOs and rigs:

Aalborg Industries ABP.O. Box 907175 29 Järfälla, SwedenPhone: + 46 8 580 24300Fax: + 46 8 580 27801e-mail: [email protected]

... or your usual Aalborg Industries contact person

documentc3

Documents

thermal oil boilers

conversion boiler body

marine boilers

instance boilers

oil gas industry

bpd fpso essential

system designbest equipment

supply of equipment