Dresser-Rand Separators. May 2006
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1 Dresser-Rand Separators May 2006
2 A little history.. California inventor separation principles early development and testing capital constraints Aker Kvaerner & Dresser-Rand formed 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
3 D-R R 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
4 The IRIS separator
5 IRIS benefits Separation 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
6 How Does the IRIS TM operate? WET GAS DRY GAS Swirl Generator Separation Zone Diffuser Section Separated Liquids
7 3 IRIS
8 IRIS field testing CEESI, Colorado 6 inch test - Feb 2003 Natural gas to 1000psi, injection of Decane upstream good repeatability obtained, solid quantitative results
9 3/4" Tubing Valve 1 IRIS field testing 3/4" Tubing/ pipe CEESI, Colorado 3/4" Tubing Valve 1 1/4"- 3/8" Tubing Valve 2 To Drain subsequently developed performance modeling code and product configurator, proposal generator 5000 IRIS-6060: Dry Gas Data - GSV vs. Speed < Psia < 106 y = x R 2 = IRIS Speed (rpm) < Psia < < Psia < < Psia < 1042 y = 120.4x R 2 = y = x R 2 = y = x R 2 = Gas Superficial Velocity (ft/sec)
10 3/4" Tubing Valve 1 IRIS field testing 3/4" Tubing/ pipe CEESI, Colorado 3/4" Tubing Valve 1 1/4"- 3/8" Tubing Valve 2 To Drain IRIS-6060: Dry Gas Tests - GSV vs. Pressure Drop PSI Pressure Drop (psid) PSI 300 PSI 100 PSI y = x R 2 = 1 y = 0.01x R 2 = y = x R 2 = y = x R 2 = Gas Superficial Velocity (ft/s)
11 3/4" Tubing Valve 1 IRIS field testing 3/4" Tubing/ pipe CEESI, Colorado 3/4" Tubing Valve 1 1/4"- 3/8" Tubing Valve 2 To Drain Pressure Drop as % of Inlet Pressure PSI 600 PSI 300 PSI 100 PSI IRIS-6060: Dry Gas Tests - GSV vs. Pressure Drop y = 0.002x R 2 = 1 y = x R 2 = 1 y = x R 2 = 1 y = x R 2 = Gas Superficial Velocity (ft/s)
12 3/4" Tubing Valve 1 IRIS field testing 3/4" Tubing/ pipe CEESI, Colorado 3/4" Tubing Valve 1 1/4"- 3/8" Tubing Valve 2 To Drain IRIS-6060: 600 PSI Wet Gas Tests - LCO Analysis LIquid Carryover (Gal/MMSCF) GSV - 16 ft/s, Speed rpm GSV - 26 ft/s, Speed rpm GSV - 39 ft/s, Speed rpm Liquid Mass Fraction of Total Flow
13 3/4" Tubing Valve 1 IRIS field testing 3/4" Tubing/ pipe CEESI, Colorado 3/4" Tubing Valve 1 1/4"- 3/8" Tubing Valve 2 To Drain Separation Efficiency (%) IRIS-6060: 600 PSI Wet Gas Tests GSV - 16 ft/s, Speed rpm GSV - 26 ft/s, Speed rpm GSV - 39 ft/s, Speed rpm Liquid Mass Fraction of Total Flow
14 IRIS sizes 1½ inch - vertical design, 600# flanges 3 inch - 600#, 900# flange ratings 6 inch - 600#, 900# flange ratings
15 IRIS flow capability 5.0% Application Range of IRIS Product Line 4.5% Minimum Pressure Drop (% of inlet) Model XX15 4.0% 3.5% 3.0% 2.5% 2.0% 1.5% 1.0% Model XX30 Model XX60 0.5% 0.0% Actual Gas Flow (CuFt/sec)
16 IRIS flow capability Approx max capacity 1.5" & 3" IRIS MMSCFD Flow in MMSCF "IRIS 1.5" IRIS Pressure in psia
17 IRIS flow capability 70 IRIS Capacity Approximate Maximum Flow Rates MMSCFD " IRIS 3" IRIS Pressure (psia)
18 3 IRIS unit installed
19 6 IRIS unit installed
20 1½ IRIS
21 1½ IRIS
22 1½ IRIS - factory test
23 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
24 3 IRIS - Gas Turbine fuel treatment
25 Packaged 6 IRIS - wellhead application
26 IRIS competition Traditional scrubber vessels Traditional scrubber vessels + vane pack axial flow cyclones
27 IRIS value proposition examples Recip inlet scrubber retrofit 5-CVIP-4 recip, offshore LA
28 IRIS value proposition examples Recip inlet scrubber retrofit 5-CVIP-4 recip, offshore LA 3 separate valve failures due to liquid damage
29 IRIS value proposition examples Recip 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
30 IRIS value proposition examples Recip 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
31 IRIS value proposition examples Recip 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 Competitive alternatives: no space to install
32 IRIS value proposition examples Discharge scrubber retrofit (Epic Energy)
33 IRIS value proposition examples Discharge scrubber retrofit (Epic Energy) recip compressor, 15MMSCFD at 350 psig oil carryover in line, backpressure, reduced capacity, monthly pig (clean)
34 IRIS 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
35 IRIS 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
36 IRIS 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 IRIS hardware, engineering, installation, downtime $160,000 opex nil
37 IRIS value proposition examples offshore process separator repair
38 IRIS value proposition examples offshore process separator repair severe liquid carryover need to service vane pack
39 IRIS value proposition examples offshore process separator repair severe liquid carryover need to service vane pack vane pack repair hardware, engineering, manpower, downtime $655,000
40 IRIS value proposition examples offshore process separator repair severe liquid carryover need to service vane pack vane pack repair hardware, engineering, manpower, downtime $655,000 install IRIS hardware, engineering, manpower, downtime $327,000
41 D-R R 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
42 Typical Application of Bi-phase Bi-phase 32 MBPD / 64 MMSCFD / 900 # ANSI installed on Shell s Mars TLP in GoM in December 2002
43 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
44 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
45 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 ton Vessel size 55ft x 12 ft dia Package size 11ft x 14ft
46 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
47 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
48 for your interest.
49
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