Post on 26-Oct-2015
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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…
Business & Product Centrefor FPSOs, FSOs and rigs
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.
Business & Product Centrefor FPSOs, FSOs and rigs
Quality and classification
Quality audits by client
ISO 9001 quality certification
All leading classification societies
Business & Product Centrefor FPSOs, FSOs and rigs
Engineering Engineering -- basic principlesbasic principles
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
Design life length 20 - 25 yearsNo compromises in system designBest equipment from the most reliable suppliers
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
Gas firingHigher temperature from furnace to exhaustDesign the superheater based on higher temperaturesHigher draft lossDe-rate the boiler approx 10%
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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.
Business & Product Centrefor FPSOs, FSOs and rigs
A wide range of productsA wide range of productsand servicesand services
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
MISSION™ OMup to 45 t/h, 24 bar
Business & Product Centrefor FPSOs, FSOs and rigs
SUNROD™ CHS- 30 MW, 24 bar
Business & Product Centrefor FPSOs, FSOs and rigs
MISSION™ OL
Compact and strong design thanks to membrane walls and two drums
Top fired
High efficiency, especially on part loads, gives outstanding total fuel economy
Business & Product Centrefor FPSOs, FSOs and rigs
MISSION™ OL12 - 55 t/h, 18 bar
Business & Product Centrefor FPSOs, FSOs and rigs
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
High efficiency, especially on part loads, gives outstanding total fuel economy
Quick response to load variations
Business & Product Centrefor FPSOs, FSOs and rigs
MISSION™ D-typeUp to 120 t/h
Business & Product Centrefor FPSOs, FSOs and rigs
Two MISSION™ D boilers (size 100 t/h)Two MISSION™ D boilers (size 100 t/h)
Business & Product Centrefor FPSOs, FSOs and rigs
Our MISSION™ D-typeProbably the best FPSO
boileron the market!
Business & Product Centrefor FPSOs, FSOs and rigs
MISSION™ 3-passFor steam or hot water - Pre-assembled unit
Business & Product Centrefor FPSOs, FSOs and rigs
THERMAL FLUID BOILERS• CAPACITIES UP TO 20 MW
• VERTICAL OR HORIZONTAL
• MINERAL OIL / SYNTHETIC FLUID
Business & Product Centrefor FPSOs, FSOs and rigs
Thermal Fluid Heater
Business & Product Centrefor FPSOs, FSOs and rigs
Thermal Fluid Heater
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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?
Business & Product Centrefor FPSOs, FSOs and rigs
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!
Business & Product Centrefor FPSOs, FSOs and rigs
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.
Business & Product Centrefor FPSOs, FSOs and rigs
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.
Business & Product Centrefor FPSOs, FSOs and rigs
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!
Business & Product Centrefor FPSOs, FSOs and rigs
Combustion systems
Burners for single, dual or triple fuel firing
For gas, condensate, crude, HFO or MDO
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
KBSD steam atomised burner
for oil firing - top view
Business & Product Centrefor FPSOs, FSOs and rigs
KBSD steam atomised burnerfor oil firing - diagram
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
Inert Gas Systems
Boilers
To funnel
Scrubber
IGS fans
To funnel
Deckwaterseal
P/V breaker(pressure/vacuum)
Business & Product Centrefor FPSOs, FSOs and rigs
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!
Business & Product Centrefor FPSOs, FSOs and rigs
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!
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
Heat Recovery Boilers
In a normal Diesel Engine or Gas Turbine there is a lot of energy to save .....
……… and money!
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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!
Business & Product Centrefor FPSOs, FSOs and rigs
Boilers for steam propulsion
We have supplied a large number of boilers for steam propulsion
Babcock & Wilcox
Combustion Engineering
Business & Product Centrefor FPSOs, FSOs and rigs
A selection of our international references
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
Texaco CaptainSupply of 3 x CHS boilers (23 MW) with triple fuel
burners
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
Armada PerkasaBoiler repair of AT-4 boiler
Supply of 1 x AQ-9 (20 t/h) boiler with dual fuel burner
Business & Product Centrefor FPSOs, FSOs and rigs
Armada PerkasaBoiler repair of AT-4 boiler
Supply of 1 x AQ-9 (20 t/h) boiler with dual fuel burner
Business & Product Centrefor FPSOs, FSOs and rigs
The AQ-9 (20 t/h) boiler
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
Model of Espoir FPSO
Business & Product Centrefor FPSOs, FSOs and rigs
Two MISSIONTM D-type boilers during production in our workshop
Business & Product Centrefor FPSOs, FSOs and rigs
MISSIONTM D-type boiler ready for delivery
Business & Product Centrefor FPSOs, FSOs and rigs
MISSIONTM D-type boiler ready for delivery
Business & Product Centrefor FPSOs, FSOs and rigs
MISSIONTM D-type boilers in Qingdao port
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
Business & Product Centrefor FPSOs, FSOs and rigs
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
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
Business & Product Centrefor FPSOs, FSOs and rigs
Quality products for marine,offshore and stationary plants
Business & Product Centrefor FPSOs, FSOs and rigs
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: stom@aalborg-industries.se
... or your usual Aalborg Industries contact person