HOFIMTM for Offshore Applications - SPE France...MAN Diesel & Turbo Schweiz AG Alexandre de...
Transcript of 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
2 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
Volkswagen Group
3 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
Revenue ‘13:
€0.5 bn
Power Engineering Business
areas
Divisions
Commercial Vehicles
MAN
Truck & Bus
Revenue ‘13: €9.1 bn
MAN
Latin America
Revenue ‘13: €3.0 bn
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
Revenue ‘13: €3.4 bn
Renk (76 %)
Company Structure
4 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
Areas of Activity Applications and Market Segments
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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
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The product range covers almost all applications in the Upstream, Midstream,
Downstream, Industrial Gases, Power Generation as well as Marine Business.
5 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
6 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
7 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
8 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
9 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
10 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
Modular Design for process adaptation Volume Flow vs. Compressor Head
11 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
12 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
13 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
14 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
15 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
Single point of contact Project Partners Today
Compressor Motor AMB Third Party VFD
16 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
17 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
18 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
19 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
First HOFIMTM on Platform : Ivar Aasen
7 m
1x100%
tandem HOFIM RB 45-5 + RB 45-7
5 m
AMB from MDT-MECOS
20 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
21 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
22 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
23 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
Power Density 0.07 MW/ton
Subsea M43:
…compact + powerfull!
MAN SUBSEA M43
Power 11.5 MW
Speed 7 200 RPM
Torque 17 200 Nm
Weight ~24 tons
Power Density 0.5 MW/ton
24 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
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
25 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
Impressions – Workshop and FAT
26 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
Impressions – Submerged Tests
Photo courtesy of Statoil
Photo courtesy of Statoil Photo courtesy of Statoil
27 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
Impressions - SIT
Photo courtesy of Statoil
28 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
Future of subsea
Today
heavy, complex, expensive
Tomorrow:
simplify, all liquid through
29 < > MAN Diesel & Turbo Schweiz AG Alexandre de Rougemont - OSPS SPE France : HOFIMTM for Offshore Applications 03.12.2014
25 years of Continuous Improvement MAN Diesel &Turbo’s unequalled success and experience
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20
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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