Download - Offshore production technology summit 2014
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Dynamic Heat Exchange SolutionsInnovative process equipment reducing operational costs on
production rigs & FPSO’s
Femke Schaëfer
London – March 10th, 2014
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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
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Introduction
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Our markets:
Sustainability Service & Maintenance
Power
Oil
Gas
Chemical
Air Handling
Food Processing
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What we do:
• Thermal designs:
based on:
Aspen/HTFS
HTRI
HEI
Computational Fluid Dynamics
Hysys
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What we do:
• Mechanical designs:
- ASME
- EN13445
- AD2000
- RTOD
- PD5500
- CODAP
- GOST
FEM analysis
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What we do :
• Process design:
Process optimization
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What we do :
• Equipment:
Heat exchangers
Air cooled coolers
And other process
equipment
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What we do :
• Materials:
Titanium
(Super)Duplex
Nickel-Alloy
Inconel
Other exotics
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What we do :
• Systems:
Incl. controls
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What we do :
• Site work: Erection Assembly Start up Commissioning Service
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What we do :
• Service & Maintenance: Upgrading Debottlenecking Inspection Specialist
maintenance for machines operating hazardous materials
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Our focus on innovation:
• Product development
• System solutions
• New technology
Compact Header®
Radiax®
Whizz-Wheel® fans Thermo-Acoustic heat
pump
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Reducing operational costs on production rigs &
FPSO’s in four steps.
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+
= Cost reduction!
++
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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
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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
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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!
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Step four
Easy Maintenance of Equipment
Why?
Reduction of HSE risks
Shorter down-time
Space reduction needed for maintenance
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How can we contribute to weight, size, power and
maintenance reduction on platforms & FPSO’s?
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Debottlenecking
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• 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
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Debottlenecking
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Debottlenecking
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Compact cooling – three solutions
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Current situation:
•Huge plot space requirement
•High power consumption for air coolers
•Heavy equipment
•Maintenance
•Big influence on CAPEX & OPEX
Case study – Compact coolingS&T heat exchangers and air-cooled coolers with compact cooling:
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Case study – Compact coolingAir-cooled coolers with compact cooling:
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•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
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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 coolingAir-cooled coolers with compact cooling:
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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 coolingAir-cooled coolers with compact cooling:
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Figure 2: high efficiency designFigure 1: standard design
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Case study – Compact cooling1st & 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
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Case study – Compact coolingS&T heat exchangers with compact cooling:
Situation: Offshore interstage compression cooling for Australian FPSO
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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 coolingS&T heat exchangers with compact cooling:
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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 coolingS&T heat exchangers with compact cooling:
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• 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 coolingS&T heat exchangers with compact cooling:
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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 coolingS&T heat exchangers with compact cooling:
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Case study – Compact coolingCooling with subsea cooling:
Situation: Offshore Gas cooler North Sea
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• Replacement of air coolers
• High material grades
• High corrosion resistance
• Maintenance free operation
• Special anti-fouling coating
• No power consumption
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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 coolingCooling with subsea cooling:
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Flare gas recoveryFlare gas compression with smart-compact Radiax ®compressor:
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• Several hundreds of millions m3 of flare gas wasted
• Gas at atmospheric pressure
• Compress to 20-80 Bar
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Flare gas recoveryFlare gas compression with smart-compact Radiax ®compressor:
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Flare gas recoveryFlare gas compression with smart-compact Radiax ®compressor:
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• Several hundreds of millions of flare gas wasted
• Gas at atmospheric pressure
• Compress to 20-80 Bar
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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
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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
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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
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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
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Thank you for your attention.Questions please
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How to contact us:
www.bronswerk.com
facebook.com/bronswerk
Linkedin.com/company/bronswerk-heat-transfer
twitter.com/bronswerk
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