You are on page 1of 81

Business Centre for FPSOs and FSOs

Boilers etc for FPSOs and FSOs

Business & Product Centre - fitted for FPSOs, FSOs with and rigs HRSG

North Sea Producer (ex Dagmar Maersk) from Aalborg Industries

Aalborg Industries Brazil

International market & customers Aalborg Industries A/S Denmark

Aalborg Industries South Korea Aalborg Industries AB Business & Product Centre for FPSOs Market Coordination Marketing, Sales & Support Business Development Technical Coordination Project Management

Aalborg Industries KK Japan

Aalborg Industries USA

Aalborg Industries Pte Singapore

Aalborg Industries The Netherlands

Aalborg Industries Ltd China / Hong Kong

Aalborg Industries Dubai Agents

After Sales Boiler conversions & repairs Installation, supervision, start-up etc

Business & Product Centre for FPSOs, FSOs and rigs

We can supply the whole boiler plant


Design and supply of equipment Turn-key installation
Clients specification

Supervision Start-up

System design Equipment supply Project management Guarantee

Installation Platforms etc

Business & Product Centre for FPSOs, FSOs and rigs

Tanker conversions into FPSOs


Conversion of existing boilers Installation of new boiler system
Clients specification

AI co-ordination by Business Centre or After Sales


New Boiler System Preliminary studies Steam, hotwater, thermal oil Boilers, burners and control Other related equipment IGS, heat exchangers By Business Centre
Business & Product Centre for FPSOs, FSOs and rigs

Boiler Conversion Inspection and report Repair or conversion Boiler body retrofit Burner upgrading Installation of new burner By After Sales

Boiler plants for oil & gas industry


From a technical point of view the boiler system for an offshore rig or FPSO is very similar to a boiler system for a petrochemical industry Our combined experience from marine boilers and land based industrial plants gives us an excellent base when working with offshore projects.

Business & Product Centre for FPSOs, FSOs and rigs

Quality and classification

Quality audits by client ISO 9001 quality certification All leading classification societies

Business & Product Centre for FPSOs, FSOs and rigs

Engineering - basic principles

Business & Product Centre for FPSOs, FSOs and rigs

Basic criteria Design life length for the FPSO is normally 20 - 25 years In case the FPSO cannot pump oil the lack of income is 2.5 - 5 MUSD each day, depending on its capacity The sooner the FPSO can be on the field the sooner the owner can start counting his money The boilers are normally fired with gas and crude as leading fuels with diesel as back-up Hazardous area or safe area - On deck or in the engine room
Business & Product Centre for FPSOs, FSOs and rigs

Design life length 20 - 25 years No compromises in system design Best equipment from the most reliable suppliers

Business & Product Centre for FPSOs, FSOs and rigs

In case the FPSO cannot pump oil . With an oil price of approx 25 USD per barrel the lack of income would be 5 MUSD per day for a 200.000 bpd FPSO Essential to have redundancy in terms of important functions onboard the FPSO, for instance boilers, turbines etc

Business & Product Centre for FPSOs, FSOs and rigs

Gas firing Higher temperature from furnace to exhaust Design the superheater based on higher temperatures Higher draft loss De-rate the boiler approx 10%

Business & Product Centre for FPSOs, FSOs and rigs

On deck / engine room? Hazardous / safe area? Even if the area is classified as safe, it gets hazardous within 3 metre radius from a potential gas leakage On deck - hazardous area On deck - safe area Engine room - safe area

Business & Product Centre for FPSOs, FSOs and rigs

On deck, exposed to harsh weather Special painting of boilers and FW tank Valves and fittings with makers painting for offshore installation Insulation with stainless cladding and silicon sealing Electric motors normally IP 56 Material must withstand harsh weather

Business & Product Centre for FPSOs, FSOs and rigs

Suggestions
Co-operate with an experienced boiler supplier already from the early design phase. Specify only the real necessary items, let the supplier make the design and take the responsibility for his system. The combustion system is a complex part of the boiler system. In order to reduce the number of interfaces to a real minimum we suggest the whole system to be supplied by one supplier.

Business & Product Centre for FPSOs, FSOs and rigs

A wide range of products and services

Business & Product Centre for FPSOs, FSOs and rigs

Aalborg Industries can offer


Boilers for Steam and Hot water Boilers for Thermal Fluid Heat Recovery after Gas Turbines Heat recovery after Diesel Engines Inert Gas Systems Heat Exchangers Turn-key installation Boiler conversions and retrofits Service and spare parts
Business & Product Centre for FPSOs, FSOs and rigs

Steam boiler system


Oil or gas fired steam boiler type
MISSION OM

MISSION OL MISSION D
Steam for process Temperature control for FW tank

Single or multiple boiler system

Make-up water

Condensate

FW tank Burner for various fuels such as Gas, Crude, MDO, HFO Control panel local at boiler remote

Dosing

2 x 100% FW pumps one pump in operation, one in automatic stand-by

Business & Product Centre for FPSOs, FSOs and rigs

Hot water system


Oil or gas fired cylindrical hot water boiler type
SUNROD CHS
Expansion tank N2 Hot water outlet Hot water inlet

Single or multiple boiler system

Make-up pump

Min flow control Burner for various fuels such as Gas, Crude, MDO, HFO Control panel local at boiler remote

Dosing Business & Product Centre for FPSOs, FSOs and rigs

Distribution pumps, one pump per boiler in operation, one in automatic stand-by

MISSION OM SUNROD CHS


Compact and strong design thanks to membrane walls and pin tubes Easy to inspect and to keep clean Side fired which makes the boiler easy to ventilate and gives easy access to the burner and its controls High efficiency, especially on part loads, gives outstanding total fuel economy Very dry steam (slightly superheated) This boiler can also be delivered as a hotwater boiler SunrodTM CHS - up to a capacity of 30 MW
Business & Product Centre for FPSOs, FSOs and rigs

MISSION OM
up to 45 t/h, 24 bar

Business & Product Centre for FPSOs, FSOs and rigs

SUNROD CHS
- 30 MW, 24 bar

Business & Product Centre for FPSOs, FSOs and rigs

MISSION OL
Compact and strong design thanks to membrane walls and two drums Top fired High efficiency, especially on part loads, gives outstanding total fuel economy

Business & Product Centre for FPSOs, FSOs and rigs

MISSION OL
12 - 55 t/h, 18 bar

Business & Product Centre for FPSOs, FSOs and rigs

MISSION D-type
For capacities above medium range Design based on our long experience from industrial boilers as well as from boilers for marine steam propulsion systems Strong and compact design High efficiency, especially on part loads, gives outstanding total fuel economy Quick response to load variations

Business & Product Centre for FPSOs, FSOs and rigs

MISSION D-type
Up to 120 t/h

Business & Product Centre for FPSOs, FSOs and rigs

Business & Product Centre for FPSOs, FSOs and rigs

Two MISSION D boilers (size 100 t/h)

Our MISSION D-type Probably the best FPSO boiler on the market!

Business & Product Centre for FPSOs, FSOs and rigs

MISSION 3-pass
For steam or hot water - Pre-assembled unit

Business & Product Centre for FPSOs, FSOs and rigs

THERMAL FLUID BOILERS


CAPACITIES UP TO 20 MW VERTICAL OR HORIZONTAL MINERAL OIL / SYNTHETIC FLUID

Business & Product Centre for FPSOs, FSOs and rigs

Thermal Fluid Heater

Business & Product Centre for FPSOs, FSOs and rigs

Thermal Fluid Heater

Business & Product Centre for FPSOs, FSOs and rigs

Aalborg Industries can deliver the whole system


Standard Steam Boilers up to 120 t/h per boiler Hot Water up to 30 MW per boiler Thermal Oil up to 20 MW per boiler Heat Recovery Boilers after Gas Turbines or Diesel Engines Inert Gas Systems Heat Exchangers
Business & Product Centre for FPSOs, FSOs and rigs

Gasturbine or Steam?
Typical FPSO: The FPSO needs steam for the process plus power for pump drives, compressors etc. Which is best? Space requirement? Investment cost? Maintenance intervals and costs? Operation cost?

Business & Product Centre for FPSOs, FSOs and rigs

Gasturbine or Steam?
Comparisons have shown that Steam boilers with TGs normally need more space Steam systems is less expensive to install Maintenance of GTs are by far more expensive Operation cost is much lower for a steam system The total cost (CAPEX + OPEX) for a system with GTs with Heat Recovery boilers is often 2 to 4 times the cost for a steam alternative!

Business & Product Centre for FPSOs, FSOs and rigs

Hot Water or Thermal Fluid?


Water above 100 C needs to be pressurised Thermal fluids can be heated above 200 C at atmospheric pressure Different thermal fluids can be used. Normally mineral oil, but for higher temperatures synthetic fluids must be used.

Business & Product Centre for FPSOs, FSOs and rigs

Hot Water or Thermal Fluid?


A system with thermal fluid cannot corrode. The water in a hot water system needs to be treated to normal boiler water quality. But hot water systems are normally closed systems, so the need of make-up water is very limited. Thermal fluid cannot freeze. Hot water can be mixed with glycol to avoid freezing and corrosion. Maintenance costs are low in both cases.

Business & Product Centre for FPSOs, FSOs and rigs

Steam, Hot Water or Thermal Fluid?

Regardless if the system shall be designed for steam, hot water or thermal fluid - We can supply the whole heating system!

Business & Product Centre for FPSOs, FSOs and rigs

Combustion systems

Burners for single, dual or triple fuel firing For gas, condensate, crude, HFO or MDO

Business & Product Centre for FPSOs, FSOs and rigs

We have adopted the steam atomised burner as our standard


Easy to install and to operate Excellent turn down Burns a wide range of fuels Robust design Limited need of maintenance Low oxygen content For hot water boilers air is used to atomise the fuel

Business & Product Centre for FPSOs, FSOs and rigs

KBSD steam atomised burner for oil firing - top view

Business & Product Centre for FPSOs, FSOs and rigs

KBSD steam atomised burner for oil firing - diagram

Business & Product Centre for FPSOs, FSOs and rigs

Dual Fuel Burners (make: Hamworthy)


for Daewoo / Terra Nova 2 x 25 t/h, gas and diesel oil

Business & Product Centre for FPSOs, FSOs and rigs

Inert Gas Systems


Risk management during unloading and tank cleaning is crucial on board an FPSO or an FSO. We offer compact IGS systems using the flue gas from the boilers Low installation cost Lowest possible operation cost

Business & Product Centre for FPSOs, FSOs and rigs

Inert Gas Systems


To funnel To funnel

Scrubber P/V breaker (pressure/vacuum)

Boilers

IGS fans

Deck water seal

Business & Product Centre for FPSOs, FSOs and rigs

Class requires that the O2 content shall be max 5% for IGS operation
O2 (%)
5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 25
Business & Product Centre for FPSOs, FSOs and rigs

Typical O2 content in flue gas

Gas Diesel

The IGS can be operated down to approx 30 % load, still having 1 % oxygen as an extra margin!

30

40

50

60

70

90

100

Boiler load (%)

Advantages by using the flue gas type IGS


Save space and reduce investment cost

Reduce the operation cost for the plant By taking both the boiler system and the IGS from one supplier the co-ordination of these two systems becomes easier and safer One supplier - one responsible!
Business & Product Centre for FPSOs, FSOs and rigs

Heat Recovery Boilers after Diesel Engines


PIONEERTM DE-1 AV-10DE AV-6N

Type Diesel engine output Diesel engine fuel type

Horizontal gas flow water tube 0.5 - 20 MW Light fuel oil Heavy fuel oil

Horizontal/vertical gas flow water tube 2 - 20 MW Light fuel oil Heavy fuel oil Up to 30 kg/s <500 C Up to ~ 5 t/h

Vertical gas flow water tube No limits Light fuel oil Heavy fuel oil No limits <500 C No limits

Exhaust gas flow Exhaust gas temperature Steam capacity


Business & Product Centre for FPSOs, FSOs and rigs

Up to 30 kg/s <500 C Up to ~ 5 t/h

Heat Recovery Boilers


9 In a normal Diesel Engine or Gas Turbine there is a lot of energy to save ..... and money!

Business & Product Centre for FPSOs, FSOs and rigs

Heat exchangers
We can offer a wide range of heat exchangers for various purposes on board an FPSO, FSO or rig Tube and shell Spiral wound tube bundle Pin tube

Business & Product Centre for FPSOs, FSOs and rigs

Marine - Product Range Heat exchangers


VESTATM EH VESTATM MX VESTATM MD VESTATM MP-C

Type Design

Oil and F.W. Electrical Heater FlowTthrough Out flow

Oil and F.W. Preheater Shell and Tube U-Tubes 10 - 5,000 kW 16 or 30 bar (g) Horizontal Vertical Tubes: St. 37.0 Shell: St. 37.0

S.W. Cooler / Condenser Shell and Tube Straight Tubes 400 - 6,000 kg/h 16 bar (g) Horizontal Vertical Tubes: CuNi 90/10 Shell: St. 37.0

Cargo Heater Shell and Tube U-Tubes 300 - 2,000 kW 16 bar (g) Horizontal Vertical Tubes: AISI 316L Shell: AISI 316L

Capacity

3 - 235 kW

Design pressure 16 bar (g) Installation Materials


Horizontal Vertical Tubes: St. 37.0 Shell: St. 37.0
Business & Product Centre for FPSOs, FSOs and rigs

Offshore plants
We have the resources to offer Boilers, Heat Recovery Boilers, IGS and Heat Exchangers for offshore Installations RIGS FPSOs and FSOs

Business & Product Centre for FPSOs, FSOs and rigs

Boiler conversions and retrofits


Our engineers have built thousands of boilers, so when a boiler needs to be modified to suit other fuels than it was originally built for, our After Sales organisation is the natural partner. Boiler repairs and conversions Boiler retrofits At any time - anywhere!
Business & Product Centre for FPSOs, FSOs and rigs

Boilers for steam propulsion


We have supplied a large number of boilers for steam propulsion Babcock & Wilcox Combustion Engineering

Business & Product Centre for FPSOs, FSOs and rigs

A selection of our international references

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: FELS / Petrobras, Brasil Name: Petrobras XVIII Semi submersible rig, built at FELS, Singapore 2 x CHS hot water boilers each with a capacity of 20 MW Hamworthy combustion system for firing gas On deck / hazardous area Turn-key installation

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: Name: Astano / Texaco Texaco Captain

FPSO, newbuilding, built at Astano shipyard in Ferrol, Spain 3 x CHS hot water boilers each with a capacity of 23 MW Hamworthy combustion system for firing gas, crude and diesel 3 x Hot water circulation pumps 1 x Expansion tank On deck / hazardous area
Business & Product Centre for FPSOs, FSOs and rigs

Texaco Captain
Supply of 3 x CHS boilers (23 MW) with triple fuel burners

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: Mitsui Engineering & Shipbuilding, Japan FSO, newbuilding, built at Mitsui Chiba shipyard 2 x CPH steam boilers, each with a capacity of 10 t/h Hamworthy combustion system for firing gas and diesel Below deck

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: ABB Global / Bluewater, The Netherlands Name: Glas Dowr FPSO, conversion of a 100,000 DWT tanker 1 x CPH steam boiler with a capacity of 45 t/h Hamworthy combustion system for firing gas and diesel On deck / hazardous area

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: Daewoo, Korea Name: Terra Nova FPSO, newbuilding, built at Daewoo shipyard 2 x CPH steam boilers, each with a capacity of 25 t/h Hamworthy combustion system for firing gas and diesel Below deck

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: Care Offshore Name: Armada Perkasa (ex Red Teal) Conversion of a tanker into an FPSO Major boiler repair of an Aalborg AT-4 boiler Overhaul / upgrading of existing burner and control system Installation of an AQ-9 boiler with a capacity of 20 t/h

Business & Product Centre for FPSOs, FSOs and rigs

Armada Perkasa
Boiler repair of AT-4 boiler Supply of 1 x AQ-9 (20 t/h) boiler with dual fuel burner

Business & Product Centre for FPSOs, FSOs and rigs

Armada Perkasa
Boiler repair of AT-4 boiler Supply of 1 x AQ-9 (20 t/h) boiler with dual fuel burner

Business & Product Centre for FPSOs, FSOs and rigs

The AQ-9 (20 t/h) boiler

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: Nortrans Offshore, Singapore Name: Espoir Field FPSO Conversion of MT White Sea at Keppel Shipyard, Singapore 2 x MISSION D-type steam boilers, each with a capacity of 80 t/h Hamworthy combustion system for firing gas and diesel (not AI supply) On deck / hazardous area
Business & Product Centre for FPSOs, FSOs and rigs

Model of Espoir FPSO


Business & Product Centre for FPSOs, FSOs and rigs

Business & Product Centre for FPSOs, FSOs and rigs

Two MISSIONTM D-type boilers during production in our workshop

Business & Product Centre for FPSOs, FSOs and rigs

MISSIONTM D-type boiler ready for delivery

Business & Product Centre for FPSOs, FSOs and rigs

MISSIONTM D-type boiler ready for delivery

Business & Product Centre for FPSOs, FSOs and rigs

MISSIONTM D-type boilers in Qingdao port

Espoir FPSO
Business & Product Centre for FPSOs, FSOs and rigs

Espoir Ivoirien (ex White Sea) - fitted with two MISSIONTM D from Aalborg AalborgIndustries Industries

Business & Product Centre for FPSOs, FSOs and rigs

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: Hyundai Heavy Industries / Elf Name: Amenam FSO FSO, newbuilding at HHI shipyard in Ulsan, Korea 2 x CHS hot water boilers each with a capacity of 12 MW Hamworthy combustion system for firing gas and diesel 3 x Hot water circulation pumps On deck / hazardous area

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: Keppel Fels, Singapore / Vietsovpetro Name: White Tiger CPP3 3 x MISSIONTM OM steam boilers, each with a capacity of 13.5 t/h Hamworthy combustion system for firing gas and diesel FW tank, FW pumps and condensate recovery unit On deck / hazardous area

Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: Vanguard SPC Ltd, Australia / Agip Name: Woollybutt FPSO Conversion of MT Four Lakes at Keppel Shipyard, Singapore 2 x MISSIONTM OM steam boilers, each with a capacity of 38.5 t/h Hamworthy combustion system for firing gas, crude and diesel FW tank, FW pumps etc On deck / hazardous area
Business & Product Centre for FPSOs, FSOs and rigs

Reference plant
Client: Prosafe Production, Singapore Name: Abo FPSO Conversion of MT Grey Warrior at Keppel Shipyard, Singapore 2 x MISSION D-type steam boilers, each with a capacity of 90 t/h Hamworthy combustion system for firing gas and diesel (not AI supply) On deck / hazardous area
Business & Product Centre for FPSOs, FSOs and rigs

Knowing the boilers inside and out - unique experience


We have delivered a large number of quality boilers during the last decades Regardless if its a question of fuel fired boilers or Heat Recovery Systems we have the know-how and organisation to support you

Business & Product Centre for FPSOs, FSOs and rigs

Quality products for marine, offshore and stationary plants

Business & Product Centre for FPSOs, FSOs and rigs

How to reach us
For personal introduction please contact our Business & Product Centre for FPSOs, FSOs and rigs: Aalborg Industries AB P.O. Box 907 175 29 Jrflla, Sweden Phone: + 46 8 580 24300 Fax: + 46 8 580 27801 e-mail: stom@aalborg-industries.se ... or your usual Aalborg Industries contact person
Business & Product Centre for FPSOs, FSOs and rigs