proprietary information

Transcription

Dresser-Rand Separators
May 2006
A little history……..

California inventor 1987-1995
z
separation principles
z
early development and testing
z
capital constraints
Aker Kvaerner & Dresser-Rand 1996-2004
z
formed JV company MppT (Multiphase Power & Processing Technologies)
z
purchased all rights and patents from inventor
z
AK market knowledge and sales force
z
D-R machinery expertise and manufacture
z
some progress
Purchase by D-R of AK’s interest in MppT mid-2005
PROPRIETARY INFORMATION
D-R Separator products

IRIS (Inline Rotary Separator)
z
separates liquids from a gas stream

Biphase: separates gas and oil (a larger, powered IRIS)

Triphase: separates gas and water from oil
The IRIS separator
IRIS benefits

Separation efficiency
z
>99% of particles over 5 microns
z
equal to cartridge filters

Compact, in line design

High liquid capacity
z
4% liquid to gas volume ratio
z
up to 30% by mass

Self powered

Ease of maintenance/replacement
How Does the IRIS operate?
TM
DRY GAS
WET GAS
Swirl Generator
Separation Zone
Diffuser Section
Separated Liquids
3” IRIS
IRIS field testing

CEESI, Colorado
z
6 inch test
- Feb 2003
z
Natural gas to 1000psi, injection of Decane upstream
z
good repeatability obtained, solid quantitative results
3/4" Tubing
Valve 1
IRIS field testing
3/4" Tubing/ pipe
Valve 1
CEESI, Colorado
To Drain
3/4" Tubing
1/4"- 3/8" Tubing
z
subsequently developed performance modeling code
z
and product configurator, proposal generator
IRIS-6060: Dry Gas Data
- GSV vs. Speed
5000
4500
y = 119.21x - 206.46
R2 = 0.9982
100 < Psia < 106
4000
IRIS Speed (rpm)

Valve 2
289 < Psia < 310
529 < Psia < 645
3500
975 < Psia < 1042
3000
y = 123.62x - 434.93
R2 = 0.9998
y = 120.4x - 115.87
2
R = 0.998
y = 161.53x - 2192.5
R2 = 1
2500
2000
1500
1000
10
15
20
25
30
35
40
45
Gas Superficial Velocity (ft/sec)
3/4" Tubing
Valve 1
IRIS field testing
3/4" Tubing/ pipe
Valve 1
CEESI, Colorado
To Drain
3/4" Tubing
1/4"- 3/8" Tubing
IRIS-6060: Dry Gas Tests
- GSV vs. Pressure Drop
35.0
1000 PSI
30.0
Pressure Drop (psid)

Valve 2
600 PSI
25.0
300 PSI
20.0
100 PSI
2.0102
y = 0.0181x
2
R =1
2.0234
y = 0.01x
2
R = 0.9999
15.0
2.0691
y = 0.0039x
2
R =1
10.0
5.0
0.0
0.00
2.3781
y = 0.0005x
2
R =1
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
Gas Superficial Velocity (ft/s)
3/4" Tubing
Valve 1
IRIS field testing
3/4" Tubing/ pipe
Valve 1
CEESI, Colorado
To Drain
3/4" Tubing
1/4"- 3/8" Tubing
IRIS-6060: Dry Gas Tests
- GSV vs. Pressure Drop
3.5
1000 PSI
Pressure Drop as % of Inlet
Pressure

Valve 2
3.0
600 PSI
1.9816
y = 0.002x
2
R =1
300 PSI
2.5
100 PSI
1.9961
y = 0.0018x
2.0
2
R =1
2.0644
y = 0.0014x
1.5
2
R = 0.9999
2.1663
y = 0.0009x
1.0
2
R =1
0.5
0.0
0
5
10
15
20
25
30
35
40
45
Gas Superficial Velocity (ft/s)
3/4" Tubing
Valve 1
IRIS field testing
3/4" Tubing/ pipe
Valve 1
CEESI, Colorado
To Drain
3/4" Tubing
1/4"- 3/8" Tubing
IRIS-6060: 600 PSI Wet Gas Tests - LCO Analysis
25.00
LIquid Carryover (Gal/MMSCF)

Valve 2
20.00
GSV - 16 ft/s, Speed - 1800 rpm
15.00
10.00
5.00
0.00
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
Liquid Mass Fraction of Total Flow
3/4" Tubing
Valve 1
IRIS field testing
3/4" Tubing/ pipe
Valve 1
CEESI, Colorado
To Drain
3/4" Tubing
1/4"- 3/8" Tubing
IRIS-6060: 600 PSI Wet Gas Tests
100.00
Separation Efficiency (%)

Valve 2
99.90
99.80
99.70
99.60
99.50
99.40
99.30
99.20
99.10
99.00
0.00
0.05
0.10
0.15
0.20
0.25
0.30
Liquid Mass Fraction of Total Flow
0.35
0.40
IRIS sizes

1½ inch
-
vertical design, 600# flanges

3 inch
-
600#, 900# flange ratings

6 inch
-
600#, 900# flange ratings
IRIS flow capability
Application Range of IRIS Product Line
5.0%
4.5%
Model XX30
Minimum Pressure Drop (% of inlet)
Model XX15
4.0%
Model XX60
3.5%
3.0%
2.5%
2.0%
1.5%
1.0%
0.5%
0.0%
0
1
2
3
4
5
6
7
8
9
10
Actual Gas Flow (CuFt/sec)
Approx max capacity 1.5" & 3" IRIS
18
Flow in MMSCF
MMSCFD
16
14
12
10
3"IRIS
1.5" IRIS
8
6
4
2
0
0
500
1000
1500
Pressure in psia
IRIS Capacity
Approximate Maximum Flow Rates
70
60
MMSCFD
50
6" IRIS
3" IRIS
40
30
20
10
0
0
200
400
600
800
1000
1200
1400
1600
Pressure (psia)
3” IRIS unit installed
6” IRIS unit installed
1½” IRIS
1½” IRIS
1½” IRIS - factory test
IRIS markets

gas seal systems

refining

GT Fuel gas treatment

recip compressor inlet

oil and gas production (including NGC*)
* Natural Gas from Coal a.k.a. Coal Bed Methane
3” IRIS - Gas Turbine fuel treatment
Packaged 6” IRIS - wellhead application
IRIS competition

Traditional scrubber vessels

Traditional scrubber vessels + vane pack

axial flow cyclones
IRIS value proposition examples

Recip inlet scrubber retrofit
z
5-CVIP-4 recip, offshore LA

z
z
3 separate valve failures due to liquid damage

z
z
z
Typical costs incurred per incident:
• parts & labor to repair
• downtime 2 days
• TOTAL
$20,000
$200,000 (20 MMSCD x $5/MMBTU x 2 days)
$220,000

z
z
z
• downtime 2 days
• TOTAL
z
$20,000
$220,000
IRIS solution
•
•
•
•
•
•
6” unit w/drainer
pipe cutting/welding
Fittings, tubing
Engineering, planning
downtime 1 day
TOTAL
$48,000
$800 (1 day)
$500
$24,000 (200 hrs x $120/hr)
$100,000
$173,000

z
z
z
• downtime 2 days
• TOTAL
z
IRIS solution
•
•
•
•
•
•
z
$20,000
$220,000
6” unit w/drainer
pipe cutting/welding
Fittings, tubing
Engineering, planning
downtime 1 day
TOTAL
$48,000
$800 (1 day)
$500
$24,000 (200 hrs x $120/hr)
$100,000
$173,000
Competitive alternatives: no space to install

Discharge scrubber retrofit (Epic Energy)

z
recip compressor, 15MMSCFD at 350 psig
z
oil carryover in line, backpressure, reduced capacity, monthly pig (clean)

z
z
Pigging
z
equipment, manpower, production loss
$152,300 per month

z
z
Pigging
z

$152,300 per month
Scrubber/coalescer
z
hardware, engineering, installation, downtime $247,000
z
opex (replace coalescer elements), downtime
$40,000 per year

z
z
Pigging
z

$152,300 per month
Scrubber/coalescer
z
z
opex (replace coalescer elements), downtime
$40,000 per year
IRIS
z
z
opex
nil

offshore process separator repair

z
severe liquid carryover
z
need to service vane pack

z
z
vane pack repair
z
hardware, engineering, manpower, downtime
$655,000

z
z
vane pack repair
z

$655,000
install IRIS
z
$327,000
D-R Separator products

IRIS (Inline Rotary Separator)
z

separates liquids from a gas stream
RST (Rotary Separator Turbine)
z
Bi-phase: separates gas and oil
z
Tri-phase: separates gas and water from oil
Typical Application of Bi-phase
Bi-phase 32 MBPD / 64 MMSCFD / 900 # ANSI
installed on Shell’s Mars TLP in GoM in December 2002
Models of Bi-phase RST
•100/200/900 RST Bi-phase
•100 MBFPD
•200 MMSCFD
•28 ton operating weight
•10 ft x 16 ft
•32/64/900 RST Bi-phase
•32 MBFPD
•64 MMSCFD
•18 ton operating weight
•8 ft x 14 ft
Tri-phase RST Field Trial
Marathon’s Ewing Bank 873 platform - Gulf of Mexico
• > 3000 hrs operation
• Water < 20 ppm OiW
• Oil < 0.5% WiO
• Operation at wellhead manifold
• 110% design flow rate (5500 BFPD)
• 20 API crude
• “Overboard quality water, pipeline
quality oil”
Application of Tri-phase
..on Shell’s Ursa TLP platform - Gulf of Mexico
• 65,000 BFPD RST Package
• Future replacement of BOT/FWKO
• Weight reduction - 450 ton
• Vessel size 55ft x 12 ft dia
• Package size 11ft x 14ft
Tri-phase RST Field Test unit
• 1,000 BPD TPRS
• readily transportable by workboat
• quick disconnects
• attended operation
• first client test in Olean May 06
Tri-phase RST Field Test unit
• 1,000 BPD TPRS
• readily transportable by workboat
• quick disconnects
• attended operation
• first client test in Olean May 06
for your interest.
www.dresser-rand.com
[email protected]