Business Centre for

FPSOs and FSOs

Boilers etc for

FPSOs and FSOs

North Sea Producer (ex Dagmar Maersk)

from Aalborg Industries

Business & Product Centre

- fitted
for FPSOs,
FSOs with
and rigs HRSG

Aalborg Industries
Brazil

International market
& customers

Aalborg Industries
South Korea

Aalborg Industries
USA

Aalborg Industries
The Netherlands

Aalborg Industries
Dubai
Agents

Business & Product Centre

for FPSOs, FSOs and rigs

Aalborg Industries A/S

Denmark

Aalborg Industries KK
Japan
Aalborg Industries AB
Business & Product Centre
for FPSOs
Market Coordination
Marketing, Sales & Support
Business Development
Technical Coordination
Project Management

Aalborg Industries Pte

Singapore

Aalborg Industries Ltd

China / Hong Kong

After Sales
Boiler conversions & repairs
Installation, supervision,
start-up etc

We can supply the whole

boiler plant
Design and supply of equipment
Turn-key installation
Clients specification

Supervision
Start-up

Business & Product Centre

for FPSOs, FSOs and rigs

System design
Equipment supply
Project management
Guarantee

Installation
Platforms etc

Tanker conversions into FPSOs

Conversion of existing boilers
Installation of new boiler system
Clients specification

AI co-ordination by Business Centre or After Sales

New Boiler System

Boiler Conversion

Preliminary studies
Steam, hotwater, thermal oil
Boilers, burners and control
Other related equipment
IGS, heat exchangers

Inspection and report

Repair or conversion
Boiler body retrofit
Burner upgrading
Installation of new burner

By Business Centre
Business & Product Centre
for FPSOs, FSOs and rigs

By After Sales

Boiler plants for

oil & gas industry
From a technical point of view the boiler system for
an offshore rig or FPSO is very similar to a boiler
system for a petrochemical industry
Our combined experience from marine boilers and
land based industrial plants gives us an excellent
base when working with offshore projects.

Business & Product Centre

for FPSOs, FSOs and rigs

Quality and classification

Quality audits by client

ISO 9001 quality certification
All leading classification societies

Business & Product Centre

for FPSOs, FSOs and rigs

Engineering - basic principles

Business & Product Centre

for FPSOs, FSOs and rigs

Basic criteria
Design life length for the FPSO is normally
20 - 25 years
In case the FPSO cannot pump oil the lack of
income is 2.5 - 5 MUSD each day, depending
on its capacity
The sooner the FPSO can be on the field the
sooner the owner can start counting his money
The boilers are normally fired with gas and
crude as leading fuels with diesel as back-up
Hazardous area or safe area - On deck or in
the engine room
Business & Product Centre
for FPSOs, FSOs and rigs

Design life length 20 - 25 years

No compromises in system design
Best equipment from the most reliable suppliers

Business & Product Centre

for FPSOs, FSOs and rigs

In case the FPSO cannot pump oil .

With an oil price of approx 25 USD per barrel the
lack of income would be 5 MUSD per day for a
200.000 bpd FPSO
Essential to have redundancy in terms of important
functions onboard the FPSO, for instance boilers,
turbines etc

Business & Product Centre

for FPSOs, FSOs and rigs

Gas firing
Higher temperature from furnace to exhaust
Design the superheater based on higher temperatures
Higher draft loss
De-rate the boiler approx 10%

Business & Product Centre

for FPSOs, FSOs and rigs

On deck / engine room? Hazardous / safe area?

Even if the area is classified as safe, it gets hazardous
within 3 metre radius from a potential gas leakage
On deck - hazardous area
On deck - safe area
Engine room - safe area

Business & Product Centre

for FPSOs, FSOs and rigs

On deck, exposed to harsh weather

Special painting of boilers and FW tank
Valves and fittings with makers painting for offshore
installation
Insulation with stainless cladding and silicon sealing
Electric motors normally IP 56
Material must withstand harsh weather

Business & Product Centre

for FPSOs, FSOs and rigs

Suggestions
Co-operate with an experienced boiler supplier already
from the early design phase.
Specify only the real necessary items, let the supplier
make the design and take the responsibility for his system.
The combustion system is a complex part of the boiler
system. In order to reduce the number of interfaces to a real
minimum we suggest the whole system to be supplied by
one supplier.

Business & Product Centre

for FPSOs, FSOs and rigs

A wide range of products

and services

Business & Product Centre

for FPSOs, FSOs and rigs

Aalborg Industries can offer

Boilers for Steam and Hot water
Boilers for Thermal Fluid
Heat Recovery after Gas Turbines
Heat recovery after Diesel Engines
Inert Gas Systems
Heat Exchangers
Turn-key installation
Boiler conversions and retrofits
Service and spare parts
Business & Product Centre
for FPSOs, FSOs and rigs

Steam boiler system

Oil or gas fired steam boiler type
MISSION OM

MISSION OL
MISSION D
Steam for process

Single or multiple boiler system

Temperature
control for
FW tank

Make-up water

Condensate

FW tank
Burner for various
fuels such as Gas,
Crude, MDO, HFO

Dosing

Business & Product Centre

for FPSOs, FSOs and rigs

2 x 100% FW pumps
one pump in operation,
one in automatic stand-by

Control panel
local at boiler
remote

Hot water system

Oil or gas fired cylindrical hot water
boiler type
SUNROD CHS
Expansion tank

Single or multiple boiler system

N2
Hot water outlet
Hot water inlet

Make-up
pump

Min flow control

Burner for various
fuels such as Gas,
Crude, MDO, HFO

Dosing
Business & Product Centre
for FPSOs, FSOs and rigs

Distribution pumps, one pump

per boiler in operation, one in
automatic stand-by

Control panel
local at boiler
remote

MISSION OM
SUNROD CHS
Compact and strong design thanks to membrane walls
and pin tubes
Easy to inspect and to keep clean
Side fired which makes the boiler easy to ventilate and
gives easy access to the burner and its controls
High efficiency, especially on part loads, gives
outstanding total fuel economy
Very dry steam (slightly superheated)
This boiler can also be delivered as a hotwater boiler SunrodTM CHS - up to a capacity of 30 MW
Business & Product Centre
for FPSOs, FSOs and rigs

MISSION OM
up to 45 t/h, 24 bar

Business & Product Centre

for FPSOs, FSOs and rigs

SUNROD CHS
- 30 MW, 24 bar

Business & Product Centre

for FPSOs, FSOs and rigs

MISSION OL
Compact and strong design thanks to membrane
walls and two drums
Top fired
High efficiency, especially on part loads, gives
outstanding total fuel economy

Business & Product Centre

for FPSOs, FSOs and rigs

MISSION OL
12 - 55 t/h, 18 bar

Business & Product Centre

for FPSOs, FSOs and rigs

MISSION D-type
For capacities above medium range
Design based on our long experience from industrial
boilers as well as from boilers for marine steam
propulsion systems
Strong and compact design
High efficiency, especially on part loads, gives
outstanding total fuel economy
Quick response to load variations

Business & Product Centre

for FPSOs, FSOs and rigs

MISSION D-type
Up to 120 t/h

Business & Product Centre

for FPSOs, FSOs and rigs

Two MISSION D boilers (size 100 t/h)

Business & Product Centre

for FPSOs, FSOs and rigs

Our MISSION D-type

Probably the best FPSO
boiler
on the market!

Business & Product Centre

for FPSOs, FSOs and rigs

MISSION 3-pass
For steam or hot water - Pre-assembled unit

Business & Product Centre

for FPSOs, FSOs and rigs

THERMAL FLUID BOILERS

CAPACITIES UP TO 20 MW

VERTICAL OR HORIZONTAL

MINERAL OIL / SYNTHETIC FLUID

Business & Product Centre

for FPSOs, FSOs and rigs

Thermal Fluid Heater

Business & Product Centre

for FPSOs, FSOs and rigs

Thermal Fluid Heater

Business & Product Centre

for FPSOs, FSOs and rigs

Aalborg Industries
can deliver the whole
system
Standard Steam Boilers up to 120 t/h per boiler
Hot Water up to 30 MW per boiler
Thermal Oil up to 20 MW per boiler
Heat Recovery Boilers after Gas Turbines or Diesel
Engines
Inert Gas Systems
Heat Exchangers
Business & Product Centre
for FPSOs, FSOs and rigs

Gasturbine or Steam?
Typical FPSO:
The FPSO needs steam for the process plus power
for pump drives, compressors etc. Which is best?

Space requirement?
Investment cost?
Maintenance intervals and costs?
Operation cost?

Business & Product Centre

for FPSOs, FSOs and rigs

Gasturbine or Steam?
Comparisons have shown that

Steam boilers with TGs normally need more space

Steam systems is less expensive to install
Maintenance of GTs are by far more expensive
Operation cost is much lower for a steam system
The total cost (CAPEX + OPEX) for a system with
GTs with Heat Recovery boilers is often 2 to 4 times
the cost for a steam alternative!

Business & Product Centre

for FPSOs, FSOs and rigs

Hot Water or Thermal

Fluid?
Water above 100 C needs to be pressurised
Thermal fluids can be heated above 200 C at
atmospheric pressure
Different thermal fluids can be used. Normally
mineral oil, but for higher temperatures synthetic
fluids must be used.

Business & Product Centre

for FPSOs, FSOs and rigs

Hot Water or Thermal

Fluid?
A system with thermal fluid cannot corrode. The
water in a hot water system needs to be treated
to normal boiler water quality. But hot water
systems are normally closed systems, so the
need of make-up water is very limited.
Thermal fluid cannot freeze. Hot water can be
mixed with glycol to avoid freezing and corrosion.
Maintenance costs are low in both cases.

Business & Product Centre

for FPSOs, FSOs and rigs

Steam, Hot Water or

Thermal Fluid?

Regardless if the system shall be designed for

steam, hot water or thermal fluid - We can
supply the whole heating system!

Business & Product Centre

for FPSOs, FSOs and rigs

Combustion systems

Burners for single, dual or triple fuel firing

For gas, condensate, crude, HFO or MDO

Business & Product Centre

for FPSOs, FSOs and rigs

We have adopted the steam

atomised burner as our
standard
Easy to install and to operate
Excellent turn down
Burns a wide range of fuels
Robust design
Limited need of maintenance
Low oxygen content
For hot water boilers air is used to atomise the fuel

Business & Product Centre

for FPSOs, FSOs and rigs

KBSD steam atomised

burner
for oil firing - top view

Business & Product Centre

for FPSOs, FSOs and rigs

KBSD steam atomised burner

for oil firing - diagram

Business & Product Centre

for FPSOs, FSOs and rigs

Dual Fuel Burners (make:

Hamworthy)
for Daewoo / Terra Nova
2 x 25 t/h, gas and diesel oil

Business & Product Centre

for FPSOs, FSOs and rigs

Inert Gas Systems

Risk management during unloading and tank
cleaning is crucial on board an FPSO or an FSO.
We offer compact IGS systems using the flue gas
from the boilers
Low installation cost
Lowest possible operation cost

Business & Product Centre

for FPSOs, FSOs and rigs

Inert Gas Systems

To funnel
To funnel

Scrubber
P/V breaker
(pressure/vacuum)

Boilers

Business & Product Centre

for FPSOs, FSOs and rigs

IGS fans

Deck
water
seal

Typical O2 content in flue gas

Class requires that the O2 content shall be max 5% for IGS operation
O2 (%)

5
4.5
4
3.5
3
Gas

2.5

Diesel

2
1.5

The IGS can be operated down to approx 30 %

load, still having 1 % oxygen as an extra margin!

1
0.5
0
25
Business & Product Centre
for FPSOs, FSOs and rigs

30

40

50

60

70

90

100

Boiler load (%)

Advantages by using the

flue gas type IGS
Save space and reduce
investment cost

Reduce the operation cost for the plant

By taking both the boiler system and the IGS from one
supplier the co-ordination of these two systems becomes
easier and safer
One supplier - one responsible!
Business & Product Centre
for FPSOs, FSOs and rigs

Heat Recovery Boilers

after Diesel Engines
PIONEERTM DE-1

AV-10DE

AV-6N

Type

Horizontal gas flow

water tube

Horizontal/vertical gas flow

water tube

Vertical gas flow

water tube

Diesel engine output

0.5 - 20 MW

2 - 20 MW

No limits

Diesel engine fuel type

Light fuel oil

Light fuel oil

Light fuel oil

Heavy fuel oil

Heavy fuel oil

Heavy fuel oil

Exhaust gas flow

Up to 30 kg/s

Up to 30 kg/s

No limits

Exhaust gas temperature

<500 C

<500 C

<500 C

Steam capacity

Up to ~ 5 t/h

Up to ~ 5 t/h

No limits

Business & Product Centre

for FPSOs, FSOs and rigs

Heat Recovery Boilers

9 In a normal Diesel Engine or Gas Turbine
there is a lot of energy to save .....
and money!

Business & Product Centre

for FPSOs, FSOs and rigs

Heat exchangers
We can offer a wide range of heat exchangers for
various purposes on board an FPSO, FSO or rig
Tube and shell
Spiral wound tube bundle
Pin tube

Business & Product Centre

for FPSOs, FSOs and rigs

Marine - Product Range

Heat exchangers
VESTATM EH

VESTATM MX

VESTATM MD

VESTATM MP-C

Type

Oil and F.W. Electrical

Heater

Oil and F.W.

Preheater

S.W. Cooler /
Condenser

Cargo Heater

Design

FlowTthrough

Shell and Tube

Shell and Tube

Shell and Tube

Out flow

U-Tubes

Straight Tubes

U-Tubes

3 - 235 kW

10 - 5,000 kW

400 - 6,000 kg/h

300 - 2,000 kW

Design pressure 16 bar (g)

16 or 30 bar (g)

16 bar (g)

16 bar (g)

Installation

Horizontal

Horizontal

Horizontal

Horizontal

Vertical

Vertical

Vertical

Vertical

Tubes: St. 37.0

Tubes: St. 37.0

Tubes: CuNi 90/10

Tubes: AISI 316L

Shell: St. 37.0

Shell: St. 37.0

Shell: St. 37.0

Shell: AISI 316L

Capacity

Materials

Business & Product Centre

for FPSOs, FSOs and rigs

Offshore plants
We have the resources to offer Boilers, Heat
Recovery Boilers, IGS and Heat Exchangers
for offshore Installations
RIGS
FPSOs and FSOs

Business & Product Centre

for FPSOs, FSOs and rigs

Boiler conversions and

retrofits
Our engineers have built thousands of boilers, so
when a boiler needs to be modified to suit other
fuels than it was originally built for, our After Sales
organisation is the natural partner.
Boiler repairs and conversions
Boiler retrofits
At any time - anywhere!
Business & Product Centre
for FPSOs, FSOs and rigs

Boilers for steam

propulsion
We have supplied a large number of boilers for
steam propulsion
Babcock & Wilcox
Combustion Engineering

Business & Product Centre

for FPSOs, FSOs and rigs

A selection of our international

references

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client: FELS / Petrobras, Brasil
Name: Petrobras XVIII
Semi submersible rig, built at FELS, Singapore

2 x CHS hot water boilers each with a capacity of 20 MW

Hamworthy combustion system for firing gas
On deck / hazardous area
Turn-key installation

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client:

Astano / Texaco

Name:

Texaco Captain

FPSO, newbuilding, built at Astano shipyard in Ferrol,

Spain
3 x CHS hot water boilers each with a capacity of 23 MW
Hamworthy combustion system for firing gas, crude and
diesel
3 x Hot water circulation pumps
1 x Expansion tank
On deck / hazardous area
Business & Product Centre
for FPSOs, FSOs and rigs

Texaco Captain
Supply of 3 x CHS boilers (23 MW) with triple fuel
burners

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client: Mitsui Engineering & Shipbuilding, Japan
FSO, newbuilding, built at Mitsui Chiba shipyard
2 x CPH steam boilers, each with a capacity of 10 t/h
Hamworthy combustion system for firing gas and diesel
Below deck

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client: ABB Global / Bluewater, The Netherlands
Name: Glas Dowr
FPSO, conversion of a 100,000 DWT tanker
1 x CPH steam boiler with a capacity of 45 t/h
Hamworthy combustion system for firing gas and diesel
On deck / hazardous area

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client: Daewoo, Korea
Name: Terra Nova
FPSO, newbuilding, built at Daewoo shipyard
2 x CPH steam boilers, each with a capacity of 25 t/h
Hamworthy combustion system for firing gas and diesel
Below deck

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client: Care Offshore
Name: Armada Perkasa (ex Red Teal)
Conversion of a tanker into an FPSO
Major boiler repair of an Aalborg AT-4 boiler
Overhaul / upgrading of existing burner and control system
Installation of an AQ-9 boiler with a capacity of 20 t/h

Business & Product Centre

for FPSOs, FSOs and rigs

Armada Perkasa
Boiler repair of AT-4 boiler
Supply of 1 x AQ-9 (20 t/h) boiler with dual
fuel burner

Business & Product Centre

for FPSOs, FSOs and rigs

Armada Perkasa
Boiler repair of AT-4 boiler
Supply of 1 x AQ-9 (20 t/h) boiler with dual
fuel burner

Business & Product Centre

for FPSOs, FSOs and rigs

 The AQ-9 (20 t/h) boiler

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client: Nortrans Offshore, Singapore
Name: Espoir Field FPSO
Conversion of MT White Sea at Keppel Shipyard, Singapore
2 x MISSION D-type steam boilers, each with a capacity
of 80 t/h
Hamworthy combustion system for firing gas and diesel
(not AI supply)
On deck / hazardous area
Business & Product Centre
for FPSOs, FSOs and rigs

 Model of Espoir FPSO

Business & Product Centre
for FPSOs, FSOs and rigs

 Two MISSIONTM D-type boilers during production in our workshop

Business & Product Centre

for FPSOs, FSOs and rigs

 MISSIONTM D-type boiler ready for delivery

Business & Product Centre

for FPSOs, FSOs and rigs

 MISSIONTM D-type boiler ready for delivery

Business & Product Centre

for FPSOs, FSOs and rigs

 MISSIONTM D-type boilers in Qingdao port

Business & Product Centre

for FPSOs, FSOs and rigs

 Espoir FPSO
Business & Product Centre
for FPSOs, FSOs and rigs

Espoir Ivoirien (ex White Sea)

- fitted with two MISSIONTM D from Aalborg
AalborgIndustries
Industries

Business & Product Centre

for FPSOs, FSOs and rigs

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client: Hyundai Heavy Industries / Elf
Name: Amenam FSO
FSO, newbuilding at HHI shipyard in Ulsan, Korea
2 x CHS hot water boilers each with a capacity of 12 MW
Hamworthy combustion system for firing gas and diesel
3 x Hot water circulation pumps
On deck / hazardous area

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client: Keppel Fels, Singapore / Vietsovpetro
Name: White Tiger CPP3
3 x MISSIONTM OM steam boilers, each with a
capacity of 13.5 t/h
Hamworthy combustion system for firing gas and
diesel
FW tank, FW pumps and condensate recovery unit
On deck / hazardous area

Business & Product Centre

for FPSOs, FSOs and rigs

Reference plant
Client: Vanguard SPC Ltd, Australia / Agip
Name: Woollybutt FPSO
Conversion of MT Four Lakes at Keppel Shipyard,
Singapore
2 x MISSIONTM OM steam boilers, each with a capacity
of 38.5 t/h
Hamworthy combustion system for firing gas, crude and
diesel
FW tank, FW pumps etc
On deck / hazardous area
Business & Product Centre
for FPSOs, FSOs and rigs

Reference plant
Client: Prosafe Production, Singapore
Name: Abo FPSO
Conversion of MT Grey Warrior at Keppel Shipyard,
Singapore
2 x MISSION D-type steam boilers, each with a
capacity of 90 t/h
Hamworthy combustion system for firing gas and
diesel (not AI supply)
On deck / hazardous area
Business & Product Centre
for FPSOs, FSOs and rigs

Knowing the boilers inside

and
out - unique experience
We have delivered a large number of quality boilers
during the last decades
Regardless if its a question of fuel fired boilers or Heat
Recovery Systems we have the know-how and
organisation to support you

Business & Product Centre

for FPSOs, FSOs and rigs

Quality products for marine,

offshore and stationary plants

Business & Product Centre

for FPSOs, FSOs and rigs

How to reach us
For personal introduction please contact our
Business & Product Centre for FPSOs, FSOs and rigs:
Aalborg Industries AB
P.O. Box 907
175 29 Jrflla, Sweden
Phone: + 46 8 580 24300
Fax:
+ 46 8 580 27801
e-mail: stom@aalborg-industries.se
... or your usual Aalborg Industries contact person
Business & Product Centre
for FPSOs, FSOs and rigs