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OSX-1 Seawater Treatment Module 2011
Cameron Process Systems Module Design and Supply - Experience and Capability October 2011
PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Get to Know Cameron Cameron is a leading provider of flow equipment products, systems and services to worldwide oil, gas and process industries. Fortune 500 company with strong balance sheet
$6.1 billion revenues in 2010
Leadership position in most every market segment served
Leading aftermarket service provider
19,500+ employees in 300+ locations worldwide PROCESS SYSTEMS
Cameron’s HSE Policy - “No One Gets Hurt, Nothing Gets Harmed” At Cameron, we are committed – ethically, financially and personally – to a working environment where no one gets hurt and nothing gets harmed.
President and Chief Executive Officer
London (Sunbury) facility YTD statistics. Total Recordable Incident Rate (TRIR) - 0.00 Lost workday incident rate (LWIR) -– 0.00 Statistics
YTD
• • • • •
0 0.00 0 0.00 100025.00
Number of recordable incidents* Total Recordable Incident Rate (TRIR) Number of lost workday accidents Lost workday incident rate (LWIR) Total hours worked
2010 0 0.00 0 0.00 7875.00
* Note: There were 2 non-recordable (minor) incidents during 2009 PROCESS SYSTEMS
Cameron’s Corporate Responsibility • To our stakeholders, to the future • The Cameron Way – how we choose to conduct ourselves • We take pride in everything we do • We live by, work by and share our core values: o Integrity o Respect o Leadership o Excellence o Innovation o Responsibility
PROCESS SYSTEMS
We are Cameron. • • • •
Known for quality and service Technology-driven Creating value Financially secure
• • • •
Building the future Committed to sustainable performance Focused on safety and well-being Delivering total solutions for our customers
PROCESS SYSTEMS
Cameron is a leading provider of flow equipment products, systems and services to worldwide oil, gas and process industries…
PROCESS SYSTEMS
Cameron’s Broad Market Coverage
Cameron is in nine market segments, offering a full suite of products and services to the drilling, production, processing, refining, petrochemical & LNG, transmission & storage and industrial segments of the industry.
Upstream to Downstream, Onshore to Offshore, Cameron is There. PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Cameron offers 60+ trusted product brands through our three business segments and ten operating divisions.
Drilling & Production Systems
Valves & Measurement
• Drilling Systems
• Distributed Valves
• Surface Systems
• Engineered & Process Valves
• Subsea Systems
• Flow Control
• Measurement Systems
Process & Compression Systems • Process Systems & Reciprocating Compression • Custom Process Systems • Centrifugal Compression Systems PROCESS SYSTEMS
A Sample of Cameron’s Solutions Comprehensive Offerings across Multiple Areas of Expertise
Aftermarket – Cameron’s CAMSERV
Unconventional Oil & Gas
Floating Production Systems (FPS)
Subsea Processing
• Integrated solutions incorporating multiple disciplines – people & products, systems & services, tools & technologies • Seamless customer experience in collaborative problem-solving • Adding quality and value to customer process from start to finish
PROCESS SYSTEMS
Company Overview Cynara Membranes CO2 Separation
SulfaTreat H2S Scavenger
Polymem UF Ultrafiltion system
Sulfaject Sulphate Reduction System
PROCESS SYSTEMS
Process Systems
PROCESS SYSTEMS
Cameron is interested in the following FPSO topsides scope:
Inlet Separation Module
LP/HP Compression modules
Crude Stabilization Module
Flare KO Module
Diluent Recovery Unit
Chemical Injection Skid
Produced Water Treatment Module
MEG Reclamation
Gas Processing Module
Seawater treatment & injection
Gas Dehydration Module
NATCO Sulphate Removal
Gas sweetening (Amine or Cyanara CO2 membrane) Unit PROCESS SYSTEMS
OIL • Free Water Knockout • NATCO® Mechanical Heater Treaters • Multi Phase Separators • PORTA-TEST Revolution® • CONSEPT ICD® • NATCO® Dual Frequency® • NATCO® Dual Polarity® •
PETRECO®
Bilectric®
• PETRECO® MeterCell
GAS • Cynara® CO2 • KCC™ MEG Reclamation • Shell / Paques • THIPOAQ® • PORTA-TEST WhirlyScrub I™, V™ • PORTA-TEST Revolution® • CONSEPT DC™ • CONSEPT IVD™ • CONSEPT SI™ • CONSEPT Spinlet™ • NATCO® CHF® Heater • NATCO® BTEX Buster® • NATCO® Desi-Dri® • NATCO® SHV™ Flare/Combuster • NATCO® Water Bath Heaters • NATCO® Glymine • Amine Treating • Glycol Dehydration • Mechanical Refrigeration • NATCO® Jewel T®
WATER Produced Water • UNICEL®Vertical Skim Vessel • WEMCO® Pacesetter® • NATCO® Cross-Flow Scrubber • VORTOIL® Deoiling Cyclones • WEMCO® ISF® • WEMCO®Depurator® • UNICEL® IGF • NATCO® Versaflo™ • PETRECO® Hydromation® Nutshell • PETRECO® Silverband Nutshell • PETRECO® Softeners • NATCO® Skim Pile • NATCO® DOX®
SOLIDS Seawater
• METROL® SeaCell® • METROL® BFCC™
• MOZLEY™ Wellhead Desander • MOZLEY™ Desanding SLC • MOZLEY™ Microspin
• METROL SeaScreen & SeaScreen Max
• MOZLEY™ Hydrotrans™
• Media Filters
• MOZLEY™ Fluidizer™
• Vacuum Deaerators • Gas Strip Deaerators
• MOZLEY™ Deltaclone™
• Polymem UF • NATCO® Sulphate Removal
PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Typical FPSO – Cameron Portfolio 1
6
13 13
2 7
3
23
17
15
22
9
21
24
25
26
4 8
5
18
27
11 20
14 12
28
19 16
PROCESS SYSTEMS
Typical FPSO – Cameron Offerings
Compression Division
Compression Division
Gas Technologies Glycol / Amine / Cynara
Oil Technologies
Oil Technologies
Water Technologies
Also includes: Valves Actuators Chokes
Meters Automation (TEST)
PROCESS SYSTEMS
Example of Packages
Completed Module
Control
Separator Vessels
Valves Compression Skid
Actuators
Module Structure
Instrumentation/ Meters
Heat Exchangers Vessel Internals
Piping Compressor
Yard Subcontract Fabricator Cameron
PROCESS SYSTEMS
FPSO Cidade de Sao Mateus, Singapore execution
PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Project Control Goals and Objectives •
• • •
Achieving the project schedule by maintaining planned activities Ensuring negative trends are predicted and addressed Monitoring performance efficiency Key Issues – – – – – – – –
Intensive Planning Project Schedule Work Breakdown Manpower Needs Time Management Progress Reporting Deliverable Tracking Material Control
PROCESS SYSTEMS
Adding Value – Project Execution •
Integrated Project Management Project Predictable Deliveries
•
From 20,000 to 50,000 man-hours projects
•
Ranging from $1MM to $100MM projects
•
Duration from 6 months to 3 years
•
Proven in-house technologies offers credibility to process guarantee Centralized Engineering – more efficient/less hours. Centralized Procurement – increased buying power – driving costs down. Managed by one company – added benefits/reduced costs to client Lead PM – from group with most significant portion. ing PMs/PEs for each package.
• • • • •
PROCESS SYSTEMS
Typical Project Organisational Breakdown Structure
PROCESS SYSTEMS
Projects Execution
Procurement Construction
Engineering Vessels & Tanks Process
Air Coolers Vessels & Tanks
Mechanical
Skids / Piping Rotating Equipment
CIE
Air Coolers
Spiral / Plate Exchangers Piping Miscellaneous Equipment Structural
Skids / Piping
Manual Valves In-Line Instruments Non In-Line Instruments
PROCESS SYSTEMS
Improved Project Schedule Assist in key documents development Drawings reviewed as completed Drawing turnaround days not weeks Clearer communication any issues resolved quickly Simultaneous working of detailed design and fabrication team progress before entire facility design completed Improved project supply chain performance
PROCESS SYSTEMS
Critical Communication Interfaces Customer Cameron Project Manager the Customer’s nominated representative Subcontract Fabricators Cameron Project Manager and the Subcontractor’s Project Manager 3rd Party Certifying Agencies Cameron Project Quality Assurance Manager and the 3rd Party Agency. The Project Manager is to be copied on all correspondence. Governmental Regulating Authorities Cameron Project Manager, assisted by the Cameron Legal representative, as required and the Governmental agency. Vendors and Suppliers Cameron Buyer and the respective vendor or supplier.
PROCESS SYSTEMS
Cost and Budget Management SAP is Cameron’s system of choice Work Breakdown Structure (WBS) WBS is a detailed definition of the SOW Budget is identified at each WBS level Contingency Management Budget is allocated in line with the Risk Management Plan
PROCESS SYSTEMS
PROCESS SYSTEMS
Schedule Management Project Planning is developed in Primavera (Cameron’s system of choice) The Schedule Identifies: Project Milestones Critical Path Activities Fixed Project Dates and Commitments Progress S Curves
PROCESS SYSTEMS
Risk Management Plan Risks, Plans Delivery Confidence is run through Pert master Criter is Cameron’s system of choice (in house developed DB) Heat Map scores Risks according to severity: High Medium Low Contingency Budget is Updated Accordingly Bi-weekly updates as a minimum PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Process Systems Technology Center – R&D Facilities
• Located in Houston
• 2 conference rooms
• ~29,000 ft2 building
• Training room
• Showcase area
• Library and file room
• 40 offices PROCESS SYSTEMS
Troubleshooting Services • •
•
• •
• • • • •
Cameron maintains an in-house and consultant service. An integrated team of specialists available to solve difficult and unusual processing problems. Combining laboratory and development services with practical experience, the team can determine the feasibility of packages for the toughest applications To their oil, water and gas products, Cameron offers: Process debottlenecking where fluid characteristics or production profiles have changed Computational fluid dynamics (CFD) evaluations Conceptual process designs and FEED studies Equipment designs to reduce equipment footprint and weight Site testing and analysis Consulting on solids handling and disposal PROCESS SYSTEMS
Other R&D Facilities • Trondheim, Norway – High pressure separation testing loop – t development activities with Statoil
• Pittsburgh, USA – CO2 membrane testing and development
• Rugby, UK – Liquid-liquid and solid liquid cyclone product improvement
• University of Manchester, UK – MEG Gas Treatment
PROCESS SYSTEMS
The value of CFD Internal Analysis
Flow Visualization and Distribution Analysis
PROCESS SYSTEMS
CFD Applications •
New tools allow rapid evaluation of floating production facility design
•
Perform CFD on startup and shutdown states and non-optimal operating conditions
•
Better able to size and analyze internal forces Normal sea states Storm states
•
Other uses New product development Vessel de-bottlenecking Process troubleshooting Component development
PROCESS SYSTEMS
Process Optimisation with PDMS •
Allows visualisation of multiple concepts during design phase
•
Visualisation facilitates enhanced operability
•
Eliminates clashes caused by multidraughting
•
Gives Manufacturing the visualisation tool
•
Easily integrates with other contractors electronically
•
Automatic isometric production ensures complete accuracy with model
•
Built-in design rules ensure proper design and ease in construction
•
Automatic BDM reduces purchasing cycle PROCESS SYSTEMS
Manufacturing Capabilities
CALGARY
ELECTRA
NEW IBERIA
MAGNOLIA
SAUDI
Carey Brightwell
David Bomer
Glenn Gros
Freddy Padron
Dave Stevens
100,500
130,000
72,000
25,500
110,000
Yard Space (Acres)
30
45
14
14
14
Shop Personnel
103
150
104
82
23
Engineering Personnel
18
5
12
2
20
10x16x5
10x14x2
N/A
N/A
10x10x2
Structural Capacity
Yes
Yes
Yes
Skid
Skid
Maximum Lift (Tons)
300
50
800
50
320
Shipping Facilities (Rail/Truck/Water)
R/T
R/T
R/T/W
T
T/W
Shop Space
Max Rolling Capacity (Width x Diameter x Thickness)
428,000 SF & 1.7 MM Standard Shift Man Hours PROCESS SYSTEMS
Cameron’s Global Network Manufacturing, Sales, Engineering and Aftermarket Worldwide presence: 300+ locations total, including 40+ manufacturing plants.
UNITED KINGDOM
CANADA
ITALY ROMANIA USA SAUDI ARABIA
MEXICO
VENEZUELA NIGERIA SINGAPORE ANGOLA
MALAYSIA INDONESIA
BRAZIL
ARGENTINA
Manufacturing Facilities
PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Adding Value – Camserv - After Market Services •
Commissioning
•
Engineering Services
•
Spares
•
Worldwide coverage
•
Retrofits & Refurbishment projects
•
Process Solution Group operational and debottlenecking studies
•
Familiar with process train/problem solving
•
Health checks
•
Training;
•
Re-Assembly, Installation and Hook-up Supervision;
•
Pre-Commissioning and Commissioning Supervision
•
Instrument Calibration PROCESS SYSTEMS
Experience Counts.... •
The company has over 80 years of experience
•
onshore and offshore, upstream, midstream and downstream
•
Comprehensive global network of aftermarket and repair facilities in the industry.
•
Centers are staffed with experienced and highly qualified personnel who know how to provide:
•
preventive maintenance services,
•
recondition products,
•
technical ,
•
repair services
•
OEM replacement parts
•
ensuring quality for the life of a client’s equipment
•
Experts are available in process engineering, preventive maintenance and debottlenecking PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Gjøa MEG reclamation unit, 2010
PROCESS SYSTEMS
Peregrino Salt and Sulphate Removal Plant Module 33,000 BPD
PROCESS SYSTEMS
Crude Stabilization Process Plant Module
1,160 Tons 11 Separator Vessels 7 Heat Exchangers 8 Horizontal Pumps 1 Compression Package 1,200 + valves 900 + instruments
PROCESS SYSTEMS
SBM Tupi Noreste FPSO “SYNERGY SUCCESS STORY”..............
Value $21m (multi package deal) •
Sulphate Reduction Membranes (Water)
•
Cynara CO2 Membranes (Gas)
•
Specialist Desalter Internals (Oil)
•
Specialist Separator Internals (ConSepT)
•
Produced Water Treatment (Water)
No other single bidder could offer all technologies A more competitive approach than any other bidder •
Fabrication – Membrane Housings in New Iberia - Packaging in UK (local to client in Holland). PROCESS SYSTEMS
OSX-1 Module • • •
• • •
Coarse Filters Cartridge Filters Sulphate Removal Membrane System SRM Feed Pump, Membranes and Clean-in-place System. Deaerator Tower – Gas Strip Type Main Injection Pump Chemical Injection System
PROCESS SYSTEMS
Mexilhao PMXL-1
C M B Companhia Mexilhão do Brasil
Dimensions: L = 20.00 meters W = 12.40 meters H = 20.00 meters Weight : 585Tons
Specifications Rich MEG Flow: 540 m3/day Max water: 240 m3/day Lean MEG Conc: 82 wt% MEG recovery 99.5% Salt Removal Rate: 4,400 kg/day PROCESS SYSTEMS
Cidade de Sao Mateus MEG
• • • • • •
Specifications Rich MEG Flow: 600m3/day Max water: 240 m3/day Lean MEG Conc: 84 wt% MEG Recovery 99.5% Salt Removal Rate: 10,200 kg/day
• • • • •
Dimensions: L = 24.00 meters W = 16.40 meters H = 27.00 meters Weight :653Tons
PROCESS SYSTEMS
Cidade de Sao Mateus M10 Crude Stabilization
• • • • •
Dimensions: L = 19,0 meters W = 27,0 meters H = 22,0 meters Weight : 762 Ton
• • •
Specifications Total Liquids: Max Produced Water:
5,600 m3/day 3,000 m3/day
PROCESS SYSTEMS
Cidade de Sao Mateus M62 Gas Condensate • • • • •
• •
Specifications Condensate:
Dimensions: L = 18,0 meters W = 25,0 meters H = 23,0 meters Weight : 911 Tons
1,600 m3/day PROCESS SYSTEMS
Cidade De Niteroi
Dimensions: L = 16.00 meters W = 9.00 meters H = 19.00 meters Weight : 300Tons
Specifications Rich MEG Flow: 100 m3/day Max water: 50 m3/day Lean MEG Conc: 84 wt% MEG Recovery 99.5% Salt Removal Rate: 2,500 kg/day PROCESS SYSTEMS
P53 PETROBRAS FPSO • Supply of three complete production modules for the Petrobras P53 Marlim Leste. • P01 TEG Dehydration and Fuel Gas treatment module, and the P03A/B Oil Separation modules includes the production, test, atmospheric and electrostatic separation processes. • Complete design and construction • The three modules represent over 3,200 metric tonnes of equipment . The 16 months delivery schedule allowed Petrobras to complete the hull conversion and transport the three modules to Brazil for final integration. • P01 Module will process over 6,000,000 Nm3/d of associated gas. Module P03A/B will treat over 180,000 bpd of crude oil. • Cameron provided the process design and procurement for all major equipment and the Singapore office was responsible for the detailed Engineering and Construction of the three modules.
PROCESS SYSTEMS
CLIENT
END
PROJECT/LOCATION
EQUIPMENT/APPLICATION
DELIVERY
Gas Dehydration & TEG Regeneration Module (400 Tons) Crude Separation, Stabilization, PWT and Fuel Gas compression module (1,000 Tons) Water Injection Module: Coarse Filters, Sulphate Reduction Package, SRM Feed Pumps, Deaearator Tower, Main Injection Pumps, Chemical Injection System
2010
FSTP
Petrobras
P56, Brazil
Petroserv
Petrobras
Pipa II , Brazil
OSX
OSX
Offshore Brazil
Aker Kvaerner
Statoil
MEG Reclamation module (300 Tons)
2009
Origin Energy, New Zealand
Gjoa Semi EPCH, Norway Kupe Gas Treatment Plant, New Origin Energy, New Zealand Zealand
Prosafe Production Services
Petrobras
FPSO Cidade de Sao Mateus, Brazil
MODEC
Petrobras
FPSO Cidade de Niteroi, Brazil
MEG Reclamation module (200 Tons) MEG Reclamation module (800 Tons) MEG Reclamation module (900 Tons) MEG Reclamation module 950 Tons) MEG Reclamation module (300 Tons)
2009 2008 2008 2008 2008
Maua, Brazil
Petrobras
Mexilhao Field Development
2008
QUIP
Petrobras
P53, Brazil
MEG Reclamation module (600 Tons) Crude Separation and Stabilization modules (1,500 Tons each) Gas Dehydration & TEG Regeneration Module (700 Tons)
2007
Gas Dehydration & TEG Regeneration Module (400 Tons)
2006
FSTP
Kerr McGee
Petrobras
P51, Brazil
Single lift 2 tier p/w treatment module comprising :3 off Liquid-Liquid Hydrocyclone vessles 6 off Solid-Liquid Hydrocyclone vessels 1 off Acquifer Water degasser vessel 1 off Produced water degasser vessel 3 Water injection booster pumps 1 Sand jetting pump ancilliary eqpt Production Separation Module (850 Tons)
Kerr McGee
Leadon, North Sea
FPSO CONSTRUCTION INC.
Petrobras
South Marlim, Campos Basin, Brasil (P 40).
NORTRANS ATLANTIC FLOATING PRODUCTION ODEBRECHT-SLP
Petronas / Vietsovpetro AFP/Texaco Statoil
Ruby, China Sea Galley, North Sea Connemara, Irish Sea
Atmospheric Separation & Pig Launcher/Receiver Module (400 tons) Gas Dehydration Package (200 Tons each) Fuel Gas Conditioning Package (150 Tons) Process Topsides NGL Recovery Module Process Topsides (Engineering Contract)
SLP/MAERSK
NSP for Conoco
MacCulloch, North Sea
Water Injection PAU
2010
2010
2007
2001
1999
1998 1998 1997
1996
PROCESS SYSTEMS
Summary •
Total systems capabilities - systems design, manufacturing, training, and service
•
The largest technology portfolio in the World
•
Our people: experience, relationships, integrity
•
Our Tools: CFD, Process Simulation design tools, and powerful Project Management Systems
•
Reliability and quality
•
Largest installed base of equipment world-wide - we’re field proven
•
COST SAVINGS - proven track record in many Alliance forms
PROCESS SYSTEMS
Cameron’s Process Systems The Total Solutions Provider • Industry’s broadest portfolio • Best Available Technology • Best-in-class project delivery • Leader in emerging technologies • Extensive Technology (R&D) facility • Process Performance Assurance • Financial Strength Your : Laszlo Szentirmai Sales Manager Eastern Europe Process Systems EACR Cameron House, 61-73 Staines Road West, Sunbury-on-Thames, Middlesex, TW16 7AH, UK TEL +44.1932.732.000 MOB +44.7740.157.501 FAX +44.1932.732.020 [email protected]
PROCESS SYSTEMS
Cameron Process Systems Module Design and Supply - Experience and Capability October 2011
PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Get to Know Cameron Cameron is a leading provider of flow equipment products, systems and services to worldwide oil, gas and process industries. Fortune 500 company with strong balance sheet
$6.1 billion revenues in 2010
Leadership position in most every market segment served
Leading aftermarket service provider
19,500+ employees in 300+ locations worldwide PROCESS SYSTEMS
Cameron’s HSE Policy - “No One Gets Hurt, Nothing Gets Harmed” At Cameron, we are committed – ethically, financially and personally – to a working environment where no one gets hurt and nothing gets harmed.
President and Chief Executive Officer
London (Sunbury) facility YTD statistics. Total Recordable Incident Rate (TRIR) - 0.00 Lost workday incident rate (LWIR) -– 0.00 Statistics
YTD
• • • • •
0 0.00 0 0.00 100025.00
Number of recordable incidents* Total Recordable Incident Rate (TRIR) Number of lost workday accidents Lost workday incident rate (LWIR) Total hours worked
2010 0 0.00 0 0.00 7875.00
* Note: There were 2 non-recordable (minor) incidents during 2009 PROCESS SYSTEMS
Cameron’s Corporate Responsibility • To our stakeholders, to the future • The Cameron Way – how we choose to conduct ourselves • We take pride in everything we do • We live by, work by and share our core values: o Integrity o Respect o Leadership o Excellence o Innovation o Responsibility
PROCESS SYSTEMS
We are Cameron. • • • •
Known for quality and service Technology-driven Creating value Financially secure
• • • •
Building the future Committed to sustainable performance Focused on safety and well-being Delivering total solutions for our customers
PROCESS SYSTEMS
Cameron is a leading provider of flow equipment products, systems and services to worldwide oil, gas and process industries…
PROCESS SYSTEMS
Cameron’s Broad Market Coverage
Cameron is in nine market segments, offering a full suite of products and services to the drilling, production, processing, refining, petrochemical & LNG, transmission & storage and industrial segments of the industry.
Upstream to Downstream, Onshore to Offshore, Cameron is There. PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Cameron offers 60+ trusted product brands through our three business segments and ten operating divisions.
Drilling & Production Systems
Valves & Measurement
• Drilling Systems
• Distributed Valves
• Surface Systems
• Engineered & Process Valves
• Subsea Systems
• Flow Control
• Measurement Systems
Process & Compression Systems • Process Systems & Reciprocating Compression • Custom Process Systems • Centrifugal Compression Systems PROCESS SYSTEMS
A Sample of Cameron’s Solutions Comprehensive Offerings across Multiple Areas of Expertise
Aftermarket – Cameron’s CAMSERV
Unconventional Oil & Gas
Floating Production Systems (FPS)
Subsea Processing
• Integrated solutions incorporating multiple disciplines – people & products, systems & services, tools & technologies • Seamless customer experience in collaborative problem-solving • Adding quality and value to customer process from start to finish
PROCESS SYSTEMS
Company Overview Cynara Membranes CO2 Separation
SulfaTreat H2S Scavenger
Polymem UF Ultrafiltion system
Sulfaject Sulphate Reduction System
PROCESS SYSTEMS
Process Systems
PROCESS SYSTEMS
Cameron is interested in the following FPSO topsides scope:
Inlet Separation Module
LP/HP Compression modules
Crude Stabilization Module
Flare KO Module
Diluent Recovery Unit
Chemical Injection Skid
Produced Water Treatment Module
MEG Reclamation
Gas Processing Module
Seawater treatment & injection
Gas Dehydration Module
NATCO Sulphate Removal
Gas sweetening (Amine or Cyanara CO2 membrane) Unit PROCESS SYSTEMS
OIL • Free Water Knockout • NATCO® Mechanical Heater Treaters • Multi Phase Separators • PORTA-TEST Revolution® • CONSEPT ICD® • NATCO® Dual Frequency® • NATCO® Dual Polarity® •
PETRECO®
Bilectric®
• PETRECO® MeterCell
GAS • Cynara® CO2 • KCC™ MEG Reclamation • Shell / Paques • THIPOAQ® • PORTA-TEST WhirlyScrub I™, V™ • PORTA-TEST Revolution® • CONSEPT DC™ • CONSEPT IVD™ • CONSEPT SI™ • CONSEPT Spinlet™ • NATCO® CHF® Heater • NATCO® BTEX Buster® • NATCO® Desi-Dri® • NATCO® SHV™ Flare/Combuster • NATCO® Water Bath Heaters • NATCO® Glymine • Amine Treating • Glycol Dehydration • Mechanical Refrigeration • NATCO® Jewel T®
WATER Produced Water • UNICEL®Vertical Skim Vessel • WEMCO® Pacesetter® • NATCO® Cross-Flow Scrubber • VORTOIL® Deoiling Cyclones • WEMCO® ISF® • WEMCO®Depurator® • UNICEL® IGF • NATCO® Versaflo™ • PETRECO® Hydromation® Nutshell • PETRECO® Silverband Nutshell • PETRECO® Softeners • NATCO® Skim Pile • NATCO® DOX®
SOLIDS Seawater
• METROL® SeaCell® • METROL® BFCC™
• MOZLEY™ Wellhead Desander • MOZLEY™ Desanding SLC • MOZLEY™ Microspin
• METROL SeaScreen & SeaScreen Max
• MOZLEY™ Hydrotrans™
• Media Filters
• MOZLEY™ Fluidizer™
• Vacuum Deaerators • Gas Strip Deaerators
• MOZLEY™ Deltaclone™
• Polymem UF • NATCO® Sulphate Removal
PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Typical FPSO – Cameron Portfolio 1
6
13 13
2 7
3
23
17
15
22
9
21
24
25
26
4 8
5
18
27
11 20
14 12
28
19 16
PROCESS SYSTEMS
Typical FPSO – Cameron Offerings
Compression Division
Compression Division
Gas Technologies Glycol / Amine / Cynara
Oil Technologies
Oil Technologies
Water Technologies
Also includes: Valves Actuators Chokes
Meters Automation (TEST)
PROCESS SYSTEMS
Example of Packages
Completed Module
Control
Separator Vessels
Valves Compression Skid
Actuators
Module Structure
Instrumentation/ Meters
Heat Exchangers Vessel Internals
Piping Compressor
Yard Subcontract Fabricator Cameron
PROCESS SYSTEMS
FPSO Cidade de Sao Mateus, Singapore execution
PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Project Control Goals and Objectives •
• • •
Achieving the project schedule by maintaining planned activities Ensuring negative trends are predicted and addressed Monitoring performance efficiency Key Issues – – – – – – – –
Intensive Planning Project Schedule Work Breakdown Manpower Needs Time Management Progress Reporting Deliverable Tracking Material Control
PROCESS SYSTEMS
Adding Value – Project Execution •
Integrated Project Management Project Predictable Deliveries
•
From 20,000 to 50,000 man-hours projects
•
Ranging from $1MM to $100MM projects
•
Duration from 6 months to 3 years
•
Proven in-house technologies offers credibility to process guarantee Centralized Engineering – more efficient/less hours. Centralized Procurement – increased buying power – driving costs down. Managed by one company – added benefits/reduced costs to client Lead PM – from group with most significant portion. ing PMs/PEs for each package.
• • • • •
PROCESS SYSTEMS
Typical Project Organisational Breakdown Structure
PROCESS SYSTEMS
Projects Execution
Procurement Construction
Engineering Vessels & Tanks Process
Air Coolers Vessels & Tanks
Mechanical
Skids / Piping Rotating Equipment
CIE
Air Coolers
Spiral / Plate Exchangers Piping Miscellaneous Equipment Structural
Skids / Piping
Manual Valves In-Line Instruments Non In-Line Instruments
PROCESS SYSTEMS
Improved Project Schedule Assist in key documents development Drawings reviewed as completed Drawing turnaround days not weeks Clearer communication any issues resolved quickly Simultaneous working of detailed design and fabrication team progress before entire facility design completed Improved project supply chain performance
PROCESS SYSTEMS
Critical Communication Interfaces Customer Cameron Project Manager the Customer’s nominated representative Subcontract Fabricators Cameron Project Manager and the Subcontractor’s Project Manager 3rd Party Certifying Agencies Cameron Project Quality Assurance Manager and the 3rd Party Agency. The Project Manager is to be copied on all correspondence. Governmental Regulating Authorities Cameron Project Manager, assisted by the Cameron Legal representative, as required and the Governmental agency. Vendors and Suppliers Cameron Buyer and the respective vendor or supplier.
PROCESS SYSTEMS
Cost and Budget Management SAP is Cameron’s system of choice Work Breakdown Structure (WBS) WBS is a detailed definition of the SOW Budget is identified at each WBS level Contingency Management Budget is allocated in line with the Risk Management Plan
PROCESS SYSTEMS
PROCESS SYSTEMS
Schedule Management Project Planning is developed in Primavera (Cameron’s system of choice) The Schedule Identifies: Project Milestones Critical Path Activities Fixed Project Dates and Commitments Progress S Curves
PROCESS SYSTEMS
Risk Management Plan Risks, Plans Delivery Confidence is run through Pert master Criter is Cameron’s system of choice (in house developed DB) Heat Map scores Risks according to severity: High Medium Low Contingency Budget is Updated Accordingly Bi-weekly updates as a minimum PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Process Systems Technology Center – R&D Facilities
• Located in Houston
• 2 conference rooms
• ~29,000 ft2 building
• Training room
• Showcase area
• Library and file room
• 40 offices PROCESS SYSTEMS
Troubleshooting Services • •
•
• •
• • • • •
Cameron maintains an in-house and consultant service. An integrated team of specialists available to solve difficult and unusual processing problems. Combining laboratory and development services with practical experience, the team can determine the feasibility of packages for the toughest applications To their oil, water and gas products, Cameron offers: Process debottlenecking where fluid characteristics or production profiles have changed Computational fluid dynamics (CFD) evaluations Conceptual process designs and FEED studies Equipment designs to reduce equipment footprint and weight Site testing and analysis Consulting on solids handling and disposal PROCESS SYSTEMS
Other R&D Facilities • Trondheim, Norway – High pressure separation testing loop – t development activities with Statoil
• Pittsburgh, USA – CO2 membrane testing and development
• Rugby, UK – Liquid-liquid and solid liquid cyclone product improvement
• University of Manchester, UK – MEG Gas Treatment
PROCESS SYSTEMS
The value of CFD Internal Analysis
Flow Visualization and Distribution Analysis
PROCESS SYSTEMS
CFD Applications •
New tools allow rapid evaluation of floating production facility design
•
Perform CFD on startup and shutdown states and non-optimal operating conditions
•
Better able to size and analyze internal forces Normal sea states Storm states
•
Other uses New product development Vessel de-bottlenecking Process troubleshooting Component development
PROCESS SYSTEMS
Process Optimisation with PDMS •
Allows visualisation of multiple concepts during design phase
•
Visualisation facilitates enhanced operability
•
Eliminates clashes caused by multidraughting
•
Gives Manufacturing the visualisation tool
•
Easily integrates with other contractors electronically
•
Automatic isometric production ensures complete accuracy with model
•
Built-in design rules ensure proper design and ease in construction
•
Automatic BDM reduces purchasing cycle PROCESS SYSTEMS
Manufacturing Capabilities
CALGARY
ELECTRA
NEW IBERIA
MAGNOLIA
SAUDI
Carey Brightwell
David Bomer
Glenn Gros
Freddy Padron
Dave Stevens
100,500
130,000
72,000
25,500
110,000
Yard Space (Acres)
30
45
14
14
14
Shop Personnel
103
150
104
82
23
Engineering Personnel
18
5
12
2
20
10x16x5
10x14x2
N/A
N/A
10x10x2
Structural Capacity
Yes
Yes
Yes
Skid
Skid
Maximum Lift (Tons)
300
50
800
50
320
Shipping Facilities (Rail/Truck/Water)
R/T
R/T
R/T/W
T
T/W
Shop Space
Max Rolling Capacity (Width x Diameter x Thickness)
428,000 SF & 1.7 MM Standard Shift Man Hours PROCESS SYSTEMS
Cameron’s Global Network Manufacturing, Sales, Engineering and Aftermarket Worldwide presence: 300+ locations total, including 40+ manufacturing plants.
UNITED KINGDOM
CANADA
ITALY ROMANIA USA SAUDI ARABIA
MEXICO
VENEZUELA NIGERIA SINGAPORE ANGOLA
MALAYSIA INDONESIA
BRAZIL
ARGENTINA
Manufacturing Facilities
PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Adding Value – Camserv - After Market Services •
Commissioning
•
Engineering Services
•
Spares
•
Worldwide coverage
•
Retrofits & Refurbishment projects
•
Process Solution Group operational and debottlenecking studies
•
Familiar with process train/problem solving
•
Health checks
•
Training;
•
Re-Assembly, Installation and Hook-up Supervision;
•
Pre-Commissioning and Commissioning Supervision
•
Instrument Calibration PROCESS SYSTEMS
Experience Counts.... •
The company has over 80 years of experience
•
onshore and offshore, upstream, midstream and downstream
•
Comprehensive global network of aftermarket and repair facilities in the industry.
•
Centers are staffed with experienced and highly qualified personnel who know how to provide:
•
preventive maintenance services,
•
recondition products,
•
technical ,
•
repair services
•
OEM replacement parts
•
ensuring quality for the life of a client’s equipment
•
Experts are available in process engineering, preventive maintenance and debottlenecking PROCESS SYSTEMS
Who are Cameron What We Deliver Module Execution Project Management – Front End – After Capital Sales Experience
PROCESS SYSTEMS
Gjøa MEG reclamation unit, 2010
PROCESS SYSTEMS
Peregrino Salt and Sulphate Removal Plant Module 33,000 BPD
PROCESS SYSTEMS
Crude Stabilization Process Plant Module
1,160 Tons 11 Separator Vessels 7 Heat Exchangers 8 Horizontal Pumps 1 Compression Package 1,200 + valves 900 + instruments
PROCESS SYSTEMS
SBM Tupi Noreste FPSO “SYNERGY SUCCESS STORY”..............
Value $21m (multi package deal) •
Sulphate Reduction Membranes (Water)
•
Cynara CO2 Membranes (Gas)
•
Specialist Desalter Internals (Oil)
•
Specialist Separator Internals (ConSepT)
•
Produced Water Treatment (Water)
No other single bidder could offer all technologies A more competitive approach than any other bidder •
Fabrication – Membrane Housings in New Iberia - Packaging in UK (local to client in Holland). PROCESS SYSTEMS
OSX-1 Module • • •
• • •
Coarse Filters Cartridge Filters Sulphate Removal Membrane System SRM Feed Pump, Membranes and Clean-in-place System. Deaerator Tower – Gas Strip Type Main Injection Pump Chemical Injection System
PROCESS SYSTEMS
Mexilhao PMXL-1
C M B Companhia Mexilhão do Brasil
Dimensions: L = 20.00 meters W = 12.40 meters H = 20.00 meters Weight : 585Tons
Specifications Rich MEG Flow: 540 m3/day Max water: 240 m3/day Lean MEG Conc: 82 wt% MEG recovery 99.5% Salt Removal Rate: 4,400 kg/day PROCESS SYSTEMS
Cidade de Sao Mateus MEG
• • • • • •
Specifications Rich MEG Flow: 600m3/day Max water: 240 m3/day Lean MEG Conc: 84 wt% MEG Recovery 99.5% Salt Removal Rate: 10,200 kg/day
• • • • •
Dimensions: L = 24.00 meters W = 16.40 meters H = 27.00 meters Weight :653Tons
PROCESS SYSTEMS
Cidade de Sao Mateus M10 Crude Stabilization
• • • • •
Dimensions: L = 19,0 meters W = 27,0 meters H = 22,0 meters Weight : 762 Ton
• • •
Specifications Total Liquids: Max Produced Water:
5,600 m3/day 3,000 m3/day
PROCESS SYSTEMS
Cidade de Sao Mateus M62 Gas Condensate • • • • •
• •
Specifications Condensate:
Dimensions: L = 18,0 meters W = 25,0 meters H = 23,0 meters Weight : 911 Tons
1,600 m3/day PROCESS SYSTEMS
Cidade De Niteroi
Dimensions: L = 16.00 meters W = 9.00 meters H = 19.00 meters Weight : 300Tons
Specifications Rich MEG Flow: 100 m3/day Max water: 50 m3/day Lean MEG Conc: 84 wt% MEG Recovery 99.5% Salt Removal Rate: 2,500 kg/day PROCESS SYSTEMS
P53 PETROBRAS FPSO • Supply of three complete production modules for the Petrobras P53 Marlim Leste. • P01 TEG Dehydration and Fuel Gas treatment module, and the P03A/B Oil Separation modules includes the production, test, atmospheric and electrostatic separation processes. • Complete design and construction • The three modules represent over 3,200 metric tonnes of equipment . The 16 months delivery schedule allowed Petrobras to complete the hull conversion and transport the three modules to Brazil for final integration. • P01 Module will process over 6,000,000 Nm3/d of associated gas. Module P03A/B will treat over 180,000 bpd of crude oil. • Cameron provided the process design and procurement for all major equipment and the Singapore office was responsible for the detailed Engineering and Construction of the three modules.
PROCESS SYSTEMS
CLIENT
END
PROJECT/LOCATION
EQUIPMENT/APPLICATION
DELIVERY
Gas Dehydration & TEG Regeneration Module (400 Tons) Crude Separation, Stabilization, PWT and Fuel Gas compression module (1,000 Tons) Water Injection Module: Coarse Filters, Sulphate Reduction Package, SRM Feed Pumps, Deaearator Tower, Main Injection Pumps, Chemical Injection System
2010
FSTP
Petrobras
P56, Brazil
Petroserv
Petrobras
Pipa II , Brazil
OSX
OSX
Offshore Brazil
Aker Kvaerner
Statoil
MEG Reclamation module (300 Tons)
2009
Origin Energy, New Zealand
Gjoa Semi EPCH, Norway Kupe Gas Treatment Plant, New Origin Energy, New Zealand Zealand
Prosafe Production Services
Petrobras
FPSO Cidade de Sao Mateus, Brazil
MODEC
Petrobras
FPSO Cidade de Niteroi, Brazil
MEG Reclamation module (200 Tons) MEG Reclamation module (800 Tons) MEG Reclamation module (900 Tons) MEG Reclamation module 950 Tons) MEG Reclamation module (300 Tons)
2009 2008 2008 2008 2008
Maua, Brazil
Petrobras
Mexilhao Field Development
2008
QUIP
Petrobras
P53, Brazil
MEG Reclamation module (600 Tons) Crude Separation and Stabilization modules (1,500 Tons each) Gas Dehydration & TEG Regeneration Module (700 Tons)
2007
Gas Dehydration & TEG Regeneration Module (400 Tons)
2006
FSTP
Kerr McGee
Petrobras
P51, Brazil
Single lift 2 tier p/w treatment module comprising :3 off Liquid-Liquid Hydrocyclone vessles 6 off Solid-Liquid Hydrocyclone vessels 1 off Acquifer Water degasser vessel 1 off Produced water degasser vessel 3 Water injection booster pumps 1 Sand jetting pump ancilliary eqpt Production Separation Module (850 Tons)
Kerr McGee
Leadon, North Sea
FPSO CONSTRUCTION INC.
Petrobras
South Marlim, Campos Basin, Brasil (P 40).
NORTRANS ATLANTIC FLOATING PRODUCTION ODEBRECHT-SLP
Petronas / Vietsovpetro AFP/Texaco Statoil
Ruby, China Sea Galley, North Sea Connemara, Irish Sea
Atmospheric Separation & Pig Launcher/Receiver Module (400 tons) Gas Dehydration Package (200 Tons each) Fuel Gas Conditioning Package (150 Tons) Process Topsides NGL Recovery Module Process Topsides (Engineering Contract)
SLP/MAERSK
NSP for Conoco
MacCulloch, North Sea
Water Injection PAU
2010
2010
2007
2001
1999
1998 1998 1997
1996
PROCESS SYSTEMS
Summary •
Total systems capabilities - systems design, manufacturing, training, and service
•
The largest technology portfolio in the World
•
Our people: experience, relationships, integrity
•
Our Tools: CFD, Process Simulation design tools, and powerful Project Management Systems
•
Reliability and quality
•
Largest installed base of equipment world-wide - we’re field proven
•
COST SAVINGS - proven track record in many Alliance forms
PROCESS SYSTEMS
Cameron’s Process Systems The Total Solutions Provider • Industry’s broadest portfolio • Best Available Technology • Best-in-class project delivery • Leader in emerging technologies • Extensive Technology (R&D) facility • Process Performance Assurance • Financial Strength Your : Laszlo Szentirmai Sales Manager Eastern Europe Process Systems EACR Cameron House, 61-73 Staines Road West, Sunbury-on-Thames, Middlesex, TW16 7AH, UK TEL +44.1932.732.000 MOB +44.7740.157.501 FAX +44.1932.732.020 [email protected]
PROCESS SYSTEMS
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