offshore production technology summit 2014

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

Dynamic Heat Exchange SolutionsInnovative process equipment reducing operational costs on

production rigs & FPSO’s

Femke Schaëfer

London – March 10th, 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


Introduction


Our markets:

Sustainability Service & Maintenance

Power

Oil

Gas

Chemical

Air Handling

Food Processing


What we do:

• Thermal designs:

based on:

Aspen/HTFS

HTRI

HEI

Computational Fluid Dynamics

Hysys


What we do:

• Mechanical designs:

- ASME

- EN13445

- AD2000

- RTOD

- PD5500

- CODAP

- GOST

FEM analysis


What we do :

• Process design:

Process optimization


What we do :

• Equipment:

Heat exchangers

Air cooled coolers

And other process

equipment


What we do :

• Materials:

Titanium

(Super)Duplex

Nickel-Alloy

Inconel

Other exotics


What we do :

• Systems:

Incl. controls


What we do :

• Site work: Erection Assembly Start up Commissioning Service


What we do :

• Service & Maintenance: Upgrading Debottlenecking Inspection Specialist

maintenance for machines operating hazardous materials


Our focus on innovation:

• Product development

• System solutions

• New technology

Compact Header®

Radiax®

Whizz-Wheel® fans Thermo-Acoustic heat

pump


Reducing operational costs on production rigs &

FPSO’s in four steps.


+

= Cost reduction!

++


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


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


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!


Step four

Easy Maintenance of Equipment

Why?

Reduction of HSE risks

Shorter down-time

Space reduction needed for maintenance


How can we contribute to weight, size, power and

maintenance reduction on platforms & FPSO’s?


Debottlenecking


• 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


http://kennisbank.bronswerk.nl/kennisbank/images/5/56/Whizzwheel00084.jpg

http://kennisbank.bronswerk.nl/kennisbank/images/5/56/Whizzwheel00084.jpg

Debottlenecking


Compact cooling – three solutions


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:


http://kennisbank.bronswerk.nl/kennisbank/images/4/44/Lokatie010.jpg


Case study – Compact coolingAir-cooled coolers with compact cooling:


•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)



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)



Figure 2: high efficiency designFigure 1: standard design


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

Case study – Compact coolingS&T heat exchangers with compact cooling:

Situation: Offshore interstage compression cooling for Australian FPSO


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



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



• 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



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 coolingCooling with subsea cooling:

Situation: Offshore Gas cooler North Sea


• 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 coolingCooling with subsea cooling:




Flare gas recoveryFlare gas compression with smart-compact Radiax ®compressor:


• Several hundreds of millions m3 of flare gas wasted

• Gas at atmospheric pressure

• Compress to 20-80 Bar



• 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


Summary



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


Summary



3. Energy consumption reduction of process equipment;

High efficiency air coolers up to 50%

Subsea cooler 100% compared to air cooler


Summary



4. Easy maintenance of process equipment;

Compact Header®; less people, heavy tools and space required

Subsea cooler; no maintenance


Thank you for your attention.Questions please


How to contact us:

www.bronswerk.com

facebook.com/bronswerk

Linkedin.com/company/bronswerk-heat-transfer

twitter.com/bronswerk


http://www.linkedin.com/company/2233102




offshore production technology summit 2014

Technology

maintenance facs

debottlenecking facs

fpsos facs

solutions facs

aerospace technology

introduction facs

exotics facs

capacity facs