HRS Company Presentation May 2010

HEATHEAT RECOVERYRECOVERY SOLUTIONS SOLUTIONS LtdLtd

Designers and Suppliers of Designers and Suppliers of Energy Recovery Equipment Energy Recovery Equipment to the Oil, Gas and Process to the Oil, Gas and Process

Industries Industries

HEAT RECOVERY SOLUTIONSHEAT RECOVERY SOLUTIONS Designers and Suppliers of Energy Recovery EquipmentDesigners and Suppliers of Energy Recovery Equipment

INTRODUCTIONINTRODUCTION

• New name, Wealth of ExperienceNew name, Wealth of Experience

• Established April 2008 to provide bespoke heat Established April 2008 to provide bespoke heat recovery equipment and services to the Oil, Gas recovery equipment and services to the Oil, Gas and Process Industriesand Process Industries

• HRS team have more than 100 years combined HRS team have more than 100 years combined management and design experience as management and design experience as previous Managing Directors of ALSTOM Energy previous Managing Directors of ALSTOM Energy Systems, ME Engineering and C.F.StruthersSystems, ME Engineering and C.F.Struthers


DESIGN AND ENGINEERINGDESIGN AND ENGINEERING

• Design to ASME, API, PEDDesign to ASME, API, PED

• Structural design using STAAD Pro. Structural design using STAAD Pro.

• FEA using SolidWorks Cosmos DesignerFEA using SolidWorks Cosmos Designer

• CFD using SolidWorks CosmosFloWorksCFD using SolidWorks CosmosFloWorks

• 3D modelling in SolidWorks3D modelling in SolidWorks

• QA – Accredited to ISO 9001 / 2008QA – Accredited to ISO 9001 / 2008


PRODUCTSPRODUCTS

• Traditional & Circular Heat Recovery Units Traditional & Circular Heat Recovery Units – Thermal fluid, water/glycol, regen gas – Thermal fluid, water/glycol, regen gas

• Heat Recovery Boilers – Natural circulation Heat Recovery Boilers – Natural circulation and once throughand once through

• Fired Heaters – Superheaters, regen gas, Fired Heaters – Superheaters, regen gas, thermal fluids, water, airthermal fluids, water, air

• Recuperators – Acid gas, regen gas, air, Recuperators – Acid gas, regen gas, air, oxygenoxygen


EXPERIENCEEXPERIENCE

• HRS team have been responsible for designing, engineering and supplying:HRS team have been responsible for designing, engineering and supplying:

- 190 Waste heat recovery units- 190 Waste heat recovery units– 60 Waste heat boilers, superheaters, economisers60 Waste heat boilers, superheaters, economisers– 92 Once through steam generators92 Once through steam generators– 22 Fired heaters22 Fired heaters– 17 Recuperators17 Recuperators


SERVICESSERVICES

• Site SurveysSite Surveys

• ConsultancyConsultancy

• Installation SupervisionInstallation Supervision

• CommissioningCommissioning

• Spare Parts and ServiceSpare Parts and Service


ORGANISATIONORGANISATION


Traditional Gas Turbine WHRU’sTraditional Gas Turbine WHRU’s

HRS team have been responsible for the design and supply of more than 190 traditional WHRU’s with integral bypass valves, such as the AKPO units for TOTAL, manufactured in Struthers workshops in Hull, UK

PROJECTS – STATOIL GULLFAKS PLATFORM

Tube Bundle



PROJECTS – SHELL ANASURIA FSOPROJECTS – SHELL ANASURIA FSO

6MW WHRU’s on SOLAR MARS 90 GT’s


PROJECTS – SHELL ANASURIA FSOPROJECTS – SHELL ANASURIA FSO

Integral Bypass, Removable Coil, Multilouvre Dampers


PROJECTS – NIOEC SHAZAND ARAKPROJECTS – NIOEC SHAZAND ARAK

Waste Heat Boiler on Sulphur Decomposition Furnace - 65,000kg/hr 47barg, 400degC Superheated Steam


PROJECTS - PEMEX FIRED HEATERPROJECTS - PEMEX FIRED HEATER

Process Fluid - Regeneration Gas, 72 bar / 288 C5 MW Radiant Upshot Fired Heater


HRS COMPANY SUMMARYHRS COMPANY SUMMARY• Since foundation in April 2008 the above contracts Since foundation in April 2008 the above contracts

have been secured and are in execution – all ‘blue have been secured and are in execution – all ‘blue chip’ clientschip’ clients

• All traditional WHRU contracts employ straight All traditional WHRU contracts employ straight tube / serpentine coils, with conventional multi tube / serpentine coils, with conventional multi louvre rectangular dampers – Technology well louvre rectangular dampers – Technology well embedded in HRS product range.embedded in HRS product range.

• Recognising significant benefits, HRS team Recognising significant benefits, HRS team developed the circular WHRU technologydeveloped the circular WHRU technology

• These early designs have now been improved and These early designs have now been improved and refined into the next generation of circular refined into the next generation of circular WHRU’s.WHRU’s.

““EVOLUTION”EVOLUTION”

THE CASE FOR CIRCULAR WHRU THE CASE FOR CIRCULAR WHRU DEVELOPMENTDEVELOPMENT


Traditional WHRU Layouts



Traditional WHRU Damper Arrangement Traditional WHRU Damper Arrangement – Total Akpo Project– Total Akpo Project


Typical Serpentine Tube Bundle Typical Serpentine Tube Bundle

Petrobras, Brazil, 316 S. Steel Coil for Heat Recovery Unit, 35te

Conclusion – Traditional Designs

• Technology really hasn’t changed much since early fired heater convection box design from the last 100 years.

• Due to larger GT’s ( RB 211, GTX 100, LM2500+) finding their way more often onto deeper and deeper water platforms, the WHRU’s have also grown in physical size. FPSO and floating platforms require substantial support to mount these units above the turbine outlet and silencer. This is due to high weight and a high COG.

• An example of this is Exxon Kizomba FPSO where the 3 off WHRU’s weighed around 110 Te total yet the support structure to mount them on, weighed an incredible 285 Te due to the tow out, pitch/roll, and wind loadings.


‘EVOLUTION’ RANGE WHRU’S


HEAT RECOVERY HEAT RECOVERY SOLUTIONSSOLUTIONS

Designers and Suppliers of Designers and Suppliers of Energy Recovery EquipmentEnergy Recovery Equipment

INTRODUCTIONINTRODUCTION

• This presentation seeks to provide the This presentation seeks to provide the details of the design concepts embodied in details of the design concepts embodied in the ‘cylindrical’ Evolution WHRU for the ‘cylindrical’ Evolution WHRU for application with Gas Turbinesapplication with Gas Turbines

• Comparisons are principally drawn with Comparisons are principally drawn with Traditional and the first generation Traditional and the first generation ‘cylindrical’ WHRU system.‘cylindrical’ WHRU system.

• Advantages of the Evolution concept and Advantages of the Evolution concept and design are demonstrateddesign are demonstrated

HEAT RECOVERY HEAT RECOVERY SOLUTIONSSOLUTIONS

Designers and Suppliers of Designers and Suppliers of Energy Recovery EquipmentEnergy Recovery Equipment

‘‘EVOLUTION’ WHRU BACKGROUNDEVOLUTION’ WHRU BACKGROUNDOver the last 40 yearsOver the last 40 years

• The HRS The HRS TEAMTEAM have been responsible for have been responsible for inventing and inventing and developing the ‘circular coil type’ developing the ‘circular coil type’

• WHRU conceptsWHRU concepts

• Also involved in the design, engineering and supply of Also involved in the design, engineering and supply of 6060 ‘Circular – Helical Coil’ type WHRU’s‘Circular – Helical Coil’ type WHRU’s to the oil and gas to the oil and gas industriesindustries

• Further recognised potential improvements to the ‘coil Further recognised potential improvements to the ‘coil type’ design, now type’ design, now fully developed and Patented in favour fully developed and Patented in favour of HRSof HRS

• Directors, Management and Engineering Directors, Management and Engineering TEAMTEAM have been have been involved in the design, development and supply of more involved in the design, development and supply of more than 100 ‘coil type’ boilersthan 100 ‘coil type’ boilers

• CF Struthers have manufactured some CF Struthers have manufactured some 60 ‘Circular – 60 ‘Circular – Helical Coil’ WHRU systems Helical Coil’ WHRU systems



Origins of the Evolution WHRUOrigins of the Evolution WHRU

• Success with the original cylindrical WHRU Success with the original cylindrical WHRU designs is demonstrated with over 60 units designs is demonstrated with over 60 units supplied and operating worldwidesupplied and operating worldwide

• Based on this extensive experience HRS sought Based on this extensive experience HRS sought to improve that original design to improve - to improve that original design to improve - reliability, run dry capability, GT exhaust back reliability, run dry capability, GT exhaust back pressure and improve flow characteristicspressure and improve flow characteristics

• The result being the improved, more compact, The result being the improved, more compact, lighter and more efficient lighter and more efficient EVOLUTION WHRUEVOLUTION WHRU rangerange


‘‘EVOLUTION’ WHRUEVOLUTION’ WHRU

• Patented DesignPatented Design• InnovativeInnovative• Integral Exhaust Gas Integral Exhaust Gas

BypassBypass• Integral ‘silencing’Integral ‘silencing’• SmallerSmaller• LighterLighter• Thermally Effective Thermally Effective • Modular ConceptModular Concept• Low draft lossLow draft loss• Low wind resistanceLow wind resistance

Optional firing with Ring-Burn system available to increase steam output from same size unit.

HELICAL COILSHELICAL COILS

HEAT RECOVERY SOLUTIONSHEAT RECOVERY SOLUTIONS Designers and Suppliers of Energy Recovery Designers and Suppliers of Energy Recovery EquipmentEquipment

TYPICAL HELICAL COILS

INSERT COILS PICTURES


Evolution CWHRUEvolution CWHRU

Bypass Silencer

Bypass Annulus

Helical Coils

RV Control Valve

100% Flow to Coil 100% Flow to Bypass


‘‘EVOLUTION WHRU FEATURESEVOLUTION WHRU FEATURES

• CFD MODELLING CFD MODELLING DEMONSTRATESDEMONSTRATES EXCELLENT FLOW EXCELLENT FLOW DISTRIBUTIONDISTRIBUTION

• LOW DRAFT LOSSLOW DRAFT LOSS

• INTEGRAL RADIAL BYPASSINTEGRAL RADIAL BYPASS DAMPERDAMPER

• MODULAR CONSTRUCTIONMODULAR CONSTRUCTION

• IDEAL FOR SUPPLEMENTARYIDEAL FOR SUPPLEMENTARY FIRINGFIRING

Designers and Suppliers of Energy Recovery EquipmentDesigners and Suppliers of Energy Recovery Equipment

‘‘EVOLUTION’ WHRU – INHERENT EVOLUTION’ WHRU – INHERENT ADVANTAGESADVANTAGES

MECHANICAL FEATURES

• INTEGRAL BYPASS - NO EXTERNAL BYPASS DUCT / DAMPER

• INTEGRAL SILENCING – NO SEPARATE SILENCER

• DIMENSIONALLY SMALLER • 10% DIAMETER SAVING OVER EARLIER CIRCULAR DESIGN• SUBSTANTIAL HEIGHT REDUCTION • LOWER WIND RESISTANCE (60% OF CONVENTIONAL WHRU)–

SAVES ON STRUCTURAL SUPPORT

• LOWER WEIGHT• 5% WEIGHT SAVING FOR HEATING SURFACE • 10% WEIGHT SAVING OVER EARLIER CIRCULAR DESIGN• 30% WEIGHT SAVING OVER CONVENTIONAL WHRU CONCEPT



PERFORMANCE FEATURES

• OPTIMAL EXHAUST GAS FLOW DISTRIBUTION• REDUCED DRAFT LOSS MEANS LESS BACK PRESSURE ON GAS

TURBINE THUS MORE POWER OUTPUT• HELICAL COIL CONCEPT RESULTS IN LOWER FLUID SIDE PRESSURE

DROP –LOWER AUXILIARY PUMP POWER REQUIREMENT• ALL HELICAL COIL HEATING SURFACE USED – NO RETURN BENDS

OUTSIDE GAS FLOW• INHERENT INDUCED FLUID FLOW SYSTEM ALLOWS NATURAL

COOLING IN BYPASS MODE – NO SEAL AIR FANS / NO TRIM COOLER

• INNOVATIVE INTEGRAL RADIAL VANE CONTROL DAMPER • LOW VELOCITY THROUGH THE DAMPER (20 M/S) – AROUND HALF

OF THAT REQUIRED FOR TRADITIONAL RECTANGULAR DAMPERS• RESULTANT LOW DRAFT LOSS – REDUCED VIBRATION/ WEAR

PROBLEMS

INDUCTION COOLING OF COIL INDUCTION COOLING OF COIL run dry operation –– 100% Seal with no run dry operation –– 100% Seal with no fans fans

COLD AIR DRAWN INTO NOZZLES FROM SAFE AREA

HIGH VELOCITY EXHAUST GAS THROUGH BYPASS CREATES VENTURI

NEGATIVE PRESSURE RESULTS IN COIL ANNULUS




MANUFACTURING FEATURES• SINGLE FACTORY BUILT PACKAGE• INTEGRAL BYPASS DUCT / INTEGRAL DAMPER/ INTEGRAL

TRANSITION DUCTS• NO RETURN BENDS – SAVES 90% OF PRESSURE PART

WELDING AND NDT• ALL HELICAL COIL HEATING SURFACE USED – NO RETURN

BENDS OUTSIDE GAS FLOW

• FACTORY BUILD• SINGLE COMPLETE MODULE – NO TEST ASSEMBLY /

DISMANTLING FOR DELIVERY• REDUCED ASSEMBLY TIME – SHORTER DELIVERY

POSSIBLE• READILY COMMISSIONED BEFORE DELIVERY – COLD AND

HOT



INSTALLATION FEATURES

• SINGLE FACTORY BUILT PACKAGE• COMPACT SINGLE LIFT INTO LOCATION – ONE DAY• COMPARE TO CONVENTIONAL WHRU SYSTEM

REQUIRING MULTIPLE COMPONENTS, SEPARATELY DELIVERED AND INSTALLED – TYPICALLY 30 DAYS

• SMALLER SIZE / LOWER WEIGHT REQUIRES LESS SPACE & SUPPORTING STEELWORK

• FITTING OUT• SINGLE COMPLETE MODULE – REQUIRES CONNECTION

OF MINIMAL INTERFACES• REDUCED COMMISSIONING WORK



OPERATION & MAINTENANCE FEATURES• OPERATION

• INHERENTLY ‘GAS TIGHT’• REDUCED ELECTRIC POWER CONSUMPTION• LESS AUXILIARY EQUIPMENT – SINGLE DAMPER / NO SEAL

AIR FANS / NO TRIM COOLER

• MAINTENANCE• SUBSTANTIALLY FEWER WELDS• LESS POTENTIAL FOR EXHAUST GAS LEAKS• INHERENT HIGH INTEGRITY DAMPER SYSTEM• ALL PRESSURE PART HELICAL COILS READILY REMOVED

FROM ABOVE



CAPEX / OPEX / LIFE CYCLE COSTS

• REDUCED CAPEX• MORE COMPACT / LOWER WEIGHT – LESS MATERIALS /

SUPPORTS• LESS AUXILIARY EQUIPMENT – SINGLE DAMPER / NO SEAL

AIR FANS / NO TRIM COOLER• LOWER INSTALLATION AND COMMISSIONING COSTS

• REDUCED OPEX• REDUCED ELECTRIC POWER CONSUMPTION • HIGHER GAS TURBINE EFFICIENCY• LESS MAINTENANCE

• = REDUCED LIFE CYCLE COSTS


Helical Coil Pressure Parts Helical Coil Pressure Parts

• Helically formed & constructed from spiral Helically formed & constructed from spiral wound, resistance welded, finned tubeswound, resistance welded, finned tubes


Helical Coil Pressure PartsHelical Coil Pressure Parts

• Helical coils have lower fluid pressure drop Helical coils have lower fluid pressure drop than serpentine coils as the bends are than serpentine coils as the bends are continuous and gradual rather than sharp 180 continuous and gradual rather than sharp 180 deg.deg.

• This beneficially improves heat transfer as the This beneficially improves heat transfer as the fluid is continuously spiralling giving added fluid is continuously spiralling giving added turbulence & increased heat transfer rates turbulence & increased heat transfer rates

• Accordingly less tube surface is required than Accordingly less tube surface is required than with serpentine coils for equal dutywith serpentine coils for equal duty



• All of the helical coil surface lies All of the helical coil surface lies ‘effectively’ in the gas stream – whilst with ‘effectively’ in the gas stream – whilst with serpentine coils the bends are outside the serpentine coils the bends are outside the gas streamgas stream

• EVOLUTION units can be either top or EVOLUTION units can be either top or bottom supported, depending on the bottom supported, depending on the process, supplementary firing, and need process, supplementary firing, and need for increased expansion flexibility.for increased expansion flexibility.



• The heating surface comprises a number The heating surface comprises a number of independent helical coils, each of independent helical coils, each individually supported on its own set of individually supported on its own set of supports. supports.



• Helical coils are wound from maximum Helical coils are wound from maximum length tubes – compared to serpentine length tubes – compared to serpentine coils some coils some 90% reduction of butt welds / 90% reduction of butt welds / preps and NDTpreps and NDT

• No cutting to length, loading into tube No cutting to length, loading into tube sheets and difficult positional weldingsheets and difficult positional welding

• With fewer / simpler welds the integrity of With fewer / simpler welds the integrity of the coil is significantly improvedthe coil is significantly improved

• Accordingly Manufacturing time / cost Accordingly Manufacturing time / cost reducedreduced



• EVOLUTION units can be either top or EVOLUTION units can be either top or bottom supported, depending on the bottom supported, depending on the required expansion flexibilityrequired expansion flexibility

• Expansion flexibility will be dictated by Expansion flexibility will be dictated by process and operational parameters – e.g. process and operational parameters – e.g. auxiliary and / or supplementary auxiliary and / or supplementary supplementary firing supplementary firing

• In the vertical configuration helical coils In the vertical configuration helical coils are fully drainableare fully drainable


Circular Radial Vane Control Circular Radial Vane Control Valve, integral with the WHRUValve, integral with the WHRU

• Innovative design with components - Innovative design with components - blades, shafts, bearings and seals - as blades, shafts, bearings and seals - as used in the industry for many years with used in the industry for many years with thousands of referencesthousands of references

• Some 200 conceptually similar control Some 200 conceptually similar control valves installed and operating. valves installed and operating.


‘‘Circular Radial Vane Control Circular Radial Vane Control DamperDamper

RADIAL VANE INLET / BYPASS DAMPER


Circular Radial Vane Control Circular Radial Vane Control Valve, integral with the WHRUValve, integral with the WHRU

• Elegant design - Reduced exhaust gas Elegant design - Reduced exhaust gas pressure drop / smoothes flow into the coil pressure drop / smoothes flow into the coil annulusannulus

• Dimensionally smaller with resultant Dimensionally smaller with resultant WHRU centre of gravity substantially WHRU centre of gravity substantially reduced reduced

• Ideal where space and weight constraints / Ideal where space and weight constraints / restrictions apply – e.g. retrofitrestrictions apply – e.g. retrofit

• Reduced structural supporting steelworkReduced structural supporting steelwork


WHRU ComparisonWHRU Comparison Titan 130, 80% Load – 16MW Heat, 40% Water/60% Titan 130, 80% Load – 16MW Heat, 40% Water/60%

GlycolGlycol

Integral Bypass

CiBAS

Evolution

Weight 32,980kgs

Footprint:22.32m2

Weight:36,800kgs

Footprint:31.92m2

Weight:31,880kgs

Footprint:20.25m2


WHRU Comparison WHRU Comparison Titan 130, 80% Load – 16MW Heat, 40% Water/60% Titan 130, 80% Load – 16MW Heat, 40% Water/60%

GlycolGlycol

Feature Units Integral Bypass CiBAS Evolution

Installation Weight kgs 32,980 37,000 31,881

Operating Weight (including fluid) kgs 34,910 39,300 34,081

Plot Area m2 22.3125 31.9225 20.25

Height m 8.7 10.5 8.6

Support Structure Width m 4.25 5.65 4.5

Support Structure Depth m 5.25 5.65 4.5

Centre of Gravity (from GT inlet flange) m 4.7 5.5 4.6

Installation time 12 hour shifts 1 1 1

Coil Maintenance Weight kgs 11,400 15,000 12,700

Coil Change Out Time 12 hour shifts 4 15 4

Level of Pre Assembly Fully Assembled Fully Assembled Fully Assembled

Delivery time Months 10 10 8

Fluid Weight kgs 1,930 2,300 2,200


ONCE THROUGH STEAM ONCE THROUGH STEAM GENERATORSGENERATORS

Innovative design, patented circular OTSG for Gas Turbines

For GT’s up to 50MWPressure – to 65bargSuperheat temperature – to 525degCSteam quantity – to 100tph

Optional firing with Ring-Burn system to increase steam output from same size unit.

CIRCULAR WHRU with RING CIRCULAR WHRU with RING BURNERBURNER

HEAT RECOVERY SOLUTIONS

Exhaust Gas In

Bolted Mounting Flange (Chimney Type)

Process Fluid In

Process Fluid Out

Ring Burner

Horizontal exhaust gas inlet for axial and side exhaust GT’s ie: LM6000, Solar Centaur, Taurus etc

Process Fluid In

Process Fluid In

Exhaust Gas In

COTSG FOR LM6000 SPRINTCOTSG FOR LM6000 SPRINT90,000lb/hr Steam at 800degC, 785psig90,000lb/hr Steam at 800degC, 785psigNOX – 2.5ppmNOX – 2.5ppmCO - 7.5ppmCO - 7.5ppm


COTSG FOR LM6000 SPRINTCOTSG FOR LM6000 SPRINTInternal ComponentsInternal Components


CO Catalyst

Steam Outlet

NH4 Injection Grid

Secondary Coils

SCR Unit

Primary Coils


MANUFACTURINGMANUFACTURING Manufacturing is usually carried out by our partner C F Struthers in the UK, however we can also manufacture in other locations around the world as required.

Millennium Works, Hull, UK, 50,000ft2 Modern Workshops, ASME U & S Stamp, ISO 9000/2000


CFS EXPERIENCECFS EXPERIENCE

45MW Fired Heater, Largest Fully Packaged Cylindrical Heater, 93.5% Efficiency, Lowest NOX 9ppm, 300te, 12m dia, 35m long



Total Akpo Project, Heat Recovery Units, 25MW Water Heaters on LM2500+ Gas Turbines



Petrobras, Brazil – Coil Assembled in Casing


CFS EXPERIENCECFS EXPERIENCETube bundle assembly

Helical Coils



CFS EXPERIENCECFS EXPERIENCEIncinerator Boiler for Waste Plant, Lancashire, UK


CFS EXPERIENCECFS EXPERIENCELarge Fabrications - Power Station Ducting

HRS Company Presentation May 2010

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