TOMORROW. A Technip Technology Publication - Issue 7 - October 2015

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1 TOMORROW A Technip Technology Publication - Issue 7 - October 2015 DIESTA: a revolution in heat exchangers One Manufacturing: consolidating technology development A broader onshore technology offer Monitoring Solutions: driving cost efficiency Tomorrow-Technip-October 2015

2 P. 8-9 A broader onshore technology offer P. 4-5 DIESTA a revolution in heat exchangers P Monitoring Solutions driving cost efficiency P. 6-7 One Manufacturing consolidating technology development Tomorrow Magazine A Technip Technology Publication Issue 7 October 2015 You can find the previous issues of Tomorrow at: tomorrow-magazine Your comments are always welcome: publicrelations@technip.com ISSN Director of Publication: Christophe Bélorgeot Chief Editor: Laura Pereira Neto Associate Editors - October 2015 issue: Nello Uccelletti, Laurent Dufour, Marc Choussat, Philip Hagyard, Jeremy Provost, Samuel Rocher, Virginie Lehning, Beatrice Vernuccio, Brian A. Roberts, Jean-François Niel, Christophe Marchand, Jean-Philippe Martin, Marie-Christine Charrier, Andrea Gragnani, Cindy Viktorin, Stan Knez, Ron Birkhoff, Laurent Decoret, Stéphane His Photography: Technip image library, Jérome Retru Design and production: Lydia Marchetti, Anne-Laure Seguette The Group Communications Department would like to thank everyone who contributed to this issue. Technip - 89 avenue de la Grande Armée Paris - France This document is printed on Heaven 42 This document is the property of Technip. Any modification, reproduction or commercial use of this document is prohibited.

3 I am pleased to introduce this new issue of Tomorrow. Since its launch three years ago, this magazine has offered a presentation of many innovative technologies that our teams have been developing, reflecting Technip s role in meeting tomorrow s world energy challenges. Nello Uccelletti President, Onshore/Offshore EDITORIAL In the challenging environment our industry is facing, technology is a competitive must for all actors. In this regards, Technip maintains, year after year, a strong focus on research and innovation, in a sector where development-to-commercialization cycle often exceeds 10 years. As for Subsea, where technology combined with leading-edge assets enables Technip to be a vertically-integrated leader from deep to shore, Onshore and Offshore also highly depend on technology, which is the starting point of every project. Expertise and know-how are so important in our activities that even for open art technologies, which are no more patented, only a few actors are able to guarantee the performance of processes and products. Technip offers a wide range of proprietary processes and equipment for Onshore and Offshore applications, some of which you discovered in previous issues of Tomorrow, such as ethylene, Fluid Catalytic Cracking Alliance, Cryomax, or Floating LNG, HVS semi, TPG500 or Spar platforms. Technip also has unique expertise and know-how in integrating technologies from third party licensors, with most of whom we formed long-standing strategic alliances over the last 50 years. In this issue, you will discover details of our portfolio of onshore technologies, which started with the first LNG plant in the early 1960 s. They were more recently widened by the acquisitions of Stone & Webster process technologies in 2012 and Zimmer Polymer Technologies late Technology allows our Onshore and Offshore teams to offer our clients optimized full-range capabilities from engineering, procurement up to construction and installation of onshore units and offshore fixed and floating platform. It also enables us to significantly increase over time, the safety and reliability of our customers installations. As well, while environmental concerns are of the utmost importance for the industry, we are able to propose more energy efficient solutions drastically lowering greenhouse and gases emissions such as CO 2, NOx and SOx. As an example, over the last 20 years, we achieved a reduction in CO 2 emissions per ton of ethylene of more than 30%. Our researchers and engineers are passionate about technology and innovation which are an integral part of Technip s DNA. I hope that you share the same passion for technology and you will find interest in reading this new issue of Tomorrow. Technip has unique expertise and know-how in integrating technologies from third party licensors, with most of whom we formed long-standing strategic alliances over the last 50 years. Tomorrow-Technip-October 2015

4 Air cooled heat exchangers are one of the most common types of process equipment and are found in most of Technip s projects. DIESTA (Dual Enhanced Surface Tubes) is a long overdue response to the need for an improvement in Air Fin Coolers. DIESTA: a revolution in air-cooled heat exchangers For decades, Air Fin Coolers (AFC s) have been used extensively to reject moderate amounts of heat into the atmosphere whenever no valuable use could be found for it. Larger quantities of heat tended to be removed using cooling water either taken directly from rivers or the sea, or from evaporative cooling towers fed with a small stream of fresh water. Over the last 25 years, AFC s have been progressively replacing traditional water cooled heat exchangers in heavy duty applications such as the main refrigerant condensers of LNG plants. Natural gas liquefaction plants are the biggest single users of AFC's today. One example will clearly describe the situation: on a 4 MMTPA liquefaction train based on the Air Products C3MR process, the largest service is the propane condenser which will reject approx. 200 MW into the atmosphere resulting in a ca. 200m long AFC. The principle of AFC s is to remove heat from a process fluid flowing inside tubes by blowing ambient air using electric motor driven fans. The tubes are installed horizontally and assembled in bundles. As heat transfer efficiency with air is low, aluminum fins are fitted on the steel tubes to increase the heat transfer area by a factor around 20 times. The need for a new industry leading product in LNG The first air cooled LNG plant was started up in 1989 in Australia but water cooling remained dominant, being used for Technip s projects in Nigeria LNG (trains 1, 2 & 3), Yemen LNG and the Qatari AP-X mega trains. The shift to AFC s results from the drive to lower project costs, the growing importance of plant reliability and the regulatory preference for air cooling that avoids any impact on the aquatic environment. However, despite this shift, AFC technology has changed little over time. In 2007, Technip and Wieland were starting to see the trend that today means the GEWA- PB tube is the dominant solution for propane evaporators and the efficiency of GEWA-KS dual enhanced tubes in the water cooled propane condensers of all six AP-X trains in Qatar was on the way to be demonstrated. However, it was realized that with few exceptions all future onshore LNG plants were going to be air cooled. Typical induced draft Air Fin Cooler There was a strong desire to transpose the GEWA- KS success to an air cooled equivalent. This resulted in the partnership with GEA-BTT, the leading supplier of AFC s for LNG and which was quick to see the opportunity of creating a new industry-leading product. DIESTA is quite simply a better exchanger. The improved heat transfer performance can be used to reduce the equipment size, to increase capacity, or to save energy.

5 4-5 A coordinated development program Technip ensured the overall economic study and the coordination of the program in terms of objectives and the cost. From our experience with dual enhanced tubes for propane evaporators, the development team had learnt that in a critical first application, a new type of equipment will be most readily accepted if it offers a lower installed cost than the traditional equipment design that it replaces. Consequently, the equipment target cost was based on this saving alone. Together the development team adopted the principles of the Technology Readiness Level of API 17N. Wieland took the lead for the definition of the internal surface geometry and its characterisation as an enhancer of heat transfer for propane condensation in particular. This entailed the construction of a purpose built test rig at Kassel University. This test rig is unique, allowing measurements in the same pressure and temperature conditions as onsite while ensuring a high level of safety for the operators. Convinced by the potential of DIESTA, Total and ADEME participated significantly to the funding of this test rig. In parallel, Wieland developed a machine capable of producing tubes with a customized internal structure, while ensuring a smooth external surface with the precise dimensions required for a good bond with the external fin. GEA-BTT took the lead for the external fin that included the screening of multiple fin geometries before selection. This was done with the support of ARMINES. Similarly to the internal structure, GEA- BTT developed the manufacturing process for high speed production of the large number of tubes required for an LNG train. Plain internal tube Enhancement of internal surface Increased turbulence, Improved heat transfer coefficient. Past Future Smooth finned surface Enhancement of external surface Better air flow distribution, Improved heat transfer coefficient. The future belongs to DIESTA A first exchanger is on order for application in a non-lng Technip project. DIESTA is now being promoted to all Technip s existing and potential clients in LNG. The outlook for DIESTA is bright not only in LNG. Today, DIESTA designs are available, thanks to the measurements performed in Kassel, data collected in an ethylene plant in Germany and Wieland s long experience with other internal structures. DIESTA designs bring big cost savings in services including gas cooling, clean fluid condensation and viscous liquid cooling. Many other applications are being found such as in gas compressor after-coolers, in refining and in ethylene for the quench water air cooler when quench water is coming from a naphtha cracker. In LNG, the highest return on investment is achieved by targeting a reduction in the condensation temperature of the refrigerant as this can increase LNG production from a pre-selected set of refrigerant compressor gas turbine drivers. This is the way in which the PB tubes are used in the propane evaporators and we can anticipate the same for DIESTA. When this happens, LNG plants will see output go up by several percent without affecting energy consumption or significantly affecting CAPEX. For further information, please contact Jeremy Provost, Heat Transfer Department Manager, Paris, France. jprovost@technip.com Read our brochure fields/publications/attachments/flyer_diesta_ web.pdf and watch our video: videos/lng-heat-exchangers Tomorrow-Technip-October 2015

6 Since the start-up of Flexibrás Açu in Brazil in 2014, Technip now operates four flexible pipe manufacturing facilities around the world. These assets are essential links in Technip s vertical integration chain and our technologies are strong competitive differentiators. A corporate initiative has been launched across the flexible pipe world to develop a consistent manufacturing strategy called ONE MANUFACTURING. The objective is to align technology and manufacturing processes and to share best practices. Through this initiative, Technip wants to reinforce its reputation for quality, safety and reliability to ensure that its tailor-made flexible pipes are the same, no matter where they are made. One Manufacturing: delivering satisfaction to our customers Better & Safer Together A dedicated international team from Brazil, France and Malaysia has been set up. They are all recognized experts in their fields (Procurement, Qualification, Technical expertise, IT, HSE, Communication, Quality, Business Performance and CAPEX). Flexible pipe design A shared strategic focus Fostering national content A strategic plan called BEST standing for Better & Safer Together has been implemented in our flexible pipe factories (see poster). This plan, led and monitored by the ONE MANUFACTURING team, is deployed through five aspirations with one common Technip s four flexible pipe plants are located in Vitória and Açu, Brazil (Flexibrás), in Le Trait, France (Flexi France) and in Tanjung Langsat, Malaysia (Asiaflex). This strong local footprint facilitates contacts with regional clients to answer local market-specific objective: delivering satisfaction to our customers. In every factory, the local strategic plans are now directly linked to these goals and are cascaded through targeted missions and specific actions to all managers and employees. requirements. Our processes require consistency in manufacturing with the same standards regardless of the plant. The ONE MANUFACTURING network is working closely with the local teams to benchmark all processes across the factories The adhesion of every factory to this new plan is beyond expectations and has facilitated a quick appropriation of the think globally, act locally concept. in order to deploy the best solutions everywhere. Acting as a hub, ONE MANUFACTURING fosters exchanges and diversity to create added value with the help of local expertise.

7 6-7 Consolidating Technology Development Field developments are becoming increasingly complex, including operations in ever deeper waters with higher pressure levels and more corrosive fluids requiring increasingly complex products too. ONE MANUFACTURING cooperates with R&D and supports innovation, developments and qualifications to prepare the next generation of flexible pipes. The program also strengthens investment optimization across the plants to anticipate and prepare now, what our clients will expect in the future. The team brings its expertise in new machinery and in strategic CAPEX: the four-year modernization and optimization project of Flexi France, the new factory in Açu dedicated to high-end pipes for the Brazilian pre-salt fields or Asiaflex for the Asia Pacific market, ensuring also that the right technologies, assets, competencies and skills are available at the right location and at the right time Asiaflex Products, Tanjung Langsat, Malaysia 2 Flexibrás Vitória, Brazil 3 Flexi France, Le Trait, France 4 Flexibrás Açu, Brazil 3 4 Facilitating and consolidating the integration of technologies For further information, please contact Jean-François Niel, Group SVP Global Manufacturing jfniel@technip.com Good communication between our four plants is essential. ONE MANUFACTURING is supporting the deployment of common IT and business performance tools in all our factories. On-line forums have been created to get support from everywhere and share lessons learnt and other relevant information, faster across the flexible community. ONE MANUFACTURING has already demonstrated its efficiency and added value. It is strengthening the bonds between our flexible pipe manufacturing plants and particularly between our main assets: our people. This initiative is definitely an advantage to be cost efficient, competitive and to maintain our leadership for the future. Tomorrow-Technip-October 2015

8 Since the formation of Technip Stone & Webster Process Technology (PT) in 2012, Technip has further enlarged its portfolio of onshore process technologies. Earlier this year, the acquisition of Zimmer Polymer Technologies was concluded and more recently PT closely aligned its expertise, alliances and research and development activities with the centers in Paris, Rome, and Lyon. The goal? To broaden the company s position as a downstream technology leader, strengthen client and partner relationships, open the door to early involvement in projects and most importantly, deliver greater value to our customers. Technip s PT business offers to the Oil & Gas, Refining, Petrochemicals, Fertilizers, Power and Mining industries technologies that are wholly and jointly owned, and others that are offered through licenses with third parties. The addition of consulting services further expands the company s worldwide market of upfront services. Broadening Technip s offering of technologies and consulting services As a leading process technology provider, PT licenses technologies, develops process design packages, supplies proprietary equipment, supports customers at start-up, guarantees plant performance and provides technical services throughout the life of a plant. With the support of two research centers in the U.S. and Germany it also invests in research and development activities that keep the technologies current. Services range from designing experiments and conducting technical and economic evaluations to testing catalysts, demonstrating processes and providing technical support to licensees. PT is also looking to actively expand its technology portfolio. PT s other mandate is to grow a technical consulting business that leverages the expertise and know-how of Technip s centers of excellence around the globe. The objective is to provide reliable information to customers at the early definition stage of a project. With coordinated support from our technology team, product lines and other resources across the company, PT helps customers plan their projects selecting each time the most profitable solution. The PT business includes an unparalleled global team of technology experts supporting worldwide business by engaging with customers early in a project s development and offering them the possibility to utilize Technip s regional project delivery organizations for the subsequent FEED and EPC phases. Technip s Process Technology Offer Technip s Onshore Consulting Services Offer Licensed proprietary technologies chosen at early stage of projects Process design packages/engineering to guarantee plant performance Assistance with plant start-up and follow-up during plant production Design, supply and installation of critical proprietary equipment Masterplanning, bankable feasibility studies Concept definition for grassroot and expansions/debottlenecking Open art unit designs Reliable investment cost estimates Profitability & financial analysis Computational Fluid Dynamics and HSE risk modeling & analysis

9 8-9 Business Domains Natural Gas Crude Oil Coal Mining Power NGL Recovery LNG Ethylene GTL Hydrogen Petrochemicals Refining CO2 Capture Process Technologies Proprietary Cryomax Technology Proprietary Cryogenic Nitrogen Rejection Technology Two Technip Stone & Webster Proprietary technologies with different clients & geographic bases - Proprietary ROG Technology Exclusive co-developer of Sasol Fischer-Tropsch reactor technology Engineering alliance with Sasol on GTL Steam reformer/proprietary technology/ complete hydrogen plant HDPE, LLDPE (INEOS alliance) LDPE (SABIC alliance) EB/SM (Badger JV, Total alliance) Polystyrene (Total alliance) Expandable Polystyrene (INEOS alliance) ABS (SABIC alliance) Polypropylene (INEOS alliance) Cumene, Bisphenol-A (Badger JV) PTA (BP alliance) Polyesters - PET, PBT Polyamides - PA6, PA6.6 Fluid Catalytic Cracking and RFCC (Axens/IFP/Total alliance) Deep Catalytic Cracking (Sinopec alliance) BenzOUT (Badger JV) Progressive Crude Distillation Exclusive alliance with Shell Cansolv for post-combustion capture Proprietary Fluosolids technology for calcining, thermal processing, and drying of metal ores and concentrates for metallurgical purposes, in combination with MECS technology for sulfuric acid production Proprietary phosphoric acid technology by the dihydrate process Technip: key provider in the onshore projects chain As a market-leading onshore downstream technology provider, Technip can offer a diversified portfolio of technologies for the production of motor fuels, plastics, fertilizers, LNG and chemicals. In addition, the company s unique position throughout the chain of onshore projects can provide our customers with best-in-class consulting services, bringing back at the concept design phase the feedback from FEED, EPC, commissioning and start-up activities. Renewables Green Chemistry Bioethanol One PT Organization Proprietary technology for bioethanol Boston/Weymouth Claremont Houston* Milton Keynes Paris Lyon Rome Zoetermeer Frankfurt Center fully dedicated to PT activities Center having selected teams dedicated to PT and Consulting activities *PT headquarters Tomorrow-Technip-October 2015

10 In the current business environment, there is an even stronger focus on cost reduction. This has also put monitoring systems in the spotlight, as they can bring cost-effective solutions to complete offshore field. Cybernetix: monitoring solutions as a means of driving cost efficiency Recording data to provide sustainable products and solutions Monitoring can be divided into two categories: monitoring of an asset (e.g. measuring bearing temperatures or vibrations of a pump to check for degradation) and monitoring of production (e.g. process flows parameters to ensure efficient handling of products). Where monitoring starts to get really valuable to an operator is when the information provided is used in a smart way. Predictive Maintenance of an equipment item, as opposed to Periodic Maintenance performed based on running hours recommendations from equipment suppliers, uses real-time data from a monitoring system to determine when maintenance is actually required. This can lead to extended times between inspections and thereby reduces the overall maintenance cost. However to gain the most advantage from Predictive Maintenance the multiplicity of information received from the monitoring systems must be analysed in a smart fashion, to provide good advice to the operator. The need for monitoring solutions for offshore mooring systems and subsea risers has been a niche market targeted by Cybernetix, a Technip entity. Increasingly, operators are understanding the value of monitoring systems for such equipment. Critical components that previously did not have any form of monitoring to predict imminent or actual failure are now available. The value of these monitoring systems is that they can monitor the fatiguing stress to which a critical component is subjected and determine the remaining life of that component. Systems to monitor component stresses are ideally installed at the start of an installation s life so that fatigue can be monitored from Day 1. Retrofittable systems however can also provide useful information about an existing facility and still allow an assessment of useful residual life. Different deployment methods address both cases. There is a great benefit to the operator in extending the life of an existing facility: to provide continuing production or utility support functions and offset final decommissioning. It is in this area that the direct relationship between monitoring systems and cost saving is easiest to demonstrate. Installing monitoring systems from Day 1 enables an operator to follow the overall behavior of components and reduce operational uncertainties during the life of an installation. The information gained can then be used to improve the components' design (e.g. by reducing safety coefficients) and improve the design software (e.g. by checking or calibrating for more accurate predictions of loadings) which will ultimately lead to lower CAPEX. Monitoring systems can bring cost-effective solutions to complex offshore fields facing safety, integrity and fatigue issues

11 10-11 The Anchor Leg Load Monitoring System is a monitoring solution for mooring lines. Different technologies can be used within the system depending on its objectives. For breakage or overstress alarms, top angles are measured by inclinometers. For stress cycling monitoring, load cells or vibrating wires (extension/compression measurements) measure parameters that enable tension calculations. By following angles or tension variations, operators have access to the actual status of the mooring lines and get valuable information to decide on maintenance or repair before a failure occurs or for making life extension decisions. The Morphopipe System is dedicated to flexible pipe risers. It is installed at a top location on the riser under the stiffener, where dynamic loads are very stringent due to environmental constraints. An array of sensors, embedded in a dedicated layer, measure the curvatures experienced by the riser. Monitoring curvature cycling loads, correlated with environment data measurements, gives access to the remaining lifetime of the equipment when compared to design calculations. In addition, the follow-up of actual dynamic cycles over the flexible riser lifetime allows re-assessment of the safety coefficients used during design phases. Some examples of how Cybernetix monitoring solutions can help reduce costs The Riser Tension Monitoring System, based on vibrating wire technology, continuously calculates the tension of a rigid riser from extension/compression measurements, allowing long-term remaining life assessment. As for flexible pipes, a better knowledge of operational behavior also helps to improve design coefficients. Maximum Curvature All the above systems, by monitoring subsea key component conditions, lead to operational risk reduction and operating cost saving. They also help to reduce design and construction uncertainties and offshore manning for inspections, which translates again into cost reductions whilst maintaining high levels of safety. For further information, please contact Virginie Lehning, Cybernetix Marketing & Technology Coordinator vlehning@cybernetix.fr Tomorrow-Technip-October2015

12 Zimmer Polymer Technologies are part of Technip The perfect polymers for your needs: Our end products, characterized by excellent quality, are processed by customers in the textile, packaging and engineering plastic markets. Technip provides engineering, project management and procurement services based on its Zimmer technologies for polyesters (PET, PBT, PTT) and polyamide (PA6, PA 6.6) production plants. Our strong research and development focus has strengthened our portfolio of technologies and helped us build an outstanding track record of more than 800 plants. Follow us on