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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.