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Atlas Copco Serving the Oil & Gas industry
In this presentation I like to focus on the the oil & gas Industry what is a great potential for future business and where we today have the product portfolio and the competences available to penetrate deaper in this market. In a first part I will present a market survey of how the market is organised and what the market channels are for the part what has a lot of opportunities. As a specific opportunity we see the sales of Zone 2 equipment, I will briefly explain what Zone 2 comprehend. Then I want to walk through the todays available product portfolio concluding in a clear vision of the Division what we want to be in the oil and gas industry. As the oil & gas market often requests specialized or customized equipment, a dedicated, flexible and versatile design & manufacturing team is required and this will be offered by AC Hurricane. PRODUCT PRESENTATION – ZoneAir XATS 1020 August 2010 Koen Verleyen
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Introducing the ZoneAir compressor range
Dedicated compressors for hazardous area applications ATEX certified for Zone 2 area No mechanical sparks / No electrical sparks / Max surface temp < 200°C Including Pyroban explosion protection system Optional Pyroban 3GP gas detection system Inside DNV offshore container
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Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits ZoneAir XATS 1020 – Applications Other ZoneAir equipment
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ATEX directive Zone classification
ATEX (ATmosphere EXplosive) is a European directive concerning equipment and protective systems intended for use in potentially explosive atmospheres. Since July 1, 2003, it is compulsory by law to certify explosion-proof equipment according to ATEX 94/9/EC. The „zones“ represent work areas in which an explosive atmosphere can occur. Note: in USA & Canada the NEC/CEC codes have different classifications. (Zone 2 = Class 1, Division 2) No hazard Safe area (rig safe) Occasional hazard Zone 2 ATEX Category 3G Frequent hazard Zone 1 ATEX Category 2G Permanent hazard Zone 0 ATEX Category 1G
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ATEX directive Zone classification
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ATEX directive Zone classification
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ATEX directive Equipment Classification
Equipment Group Group I = mining / Group II = non-mining Category from Group II Cat 3 / Cat 2 / Cat 1 Explosion material Group G = gas / D = dust Explosion sub-group IIa / IIb / IIc Temperature Class T1 / T2 / T3 / T4 / T5 / T6 Identification for Zone 2 compressors: II 3G IIa T3 CE label Notifying body (eg Sira = 0518) Explosion protection symbol
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ATEX directive Classification
Explosion groups: gases & vapors in 3 groups IIa, IIb, IIc equipment for IIc can be used for IIb and IIa Temperature class: max equipment surface temperature T6 equipment can be used for T5-T1
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ATEX directive What changes needed on our equipment?
For Category 3G equipment Technical file Avoid / isolate mechanical sparks (anti static hoses, fans, flame arrestors…) Avoid / isolate electrical sparks (eg increased safety components) Limit surface temp to <200°C (extra cooling)
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ATEX directive Protection concepts (EN60079)
This refers to principles which are suitable for preventing ignition sources in systems, devices and components.
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ATEX directive Protection concepts (EN60079) - examples
Control panel
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ATEX directive Protection concepts (EN60079) - examples
Emergency stop Battery
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ATEX directive Also the customer has a responsability !
Compliancy with ATEX 99/92/EC: minimum requirements for improving the safety & health of workers potentially at risk from explosive atmospheres.
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Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits ZoneAir XATS 1020 – Applications Other ZoneAir equipment
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Rig safe / Zone 2 compressors differences
No certification / no clear definition ATEX 94/9/EC certified for safe area only for Zone 2 area (occasional explosive hazard) Standard components Safe components (ATEX), No ignition sources Maximum 200°C surface temperature Standard engine - Some require mechanical / no electric controls - Others are OK with electronic Tier 3 / electric controls ATEX engine - Including explosion protection kit (flame arrestors, exhaust gas cooler, water cooled manifolds and turbo charger, safe electrics, …) Optional 3GP gas detection system (replacing the exhaust flame arrestor) Offshore features: spillage free frame, spark arrestor, over speed valve, pneumatic starter, battery switch, platform shutdown, manual fuel cut-off valve, offshore paint … Normally inside DNV frame ATEX certification for zone 2 requires that all electrical equipment iis ATEX certified and that surface temperature not exceeds 200degC or 392degC. To reach this very expensive equipment is required and prices go up from 5-10times a standard unit. Due to this often less specified units that only partly comply with ATEX are developed and call rigsafe or safezone. The specification is defined by the suppliers. As we look into the market there are mainly Zone2 portable compressors from IR build in 1980’s and continuously refurbished. Note: Coates Offshore has defined a “safezone” compressor – similar to rig safe but with a marine engine for lower surface T, compared to industrial engine / no certification / only for safe area.
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Atlas Copco rig safe equipment
DrillAir range - TwinAir offshore - others models on request B18-62/2175 booster offshore - other models on request NOTE: please specify exactly the requried features, because customers have different view on rig safe specification
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Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits ZoneAir XATS 1020 – Applications Other ZoneAir equipment
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Atlas Copco ZoneAir XATS 1020
Model : ZoneAir XATS 1020 ATEX 94/9/EC certified for Zone 2 Powered by Cummins QSM 11 engine (Tier 3) 15 ft DNV container FAD Pressure 1020 cfm / 29 m3/min 150 psi / bar
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Specifications ATEX 94/9/EC certified for Group II Cat 3 IIa T3
Fully CE compliant compressor DNV certified 15ft container + certified slings 3-layer offshore paint (epoxy, polyurethane) Sound attenuated (OND compliant) Cummins QSM 11 Tier 3 engine (500 hp) Pyroban explosion protection system Pneumatic starter with air reservoir Pyroban 3GP gas detection system (option) Stainless steel fueltank for 8 hours operation (option) External fuel tank connections SS braided fuel lines Manual fuel cut-off valve
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Specifications (2) Atlas Copco C190 element with auto regulating system & separator tank Aftercooler + waterseparator and auto drain system Internal Lighting Stackable for transport and operation Separate air inlet duct for cooler air Spillage free subframe (110% bonded) – can slide out for repair and maintenance jobs Forklift slots Stainless Steel hardware Marine cable transfer point Central drains
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Specifications (3) Anti-static fans and belts
Teflon coated Aluminum coolers Earthing point ATEX control panel with SS lockable cover 2 horns and flasher lights 2 E-stops on opposite sides Emergency Platform Shutdown ESD Ambient conditions -10°C - +50°C All technical documentation, certificates, manuals, drawings
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Engine Cummins ATEX engine QSM11 Tier 3 compliant engine
Power: 500 hp, de-rated to 352 hp (262 kW) for ATEX application 6-cylinder with 10.8-litre displacement Pneumatic starter with air reservoir for +3 start attempts Shutdown on overspeed, low oil pressure, high water temp, gas detection Pyroban kit included
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Pyroban explosion protection
Inlet Shutdown valve | shuts engine down if engine overspeeds. Also contains integral inlet flame arrester. Water cooled exhaust gas cooler | limits surface and exhaust temperatures to the specified temperature class. Water cooled exhaust flexible | Maintains temperature Class whilst insulating engine vibration / movement Spark arrester | Stops hot carbon particles exiting the system Crankcase / Airbox breather | Pyroban EExd flameproof alternator | Pyroban EExe increased safety battery | Exhaust Flame arrester | heavy, maintenance intensive component used to prevent flames reaching atmosphere from the exhaust system Option 3GP | gas detection system (eliminates exhaust flame arresters)
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Pyroban engine components
Exhaust temp switch 195°C set point Easily re-calibrated Simple functionality test Volt free N/C contact Opens on rising temperature M20 gland entry ½ inch NPT thread fitting Water temp switch 100°C set point Easily re-calibrated Simple functionality test Volt free N/C contact Opens on rising temperature M20 gland entry ½ inch NPT thread fitting
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Pyroban engine components
Oil pressure switch 0.8 bar falling set point Easily re-calibrated Simple functionality test Volt free N/O contact Closes on rising pressure M20 gland entry 1/4 inch NPT thread fitting Speed sensor Magnetic flywheel pick up Supplied with connector and lead Covered under 3GP system cert 5/8-18UNF thread Supplied with 5/8 to 3/4-16 UNF adapter
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Solenoid control valve
Pyroban engine components E-stop switch ATEX certified EEx de Volt free contacts N/C Open to shutdown Panel mount Supplied as standard Solenoid control valve ATEX certified EEx d 12V and 24V dc versions M20 gland entry ¼ inch NPT pipe fittings Controls air intake flap Controls fuel ram Universal port configuration Suitable for gaseous and liquid media
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Pyroban engine components
Pyroban ESB battery ATEX/ EC Ex certified Ex de 12V 110AHr or 24V 55AHr Deep discharge AGM (absorbed glass matt) cell construction Integral battery isolator Stainless Steel 316 Supplied fully charged / Suitable for air freight Alternator ATEX/IECEx certified Exd 12V 45A DC or 24V 16A DC or 24V 25A DC Supplied with 4m or 8m cable Min 2000 RPM, Max 8000 RPM
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Pneumatic starter Model: Jetstream from IPU
Pre-engaged air starter eliminates the possibility of sparks. Air reservoir inside container, external filling point + internal re-fill when compressor is running
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Engine Surface temp + exhaust gas temp < 200°C
Confirmed by thermal tests
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Fuel system Stainless steel fueltank for +8 hrs operation at full load
External fuel supply (3-way valve) for bulk tank connection Manual fuel cut-off valve Mechanical fuel gauge in fueltank (level indication)
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Fuel system Fuel pre-filter 30 micron + water separator
Cummins fuel filter Stainless Steel braided fuel lines
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Compressor New AC C190 element
Same components as the standard XATS 456 / XATS 950 Best in class performance and efficiency
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Control system Ex d (flame proof) box with digital controller Xc2002 ATEX + Intrinsic Safe barriers Ex e (increased safety) box with remote push buttons + analogue gauges for vessel pressure & discharge temperature. 3GP display of gas detection system (option) 2 E-stops on opposite corners
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Control system Intrinsic safe transmitters (ATEX approved)
Regulating p / vessel p / air discharge p Element T / air discharge T oil stop valve p sensor Fuel level switch (low level warning)
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Control system 2 ATEX horns and flash lights on opposite corners
active at safety shutdown
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Customer connections Marine cable transfer point
Water proof entrance for external power supply (ESD and internal lights) Filling point for air reservoir (6-12 bar air pressure) 2 “ air discharge (will become 2* 2” + 2* ¾”) After cooler drain + water separator drain (auto + manual override)
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Cooling system Cold air in from long sides / hot air out from short sides Engine cooling with direct fan drive (2-pump – 2-loop system) Compressor cooling with hydraulic fan drive
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Oil reservoir for hydraulic fan drive
Cooling system Oil reservoir for hydraulic fan drive
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Cooling system Cummins 2-pump – 2-loop system: the extra low temp cooler loop is necessary to meet the Tier 3 emission levels while improving engine performance and efficiency. ENGINE COOLERS COMPRESSOR COOLERS Driver therm. 90°C Passenger therm. 60°C Pump Plenum / Collector Exhaust heat exchanger IC Cummins Outer Rad. Inner C190 After cooler Hydraulics Oil E6 E5 E8 Engine pump
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Central drains Drain liquids fast and efficient
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Exhaust muffler Including spark arrestor Heat wrap will be installed
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Pyroban exhaust gas cooler
Will be placed horizontally underneath engine on ASR Unit 2
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Sub frame Slide out the sub frame for major repair jobs
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General overview Horn + flashlight Control Panel Emergency stop
Fuel pre-filters Central drains 3GP system + calibration bottles Battery + isolation switch Hydraulic oil tank for fan drive Fuel tank Fuel fill neck + manual cut-off valve
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General overview (2) Air reservoir for air starter
Compressor oil filters Air filters
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Pyroban 3GP gas detection (optional)
Pro-active gas detection system with forced gas calibration Full ATEX 94/9/EC compliance Provides redundant safety shutdown system (essential to 94/9/EC compliance) Extra I/O’s for customized control and monitoring Replace the exhaust flame traps Reduce offshore maintenance and guarantee longer uptime (no 8-24 hr maintenance intervals) Reduce engine back pressure and therefore increase life expectancy No solvent disposal, better for environment
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Pyroban 3GP gas detection (optional)
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Calibration gas bottle
Pyroban 3GP gas detection (optional) Main Enclosure Gas Sensing Head Houses main electronics IP68 stainless steel 316 Din rail assembly EEx n certified (non-sparking) Integral gas test on start up IP54 stainless steel 316 Gore Tex gas path Pellistor based sensing technology Calibration gas bottle User Display Integral low bottle pressure switch (15 bar) 1 bar output pressure 2 litre 200 bar bottle contents Available worldwide 0.5% propane in air (25% of LEL Propane) Non flammable, non toxic, non asphyxiant. IP66 stainless steel Override & set up functions under flap Clear, wide temperature range display
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ZoneAir 3D tool – features & benefits
Learn about the top 15 features & benefits Available on
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Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits ZoneAir XATS 1020 – Applications Other ZoneAir equipment
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Field de-commissioning
ZoneAir applications Offshore life cycle Field exploration Field development Field Production Field de-commissioning UBD drilling Cuttings handling Well testing UBD drilling Pipeline testing, de-watering, dyring Fracturing Gas lifting sandblasting Painting Fracturing Gas lifting Inert gas blanketing Cleaning Dismantling Disposal
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Well testing (gas flairing)
Explore financial viability of the well: By analysing oil content, gas content, water content, mud/sand content By analysing pressure (stable or drop) Equipment is able to: Quickly control pressure & flow rate at the surface Separate the resulting effluent into 3 separate fluids (Gas, oil & water). Collect samples Disposal of resulting waste fluids/gases in an environmentally sound manner. Excess gases are burnt off using compressed air to accelerate the flow = GAS FLAIRING
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Well testing: typical rental package
compressor 2,200 – 4, bar >> gas flairing + pneumatic controls Saturated steam generator 4.5 MBTU 10 bar >> raise effluent temp, reduce viscosity for better separation Sand Filters Heat exchangers 2 operators (1 per shift)
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Sandblasting & painting
Maintenance on offshore rigs or FPSO vessels require rig safe or Zone 2 equipment. XATS 1020 delivers air for typically 3 nozzles.
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Drilling waste management
Development wells will be drilled to tap into the underlying hydrocarbons Large quantities of waste materials including drill cuttings and lubricating fluid (drilling mud) must be dealt with, depending on regional legislation Methods of disposing vary from region to region, and range from discharging directly into the sea (frequently used offshore Asia Pacific) to storing waste in silos for shipping onshore and safe disposal Air compression systems are used in order to facilitate the transportation of drill cuttings, through processing equipment and into silos for offloading Rig safe compressors are typically used as they do not need to be positioned in the hazardous areas, although some North Sea customers prefer to use Zone II as a best practice measure due to the added safety benefits
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Drilling waste management
Different types of MUDS can be used: Oil based muds (OBM) Water based muds (WBM) Synthetic based Muds (SBM)
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Underbalanced drilling (UBD)
Procedure used to drill oil and gas wells where the pressure in the wellbore is kept lower than the fluid pressure in the formation being drilled. As the well is being drilled, formation fluid flows into the wellbore and up to the surface
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N2 / O/G Gas lifting N2 / O/G N2 Inert gas is injected into the drilling mud to reduce its its hydrostatic force throughout the well depth. This gas is commonly nitrogen, but air, CO2, processed gas and natural gas are alternatives Advantages: Avoid formation damages Increase rate of penetration Avoid differential sticking (drill pipe stuck to the wall) O/G O/G O/G O/G
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Pipeline Services Pipeline services Cleaning Dewatering Drying
Inspection Coating Corrosion Mechanical Wiping Pigs Cracks Leakages Coating pig De-watering Pigs Cleaning Pigs Deformations Temperatures Abrasive Flushing
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ZoneAir applications: typical customers
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Agenda ATEX directive Rig safe <> Zone 2
ZoneAir XATS Features & benefits ZoneAir XATS 1020 – Applications Other ZoneAir equipment
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Other ZoneAir equipment
Other Zone 2 certified equipment available on demand Examples: ZoneAir PB32XRVO1550 compressor bar 5 units ordered driven by CAT C32 ATEX ZoneAir XAHS 375 compressor bar inquiries only driven by Iveco 7675si ATEX ZoneAir PB9-64/5000 booster bar 4 units ordered driven by CAT C9 ATEX
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PB32XRVO1550 Zone 2 compressor 1550 cfm / 365 psi
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ZoneAir XAHS375 ATEX certified Inside 10 ft DNV container
Driven by mechanical ATEX engine Iveco 7675si All mechanical control system (Sentinel) No electrics
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PB9-64/5000 Zone 2 booster 750 cfm / 5000 psi
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