hofimtm for offshore applications - spe france...man diesel & turbo schweiz ag alexandre de...

1 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014

Higher reliability with a

simplified motor compressor concept

SPE France

Alexandre de Rougemont

December 3rd, 2014

HOFIMTM for Offshore Applications


Volkswagen Group


Revenue ‘13:

€0.5 bn

Power Engineering Business

areas

Divisions

Commercial Vehicles

MAN

Truck & Bus

Revenue ‘13: €9.1 bn

MAN

Latin America


MAN SE

The MAN Group in 2013: €15.7 billion revenue, 53,509 employees

Investments Sinotruk (25.0 % +1 share), Scania (17.4 %*)

* Voting rights

MAN

Diesel & Turbo


Renk (76 %)

Company Structure


Areas of Activity Applications and Market Segments

7

1

4

8

4

5

3

9

10 11

12

13

13

14

15

16

17 18

21

19

20

22

2

21

1 Deep Sea / Subsea

2 FPSO-Ship

3 Offshore Platform

4 Marine Propulsion

5 Diesel / Gas-Electric

Propulsion

6 Marine Gen-Set

7 Waste-Heat-Recovery (WHR)

System

8 Floating Power Station

9 XTL Plant

(Very Large ASU)

10 LNG Liquefaction

11 Onshore Production

12 Gas Storage

13 Gas Transport

14 Refinery

15 Reactors

16 LNG ReGasification

17 Chemical / Petrochemical

18 Gasification

(Small and Medium ASU)

19 Power Generation

20 Enhanced Oil Recovery

21 CCS

22 Iron, Steel & Mining

6

21

5 5

The product range covers almost all applications in the Upstream, Midstream,

Downstream, Industrial Gases, Power Generation as well as Marine Business.


Introduction: Selection of Products Business Unit Oil & Gas

HOFIM / MOPICO (RM)

ZH

Barrel Type Compressor (RB)

ZH BE

Gear Type Compressor (RG)

BE

Horizontal Split Compr. (RH)

BE ZH

ZH Zürich

BE

Isotherm Compressor (RIKT)

ZH

CHZ

DWE Berlin Deggendorf

Reactor Systems

DWE

CHZ


upstream

subsea

upstream

offshore

(platform/FPSO)

midstream

pipeline

compression

midstream

underground

storage

Clean Gas

Applications

Upstream

Applications

HOFIM™ One product for multiple applications

Marinisation programme


Flare

HP Compressor LP Compressor

Coupling Coupling

Coupling

Motor Gearbox Shaft Seals

Conventional train configuration

+ No lube oil system

+ No shaft seals, no seal system

Fla

re/v

en

t

+ No emissions

+ No gearbox, no Vorecon

Eliminate traditional components Motivation

MOPICO / HOFIM Sealed

HP Compressor Motor LP Compressor


Overhung

impeller

Magnetic bearing

(radial and axial)

High speed

motor

First

compressor

stage

Second

compressor stage

from

Suction

header

Cooling gas

connectors

to Discharge

header

The MOPICO® Concept 1987

MOtor

PIpeline

COmpressor


HOFIM™ High speed Oil Free Integrated Motor compressor

Motor

Radial

Bearing

Second Stage

group,

Cartridge Process Gas

Connections

Train

Axial

Bearing

Compressor

Radial

Bearing

High

Speed

Motor

Compressor

Radial

Bearing

single HOFIMTM

tandem HOFIMTM


Modular Design for process adaptation Volume Flow vs. Compressor Head


HOFIM™ – Compressor Very similar to conventional

Compressor features:

Basic design close to traditional Barrel

Compressors

Standardized frame-sizes (28, 35, 45)

Outer casing forged, acc. PED / ASME

Suitable for sour gas, acc. NACE

Well referenced impeller design

Only one radial compressor bearing

required

Suction

Nozzle

Radial Magnetic

Bearing Impellers

Discharge

Nozzle

Casing


HOFIM™ – Motor Own design since 2004

MAN Diesel & Turbo High Speed Motor

2-pole, three phase, medium voltage

induction motor

Squirrel cage rotor (solid rotor)

Process gas cooling

Suitable for wet sour gas, acc. NACE

Hazardous area Certification acc.

ATEX of entire HOFIM™ or MOPICO®

for Zone 1 (Class I, Division 1)

Pressure barrier

with Cable Pass

Through with

double block and

bleed

Pressure casing

acc. PED / ASME

Stack & Windings

acc. IEC 60034-1

Two frame sizes

M33 : 10 MW, 12’500 rpm

M43 : 18 MW, 10’000 rpm


HOFIM™ – Bearings Active Magnetic Bearings

Active Magnetic Bearings (AMB)

Speed range 0 - 105%

Active damping of rotor vibrations

Unlimited starts / stops

UPS for safe shutdown included

No wearing parts in normal

operation

Landing Bearing

Controller

+

Actuator

(electro magnet)

Position

“setpoint”

Amplifier Position Signal

Position

Sensor

PID _

Air Gap

Air Gap / 2

Motor-Rotor

Rotor

Lamination


MECOS – Best in class Active Magnetic Bearing System

> 20 Years of MAN Application experience

> 20 Years of MECOS AMB experience

< 20 miles of distance

teaming up is a logical step

• Robust design

• Fully digital control based on high volume application

• Modern tools

• Remote monitoring and maintenance capabilities


Single point of contact Project Partners Today

Compressor Motor AMB Third Party VFD


Conventional HOFIMTM S

afe

are

a

Hazard

ou

s a

rea

Footprint 51.2 m2 19.5 m2,

Weight 84’150 kg 38’000 kg

Comparison: Conventional vs. HOFIMTM

Footprint & Weight Advantages

HOFIMTM

AMB controls


HOFIMTM vs. Conventional Size and simplicity

Conventional

MAWP: 110 bara

V: 3’500 m3/h

Power: 4 MW

Size: 14m x 4m

Weight: 76 tons

vs.

HOFIMTM

MAWP: 166 bara

V: 11’000 m3/h

Power: 14 MW

Size: 7.6m x 4.7m

Weight: 75 tons


Designed for MTTF > 5 years

Source: OREDA 2009

Elimination of Dry Gas Seals

• 30 Electronic Transmitters

• 6 Control Valves and other local

instruments

• 120 hand valves

• 72 adjoining flanges

• Numerous tubing fittings and

threaded connections

Elimination of Lube Oil System

• valves

• pump

• electrical motor

• oil demister

• …

Instrumentation

DGS System

Lube Oil System

Gearbox

Valves

Anti-Surge

System

Control unit

Piping

Unknown

Other

Failure causes


First HOFIMTM on Platform : Ivar Aasen

7 m

1x100%

tandem HOFIM RB 45-5 + RB 45-7

5 m

AMB from MDT-MECOS


K-Lab the basis for …

Full scale testing

Exposure to real offshore

gas/fluids – up to 30%

liquid mass fraction

Motor –Compressor

Qualification

AMB System

enhancements

Other Component

qualifications

Simulation of upset

conditions

Installation @ K-Lab, December 2007

Picture courtesy of StatoilHydro

Over 9’000 hours wet/well-stream gas Upstream certified by Statoil


Åsgard Subsea Compression Project

“world’s first

project of its kind”

• Increased recovery

• Accelerated production

• Reduced CAPEX / phased investment

• Operational flexibility

• Reduced OPEX

• HSE benefits


Introduction to Subsea HOFIMTM

MAN Diesel & Turbo Hardstrasse 319, 8005 Zürich, Switzerland

Type: Subsea HOFIMTM

Compressor: RB 45-7

Barrel type multi-stage radial

Motor: High-speed induction motor

with solid rotor technology

Bearings: Active Magnetic Bearings

Design

pressure:

internal 220 bar

external 150 bar

Rated Power: 11’500 kW

Weight 57 ton

Altitude - 300 m.a.s.l (subsea)

IP rating 68

Designed for wet gas


Illustration of power density of the M43-

motor familiy

V 18 51/60 DF

5.4

2 m

4.71 m

1.4 m

1.3

6 m

M43

MAN M43 Standard

Power 18 MW (Design)

Speed 10 000 RPM

Torque 17 200 Nm

Weight ~16 tons

Power Density 1.1 MW/ton

MAN 18 V 51/60 DF

Power 18 MW (with 18 cylinders)

Speed 514 RPM

Torque 334 400 Nm

Weight ~265 tons


Subsea M43:

…compact + powerfull!

MAN SUBSEA M43

Power 11.5 MW

Speed 7 200 RPM

Torque 17 200 Nm

Weight ~24 tons



Illustration of power density of the M43-

motor familiy

Lok 2000:

6.1MW

MAN 7L51/60DF: 7 MW

MAN M43: 18 MW Vestas V112-3.0: 3 MW (Rotor: D 112m, tip speed 100 m/s)

MAN M43 Subsea HOFIM: 11.5 MW


Impressions – Workshop and FAT


Impressions – Submerged Tests

Photo courtesy of Statoil

Photo courtesy of Statoil Photo courtesy of Statoil


Impressions - SIT

Photo courtesy of Statoil


Future of subsea

Today

heavy, complex, expensive

Tomorrow:

simplify, all liquid through


25 years of Continuous Improvement MAN Diesel &Turbo’s unequalled success and experience

0

20

40

60

80

100

1990 1995 2000 2005 2010

First

MOPICO®

First HOFIM™ Standalone

First tandem

HOFIM™

Standalone

First HOFIM™

Sealed

First HOFIM™

with MAN Motor

for Commercial

Operation First tandem

HOFIM™

Sealed

First

HOFIM™

Offshore

105

units

First

subsea

HOFIM™

K-LAB

Marinisation programme


Questions?

hofimtm for offshore applications - spe france...man diesel & turbo schweiz ag alexandre de...

Documents