dresser-rand · pdf file•32/64/900 rst bi-phase •32 mbfpd •64 mmscfd •18...

Dresser-Rand Separators

May 2006

PROPRIETARY INFORMATION

A little history……..A little history……..California inventor 1987-1995

separation principles

early development and testing

capital constraints

Aker Kvaerner & Dresser-Rand 1996-2004formed JV company MppT (Multiphase Power & Processing Technologies)

purchased all rights and patents from inventor

AK market knowledge and sales force

D-R machinery expertise and manufacture

some progress

Purchase by D-R of AK’s interest in MppT mid-2005

PROPRIETARY INFORMATION

DD--R Separator productsR Separator products

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

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

Triphase: separates gas and water from oil

The IRIS separatorThe IRIS separator

PROPRIETARY INFORMATION

IRIS benefitsIRIS benefitsSeparation efficiency

>99% of particles over 5 microns

equal to cartridge filters

Compact, in line design

High liquid capacity

4% liquid to gas volume ratio

up to 30% by mass

Self powered

Ease of maintenance/replacement

PROPRIETARY INFORMATION

How Does theHow Does the IRISIRISTM TM operate?operate?

DRY GAS

Separation ZoneSwirl Generator Diffuser Section

WET GAS

Separated Liquids

PROPRIETARY INFORMATION

3” IRIS3” IRIS

PROPRIETARY INFORMATION

IRIS field testingIRIS field testingCEESI, Colorado

6 inch test - Feb 2003

Natural gas to 1000psi, injection of Decane upstream

good repeatability obtained, solid quantitative results

PROPRIETARY INFORMATION

CEESI, Coloradosubsequently developed performance modeling code

and product configurator, proposal generator

3/4" Tubing

3/4" Tubing

3/4" Tubing/ pipe

1/4"- 3/8" Tubing

Valve 1

Valve 1Valve 2

To Drain

IRIS field testingIRIS field testing

IRIS-6060: Dry Gas Data - GSV vs. Speed

y = 161.53x - 2192.5R2 = 1

y = 119.21x - 206.46R2 = 0.9982

y = 123.62x - 434.93R2 = 0.9998y = 120.4x - 115.87

R2 = 0.998

1000

1500

2000

2500

3000

3500

4000

4500

5000

10 15 20 25 30 35 40 45

Gas Superficial Velocity (ft/sec)

IRIS

Spe

ed (r

pm)

100 < Psia < 106

289 < Psia < 310

529 < Psia < 645

975 < Psia < 1042

PROPRIETARY INFORMATION

CEESI, Colorado

3/4" Tubing

3/4" Tubing

3/4" Tubing/ pipe

1/4"- 3/8" Tubing

Valve 1

Valve 1Valve 2

To Drain

IRIS-6060: Dry Gas Tests - GSV vs. Pressure Drop

y = 0.0181x2.0102

R2 = 1y = 0.01x2.0234

R2 = 0.9999

y = 0.0039x2.0691

R2 = 1

y = 0.0005x2.3781

R2 = 10.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00Gas Superficial Velocity (ft/s)

Pres

sure

Dro

p (p

sid)

1000 PSI

600 PSI

300 PSI

100 PSI

IRIS field testingIRIS field testing

PROPRIETARY INFORMATION

CEESI, Colorado

3/4" Tubing

3/4" Tubing

3/4" Tubing/ pipe

1/4"- 3/8" Tubing

Valve 1

Valve 1Valve 2

To Drain

IRIS-6060: Dry Gas Tests - GSV vs. Pressure Drop

y = 0.002x1.9816

R2 = 1

y = 0.0018x1.9961

R2 = 1

y = 0.0014x2.0644

R2 = 0.9999y = 0.0009x2.1663

R2 = 1

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

0 5 10 15 20 25 30 35 40 45Gas Superficial Velocity (ft/s)

Pres

sure

Dro

p as

% o

f Inl

et

Pres

sure

1000 PSI

600 PSI

300 PSI

100 PSI

IRIS field testingIRIS field testing

PROPRIETARY INFORMATION

CEESI, Colorado

3/4" Tubing

3/4" Tubing

3/4" Tubing/ pipe

1/4"- 3/8" Tubing

Valve 1

Valve 1Valve 2

To Drain

IRIS-6060: 600 PSI Wet Gas Tests - LCO Analysis

0.00

5.00

10.00

15.00

20.00

25.00

0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35

Liquid Mass Fraction of Total Flow

LIqu

id C

arry

over

(Gal

/MM

SCF) GSV - 16 ft/s, Speed - 1800 rpm

GSV - 26 ft/s, Speed - 2880 rpm

GSV - 39 ft/s, Speed - 4630 rpm

IRIS field testingIRIS field testing

PROPRIETARY INFORMATION

3/4" Tubing

3/4" Tubing

3/4" Tubing/ pipe

1/4"- 3/8" Tubing

Valve 1

Valve 1Valve 2

To Drain

IRIS field testingIRIS field testingCEESI, Colorado

IRIS-6060: 600 PSI Wet Gas Tests

99.00

99.10

99.20

99.30

99.40

99.50

99.60

99.70

99.80

99.90

100.00

0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40Liquid Mass Fraction of Total Flow

Sepa

ratio

n Ef

ficie

ncy

(%)

GSV - 16 ft/s, Speed - 1800 rpm

GSV - 26 ft/s, Speed - 2880 rpm

GSV - 39 ft/s, Speed - 4630 rpm

PROPRIETARY INFORMATION

IRIS sizesIRIS sizes

1½ inch - vertical design, 600# flanges

3 inch - 600#, 900# flange ratings

6 inch - 600#, 900# flange ratings

PROPRIETARY INFORMATION

IRIS flow capabilityIRIS flow capability

0.0%

0.5%

1.0%

1.5%

2.0%

2.5%

3.0%

3.5%

4.0%

4.5%

5.0%

0 1 2 3 4 5 6 7 8 9 10

Actual Gas Flow (CuFt/sec)

Min

imum

Pre

ssur

e D

rop

(% o

f inl

et)

Application Range of IRIS Product Line

Model XX60Model XX30Model XX15

PROPRIETARY INFORMATION

MM

SCFD

Approx max capacity 1.5" & 3" IRIS

0

2

4

6

8

10

12

14

16

18

0 500 1000 1500Pressure in psia

Flo

w in

MM

SC

F

3"IRIS1.5" IRIS

IRIS flow capabilityIRIS flow capability

PROPRIETARY INFORMATION

IRIS flow capabilityIRIS flow capability

IRIS CapacityApproximate Maximum Flow Rates

0

10

20

30

40

50

60

70

0 200 400 600 800 1000 1200 1400 1600

Pressure (psia)

6" IRIS3" IRIS

MM

SCFD

PROPRIETARY INFORMATION

3” IRIS unit installed3” IRIS unit installed

PROPRIETARY INFORMATION

6” IRIS unit installed6” IRIS unit installed

PROPRIETARY INFORMATION

1½” IRIS1½” IRIS

PROPRIETARY INFORMATION

1½” IRIS1½” IRIS

PROPRIETARY INFORMATION

1½” IRIS 1½” IRIS -- factory testfactory test

PROPRIETARY INFORMATION

IRIS marketsIRIS 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

PROPRIETARY INFORMATION

3” IRIS 3” IRIS -- Gas Turbine fuel treatmentGas Turbine fuel treatment

PROPRIETARY INFORMATION

Packaged 6” IRIS Packaged 6” IRIS -- wellhead applicationwellhead application

PROPRIETARY INFORMATION

IRIS competitionIRIS competition

Traditional scrubber vessels

Traditional scrubber vessels + vane pack

axial flow cyclones

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examplesRecip inlet scrubber retrofit

5-CVIP-4 recip, offshore LA

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examplesRecip inlet scrubber retrofit

5-CVIP-4 recip, offshore LA

3 separate valve failures due to liquid damage

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examplesRecip inlet scrubber retrofit

5-CVIP-4 recip, offshore LA

3 separate valve failures due to liquid damage

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

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examplesRecip inlet scrubber retrofit

5-CVIP-4 recip, offshore LA

3 separate valve failures due to liquid damage

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

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

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examplesRecip inlet scrubber retrofit

5-CVIP-4 recip, offshore LA3 separate valve failures due to liquid damageTypical costs incurred per incident:

• parts & labor to repair $20,000• downtime 2 days $200,000 (20 MMSCD x $5/MMBTU x 2 days)• TOTAL $220,000

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

Competitive alternatives: no space to install

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examples

Discharge scrubber retrofit (Epic Energy)

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examples

Discharge scrubber retrofit (Epic Energy)recip compressor, 15MMSCFD at 350 psig

oil carryover in line, backpressure, reduced capacity, monthly pig (clean)

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examples

Discharge scrubber retrofit (Epic Energy)recip compressor, 15MMSCFD at 350 psig

oil carryover in line, backpressure, reduced capacity, monthly pig (clean)

Pigging

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

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examples

Discharge scrubber retrofit (Epic Energy)recip compressor, 15MMSCFD at 350 psig

oil carryover in line, backpressure, reduced capacity, monthly pig (clean)

Pigging

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

Scrubber/coalescer

hardware, engineering, installation, downtime $247,000

opex (replace coalescer elements), downtime $40,000 per year

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examples

Discharge scrubber retrofit (Epic Energy)recip compressor, 15MMSCFD at 350 psigoil carryover in line, backpressure, reduced capacity, monthly pig (clean)

Piggingequipment, manpower, production loss $152,300 per month

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

IRIShardware, engineering, installation, downtime $160,000opex nil

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examples

offshore process separator repair

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examples

offshore process separator repairsevere liquid carryover

need to service vane pack

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examples

offshore process separator repairsevere liquid carryover

need to service vane pack

vane pack repairhardware, engineering, manpower, downtime $655,000

PROPRIETARY INFORMATION

IRIS value proposition examplesIRIS value proposition examples

offshore process separator repairsevere liquid carryover

need to service vane pack

vane pack repairhardware, engineering, manpower, downtime $655,000

install IRIShardware, engineering, manpower, downtime $327,000

PROPRIETARY INFORMATION

DD--R Separator productsR Separator products

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

RST (Rotary Separator Turbine)Bi-phase: separates gas and oil

Tri-phase: separates gas and water from oil

PROPRIETARY INFORMATION

Typical Application of Bi-phaseBi-phase 32 MBPD / 64 MMSCFD / 900 # ANSI

installed on Shell’s Mars TLP in GoM in December 2002

PROPRIETARY INFORMATION

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

PROPRIETARY INFORMATION

TriTri--phase RST Field Trialphase RST Field TrialMarathon’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”

PROPRIETARY INFORMATION

Application of TriApplication of Tri--phasephase..on Shell’s Ursa TLP platform ..on Shell’s Ursa TLP platform -- Gulf of MexicoGulf 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

PROPRIETARY INFORMATION

TriTri--phase RST Field Test unitphase RST Field Test unit• 1,000 BPD TPRS

• readily transportable by workboat

• quick disconnects

• attended operation

• first client test in Olean May 06

PROPRIETARY INFORMATION

TriTri--phase RST Field Test unitphase RST Field Test unit• 1,000 BPD TPRS

• readily transportable by workboat

• quick disconnects

• attended operation

• first client test in Olean May 06

PROPRIETARY INFORMATION

for your interest.

www.dresser-rand.cominfo@dresser-rand.com