HEATER TREATER SOLUTIONS - WBPCwbpc.ca/pub/documents/archived-talks/2015/Presentati… · ·...
Transcript of HEATER TREATER SOLUTIONS - WBPCwbpc.ca/pub/documents/archived-talks/2015/Presentati… · ·...
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HEATER TREATER SOLUTIONSHEATER TREATER SOLUTIONS
Grit Industries Inc. and the CWT Indirect HeaterGrit Industries Inc. and the CWT Indirect Heater
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GRIT INDUSTRIES INC.GRIT INDUSTRIES INC.
Founded in 1985 by president Wayne King
Head office in Lloydminster, Alberta (administration, R&D, and service base)
100,000 ft² manufacturing facility located in North Battleford, Saskatchewan
120-plus work force including production workers, service technicians, sales, engineering, and administration
Distribution network across Canada and the USA
Founded in 1985 by president Wayne King
Head office in Lloydminster, Alberta (administration, R&D, and service base)
100,000 ft² manufacturing facility located in North Battleford, Saskatchewan
120-plus work force including production workers, service technicians, sales, engineering, and administration
Distribution network across Canada and the USA
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GRIT INDUSTRIES INC.GRIT INDUSTRIES INC.
Manufacturer of heating solutions for the oil and gas sectors
Manufacturer of secondary containment systems
Manufacturer of solids-handling equipment
Provider of installation and maintenance services
Innovative solutions for industry problems
Manufacturer of heating solutions for the oil and gas sectors
Manufacturer of secondary containment systems
Manufacturer of solids-handling equipment
Provider of installation and maintenance services
Innovative solutions for industry problems
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VERTICAL HEATER TREATERVERTICAL HEATER TREATER
Problems and SolutionsProblems and Solutions
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VERTICAL HEATER TREATER: A HISTORYVERTICAL HEATER TREATER: A HISTORY
VHT was developed to facilitate gas, oil, and water separation with the application of heat
The VHT traditionally uses a fire tube heater which, by design, is a simplistic device with an inherently low thermal efficiency
The fire tube design contributes to a high rate of structural tube failures
Chemical additives were introduced to assist separation while reducing the amount of heat required - thus reducing tube failures
VHT was developed to facilitate gas, oil, and water separation with the application of heat
The VHT traditionally uses a fire tube heater which, by design, is a simplistic device with an inherently low thermal efficiency
The fire tube design contributes to a high rate of structural tube failures
Chemical additives were introduced to assist separation while reducing the amount of heat required - thus reducing tube failures
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VERTICAL HEATER TREATER: PRESENTVERTICAL HEATER TREATER: PRESENT
Incoming standards for the Bakken Petroleum Region (April, 2015) will result in the VHT being further utilized for Reid Vapor Pressure (RVP) reduction through the elevation of crude temperatures
The result will be increased operation of the fire tube beyond traditional levels
Problems, failures, and serious incidences will increase dramatically beyond the pre-chemical treating era
Incoming standards for the Bakken Petroleum Region (April, 2015) will result in the VHT being further utilized for Reid Vapor Pressure (RVP) reduction through the elevation of crude temperatures
The result will be increased operation of the fire tube beyond traditional levels
Problems, failures, and serious incidences will increase dramatically beyond the pre-chemical treating era
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TYPICAL VHT COMPONENTSTYPICAL VHT COMPONENTS
ASME pressure vessel
Fire tube section (ASME or non-ASME)
Stack
Gas fired burner head (lbs of gas)
Tank temperature controls
ASME pressure vessel
Fire tube section (ASME or non-ASME)
Stack
Gas fired burner head (lbs of gas)
Tank temperature controls
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FIRE TUBE SECTION-HEAT EXCHANGERFIRE TUBE SECTION-HEAT EXCHANGER
Simple pipe construction of a selected diameter to provide the required transfer area for a given application
Produced in a U-shape so that the inlet and outlet are at the same side of the vessel
Burner flame fires into the lower pass with cooler combustion gases exiting on the upper pass
End up with “hot” and “cold” ends resulting in non-uniform heating of the fluids
Occupies a relatively small x-sec area of the vessel - poor heat distribution
Simple pipe construction of a selected diameter to provide the required transfer area for a given application
Produced in a U-shape so that the inlet and outlet are at the same side of the vessel
Burner flame fires into the lower pass with cooler combustion gases exiting on the upper pass
End up with “hot” and “cold” ends resulting in non-uniform heating of the fluids
Occupies a relatively small x-sec area of the vessel - poor heat distribution
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FIRE TUBE: DESIGN MERITSFIRE TUBE: DESIGN MERITS
Simple
Low initial capital cost
Simple means anyone can manufacture (non-ASME version) - plentiful
Industry is very familiar with operation
Simple
Low initial capital cost
Simple means anyone can manufacture (non-ASME version) - plentiful
Industry is very familiar with operation
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FIRE TUBE: DESIGN DEFICIENCIESFIRE TUBE: DESIGN DEFICIENCIES
Poor thermal efficiency (industry studies indicate 40-45% at best) Hot section is subject to extreme temperatures (direct flame impingement) High temperatures cause premature gasket failures High skin temperatures mean that the oil cannot be in direct contact with the tube, must
heat the water phase (increases vessel size) High temperatures cause the water in contact with the tube to boil which leads to tube
scale (mineral deposits) Tube scale reduces heat transfer and results in increased localized skin temperatures and
tube degradation High temperatures reduce the life of corrosion inhibiters (coatings) Reduced heat transfer requires increasing the firing rates, which compounds the
problems Tube failure is imminent
Poor thermal efficiency (industry studies indicate 40-45% at best) Hot section is subject to extreme temperatures (direct flame impingement) High temperatures cause premature gasket failures High skin temperatures mean that the oil cannot be in direct contact with the tube, must
heat the water phase (increases vessel size) High temperatures cause the water in contact with the tube to boil which leads to tube
scale (mineral deposits) Tube scale reduces heat transfer and results in increased localized skin temperatures and
tube degradation High temperatures reduce the life of corrosion inhibiters (coatings) Reduced heat transfer requires increasing the firing rates, which compounds the
problems Tube failure is imminent
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COLD WEATHER TECHNOLOGY (CWT)COLD WEATHER TECHNOLOGY (CWT)
Grit Industries Inc.’s CWT Product LineGrit Industries Inc.’s CWT Product Line
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COLD WEATHER TECHNOLOGY (CWT)COLD WEATHER TECHNOLOGY (CWT)
Innovative heating system using two-phase thermal syphon vacuum process
Requires no electrical source to operate (no pumps or motors)
Virtually silent operation once it has been brought to temperature
Been in use as a natural gas line heater for over 12 years throughout North America
Been in use directly heating light oil in tanks for processing purposes for over six years
Consistent thermal efficiencies between 70 - 80% (into process), third-party testing
Approved for use in North Dakota and Saskatchewan for in-tank treating of light oil
Innovative heating system using two-phase thermal syphon vacuum process
Requires no electrical source to operate (no pumps or motors)
Virtually silent operation once it has been brought to temperature
Been in use as a natural gas line heater for over 12 years throughout North America
Been in use directly heating light oil in tanks for processing purposes for over six years
Consistent thermal efficiencies between 70 - 80% (into process), third-party testing
Approved for use in North Dakota and Saskatchewan for in-tank treating of light oil
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CWT: THE PROCESSCWT: THE PROCESS
Utilizes an ASME Sec IV steam boiler Closed system under vacuum with no
make-up water required Low pressure flame bed supplies heat to
the water/glycol mixture causing the water to boil almost instantly, results in an exceptional response time
Uses the latent heat of vaporization, efficient
Steam temperature self adjusts to 250° F Uses process line temperature sensor
ensuring exacting control ASME Sec IV controls insure safety
Utilizes an ASME Sec IV steam boiler Closed system under vacuum with no
make-up water required Low pressure flame bed supplies heat to
the water/glycol mixture causing the water to boil almost instantly, results in an exceptional response time
Uses the latent heat of vaporization, efficient
Steam temperature self adjusts to 250° F Uses process line temperature sensor
ensuring exacting control ASME Sec IV controls insure safety
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CWT: THE ADAPTATION - FROMCWT: THE ADAPTATION - FROM
SINGLE WELL IN TANK TREATINGSINGLE WELL IN TANK TREATING BATTERY IN TANK TREATINGBATTERY IN TANK TREATING
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CWT: THE ADAPTATION - TOCWT: THE ADAPTATION - TO
VERTICAL HEATER TREATERVERTICAL HEATER TREATER PROCESS DEMO UNIT
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CWT: THE ADAPTATION - TOCWT: THE ADAPTATION - TO
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CWT: HEAT EXCHANGER FEATURESCWT: HEAT EXCHANGER FEATURES
Purpose designed for treater applications ASME Sec VIII flange and tubes Approved for use in North Dakota Standard models with 50.5 ft² and 101 ft²
of tube transfer area (will replace 0.5 mm btu/hr and 1.0 mm btu/hr fire tubes)
Uses latent heat transfer (condensing steam)yielding a uniform temperature profile across the entire exchanger
Multiple tube arrangement utilizes a larger x-sec area of the vessel (16 5/8” wide), yields superior heat distribution
Purpose designed for treater applications ASME Sec VIII flange and tubes Approved for use in North Dakota Standard models with 50.5 ft² and 101 ft²
of tube transfer area (will replace 0.5 mm btu/hr and 1.0 mm btu/hr fire tubes)
Uses latent heat transfer (condensing steam)yielding a uniform temperature profile across the entire exchanger
Multiple tube arrangement utilizes a larger x-sec area of the vessel (16 5/8” wide), yields superior heat distribution
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CWT: HEAT EXCHANGER FEATURESCWT: HEAT EXCHANGER FEATURES
Lowering the water-oil interface level increases the capacity of existing treaters(or decreases the heat requirement) by heating the oil directly
The water flow through removes the bare minimum of heat as the water is not the heating medium
Eliminates natural drafting when idling
Horizontal treater configurations available
Lowering the water-oil interface level increases the capacity of existing treaters(or decreases the heat requirement) by heating the oil directly
The water flow through removes the bare minimum of heat as the water is not the heating medium
Eliminates natural drafting when idling
Horizontal treater configurations available
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CWT: IMAGESCWT: IMAGES
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CWT: IMAGESCWT: IMAGES
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CWT: HEAT EXCHANGER OPTIONAL LAYOUTSCWT: HEAT EXCHANGER OPTIONAL LAYOUTS
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CWT: ADDRESSING FIRE TUBE DEFICIENCIESCWT: ADDRESSING FIRE TUBE DEFICIENCIES
FIRE TUBEFIRE TUBE Low Efficiency (40-45%)
Excess fuel consumption
Increased GHG emissions
Oversized burners (lbs of gas pressure)
Increased exchange area
Low Efficiency (40-45%)
Excess fuel consumption
Increased GHG emissions
Oversized burners (lbs of gas pressure)
Increased exchange area
CWTCWT Independently tested at 70-80%
Up to 60% fuel savings
Reduces GHG emissions
Low press. flame bed (oz gas pressure)
Independently tested at 70-80%
Up to 60% fuel savings
Reduces GHG emissions
Low press. flame bed (oz gas pressure)
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CWT: ADDRESSING FIRE TUBE DEFICIENCIESCWT: ADDRESSING FIRE TUBE DEFICIENCIES
FIRE TUBEFIRE TUBE Non- uniform heating
Extreme heat at burner end causes premature gasket failures
Excessive heat results in coating failure
Non- uniform heating
Extreme heat at burner end causes premature gasket failures
Excessive heat results in coating failure
CWTCWT Steam provides uniform temperature
profile across the exchanger
Maximum 250° F steam temperature with ability to operate lower as required, within gasket specifications
Operates within coating specifications
Steam provides uniform temperature profile across the exchanger
Maximum 250° F steam temperature with ability to operate lower as required, within gasket specifications
Operates within coating specifications
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CWT: ADDRESSING FIRE TUBE DEFICIENCIESCWT: ADDRESSING FIRE TUBE DEFICIENCIES
FIRE TUBEFIRE TUBE High skin temperatures requires
heating of the water phase
Heating of the water phase causes scaling leading to external tube degradation and decreased transfer efficiency
Use of low grade fuels can lead to internal tube corrosion
High skin temperatures requires heating of the water phase
Heating of the water phase causes scaling leading to external tube degradation and decreased transfer efficiency
Use of low grade fuels can lead to internal tube corrosion
CWTCWT 250° F skin temperature allows for direct
heating of the oil
250° F skin temperature prevents tube scaling maintaining transfer efficiency throughout the units life
Requires clean dry gas. Internal vacuum eliminates internal exchanger corrosion
250° F skin temperature allows for direct heating of the oil
250° F skin temperature prevents tube scaling maintaining transfer efficiency throughout the units life
Requires clean dry gas. Internal vacuum eliminates internal exchanger corrosion
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CWT: ADDRESSING FIRE TUBE DEFICIENCIESCWT: ADDRESSING FIRE TUBE DEFICIENCIES
FIRE TUBEFIRE TUBE Fire tube inspections consist of waiting for
leakage to become obvious
Industry indicates fire tube life can be as low as two years at current firing rates
New regulations will require fire tubes to be operated for longer intervals resulting in an increased failure rate
Fire tube inspections consist of waiting for leakage to become obvious
Industry indicates fire tube life can be as low as two years at current firing rates
New regulations will require fire tubes to be operated for longer intervals resulting in an increased failure rate
CWTCWT With no scaling or heat degradation,
inspections become virtually unnecessary
Independent 3rd party destructive testing puts the boiler life at over 40 years, with a predicted exchanger life at over 15 years
New regulations easily met
With no scaling or heat degradation, inspections become virtually unnecessary
Independent 3rd party destructive testing puts the boiler life at over 40 years, with a predicted exchanger life at over 15 years
New regulations easily met
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FIRE TUBE AND CWT ECONOMICSFIRE TUBE AND CWT ECONOMICS
FIRE TUBEFIRE TUBE Low initial capital cost
High cost of operation
Short life cycle (2 - 3 yrs)
High life cycle / maintenance costs
Low initial capital cost
High cost of operation
Short life cycle (2 - 3 yrs)
High life cycle / maintenance costs
CWTCWT Higher initial capital cost
High efficiency ensures low cost of operation
Low temperature vacuum system has a proven extended life cycle (boiler at over 40 years, exchanger predicted to be 15 yrs)
Low life cycle / maintenance costs
Higher initial capital cost
High efficiency ensures low cost of operation
Low temperature vacuum system has a proven extended life cycle (boiler at over 40 years, exchanger predicted to be 15 yrs)
Low life cycle / maintenance costs
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ECONOMICS: THE COST OF STATUS QUOECONOMICS: THE COST OF STATUS QUO
Ex: 600 bbl/day oil production, $50/bbl, 24 month fire tube life cycle, 3 day replacement timeEx: 600 bbl/day oil production, $50/bbl, 24 month fire tube life cycle, 3 day replacement time
Vacuum truck to pull down treater fluids $1,000
Crew to disconnect and prep for fire tube pull $1,500
Picker truck to pull and reinstall fire tube $1,500
Cost of replacement fire tube, gasket and freight (non-ASME) $4,000
Crew to replace fire tube, reconnect and commission $2,000
Disposal $500
Lost cash flow $90,000
Total cost (providing no spills, fires, injuries, liabilities) $100,500
Equivalent yearly cost of replacement $50,250
Vacuum truck to pull down treater fluids $1,000
Crew to disconnect and prep for fire tube pull $1,500
Picker truck to pull and reinstall fire tube $1,500
Cost of replacement fire tube, gasket and freight (non-ASME) $4,000
Crew to replace fire tube, reconnect and commission $2,000
Disposal $500
Lost cash flow $90,000
Total cost (providing no spills, fires, injuries, liabilities) $100,500
Equivalent yearly cost of replacement $50,250
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ECONOMICS: CWT SOLUTIONECONOMICS: CWT SOLUTION
Ex: 600 bbl/day oil production, $50/bbl, 15 year exchanger life cycle, 30 year boiler life cycle, 3 day replacement time (i.e. one exchanger replacement over 30 year period)Ex: 600 bbl/day oil production, $50/bbl, 15 year exchanger life cycle, 30 year boiler life cycle, 3 day replacement time (i.e. one exchanger replacement over 30 year period)
Vacuum truck to pull down treater fluids $1,000
Crew to disconnect and prep for exchanger pull $2,000
Picker truck to pull and reinstall exchanger $2,500
Cost of replacement exchanger/gasket/freight (ASME CERTIFED) $17,500
Crew to replace exchanger, reconnect and commission $2,000
Disposal $500
Lost cash flow $90,000
Total cost (at year 15) $115,500
Equivalent yearly cost of replacement (over 30 years) $3,850
Vacuum truck to pull down treater fluids $1,000
Crew to disconnect and prep for exchanger pull $2,000
Picker truck to pull and reinstall exchanger $2,500
Cost of replacement exchanger/gasket/freight (ASME CERTIFED) $17,500
Crew to replace exchanger, reconnect and commission $2,000
Disposal $500
Lost cash flow $90,000
Total cost (at year 15) $115,500
Equivalent yearly cost of replacement (over 30 years) $3,850
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RECAPRECAP
CWT Indirect Heater: Innovative - Safe - EconomicCWT Indirect Heater: Innovative - Safe - Economic
Certified equipment
Safe
Efficient
Durable
Silent
12 month warranty on parts and labour
Low life cycle cost 8% of the fire tube
Certified equipment
Safe
Efficient
Durable
Silent
12 month warranty on parts and labour
Low life cycle cost 8% of the fire tube
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PAYMENT OPTIONSPAYMENT OPTIONS
385 (equivalent to 500,000 BTU/hr fire tube)385 (equivalent to 500,000 BTU/hr fire tube)
Purchase: $46,000.00
Lease: $2,750 per month 50% of payments in first year can be
applied to buyout as a credit
Annual PM service included Operational issues (such as caused by dirty,
wet gas) not covered
Purchase: $46,000.00
Lease: $2,750 per month 50% of payments in first year can be
applied to buyout as a credit
Annual PM service included Operational issues (such as caused by dirty,
wet gas) not covered
770 (equivalent to 1,000,000 BTU/hr fire tube)770 (equivalent to 1,000,000 BTU/hr fire tube)
Purchase: $56,000.00
Lease: $3,350 per month 50% of payments in first year can be
applied to buyout as a credit
Annual PM service included Operational issues (such as caused by dirty, wet
gas) not covered
Purchase: $56,000.00
Lease: $3,350 per month 50% of payments in first year can be
applied to buyout as a credit
Annual PM service included Operational issues (such as caused by dirty, wet
gas) not covered
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GRIT INDUSTRIES INC.GRIT INDUSTRIES INC.
Lloydminster Main Office:10-50-1-4 Airport Road NW
Lloydminster, Alberta
T9V 3A5
Canada
1-877-TRY-GRIT (879-4748)
P: (780) 875-5577
F: (780) 808-8415
Lloydminster Main Office:10-50-1-4 Airport Road NW
Lloydminster, Alberta
T9V 3A5
Canada
1-877-TRY-GRIT (879-4748)
P: (780) 875-5577
F: (780) 808-8415
North Battleford PlantP:(306) 445-6695
F: (306) 445-2812
North Battleford PlantP:(306) 445-6695
F: (306) 445-2812