CADE-2015

C A D E s o l u c i o n e s d e i n g e n i e r í a, S.L. - E S P A Ñ A - S P A I N

Solution focused, expertise driven

KSA – May 2015

CADE is a specialized provider of advanced engineering and consulting services that integrates advanced capabilities in mechanical andprocess engineering in order to develop equipment, technology, and plants in OIL&POWER

HIGHLIGHTS

- Staff: 25 (90% mechanical and process engineers)- Turnover 1M€ (15% international)- Projects executed: 1000- Markets served: UE, MENA, USA and LATAM- Certifications: ISO 9001, 14001, 166001, 27000- Areas of expertise:

Process & Mechanical Consulting and Expert advisory Design and performance of Heat and Process Equipment Heat Transfer and Process Simulation High pressure & temperature processes and equipment Complex Piping simulation Reliability and Integrity Failure evaluation

The Company

Lines of Business: Engineering and Consulting Services

Expert Engineering Assessment

EVALUATION AND CONSULTING OF CRITICAL EQUIPMENT AND PIPING SYSTEMS

• Evaluation and determination of causes of operation failure. Root failure cause investigation

• Evaluation, analysis and proposal of upgrade/optimization measures

• Operation/Failure Troubleshooting• Functioning, operation and maintenance, safety and economic

balance• Operational life evaluation. Remaining life expectance• Reliability assessment• Expert advisory. Resolution of litigious. Expert witness• High value service for our client

PROCESS EQUIPMENT AND PIPING

• Thermal / process design (TEMA, API) – HTRI/ASPEN

• Mechanical Design (ASME, AD2000, EN13445) – PVELITE

• FEM Mechanical Structural Analysis – ANSYS

• Computational Fluid Dynamics (CFD) – CFX –PEN FOAM

• Flexibility and stress piping analysis – CAESAR II

• Detail engineering of equipment and structures (3D/2D)

• CE Marking

PLANT ENGINEERING• Technology consulting• Basic/Process Engineering• Detail Engineering• Purchasing Management• Construction Supervision• Start-up• Permitting

CSP Technology

EXPERT CSP ASSESSMENT• Design and optimization of HTF/TES/SG systems. Expert

advisory.• Sizing solar field• Development of energy storage technology and applications• Manageability• Minimization of parasitic losses

EXPERT ENGINEERING ASSESMENT IN CSP AND PARTNERCONSULTING• Basic and detail engineering (Engineering owner)• Assessment / Analysis of potential optimization in operating

plants (thermal, hydraulic, and operating strategies).HTF/TES/SG systems.

• Advanced mechanical analysis of equipment and parts• Failure analysis of critical equipment. Implementation and

monitoring of upgrading measures

Technology for CSP commercial plants – electric production(>50MW):• Thermal storage systems (TES)• CSP structures

Advanced Engineering

Lines of Business: Own Technologies

Expert Engineering Assessment

INNOSPRAY® technology allows to process waste water flowswith a high content of inorganic load (high conductivity water)transforming them into a dried product through an innovativeprocess based on multi-stage evaporation and spray dryingtechnology. INNOSPRAY® process is conceived to be fullyintegrated with solar thermal power for a complete eco friendlyand zero effluent technology with water recovery.

The development of INNOSPRAY® has been conceived to supplyan efficient, versatile drying method aimed to minimize andvalorize residual streams, obtaining products of controlledgranulometry for the chemical industry and production ofnanoparticles.

Technology for valorization of wet biomass and hydrocarbonwastes through supercritical water gasification, which allows toobtain syngas for direct energetic valorization by combustion oraimed to produce hydrogen. Zero effluent with water recovery andcarbon dioxide capture.

A very competitive product named S-GEN has been speciallydeveloped for complete elimination of UWWTP sludge, obtaininghigh calorific & high pressure GAS for direct valorization or CHPapplications in plants, and clean water recovery.

CSP Technology

Highly competitive SHC (Solar Heating & Cooling) technology forthe supply of process heating / cooling for industries throughhigh temperature solar thermal power in form of thermal oil,steam or hot air (200-400ºC) and cold water (5-12ºC), withthermal storage capacity up to 12 hours after sunset.

It allows its integration in existent industries replacing, totally orpartially, fossil fuels for solar power, decreasing industry’spower cost and the risk of fuel’s price volatility.

Advanced Engineering

SHC - Process Heating/Cooling

through solar thermal powerDrying process for wastewater

Zero effluent concept

Supercritical Water Gasification

Valorization and elimination of

organic sludges

Business Overview

AREAS OF EXPERTISE:

Thermal and Process

Equipment

Heat Transfer

Heat Recovery

Steam Generation

Drying processes

Energy Storage

Super Critical Fluids

FIELDS AND SECTORS

Oil&Gas

Power Generation

Refinery and Petrochemical

Chemical&Process

CSP & Renewables

Enviro & Waste

CLIENTS & PARTNERS

Plant Owners & O&M

TechnologyLicensors

EPC Contractors

Engineering

Manufacturingcompanies

MARKETS

Europe

South America

Middle East

GLOBAL VISION

EEA – Expert Engineering Assessment

OPERATION FAILURE

INTEGRITY ASME FFS

PERFORMANCE O&M

RESPONSABILITY AND WARRANTY

BENEFITS FOR PLANT OWNER

PRODUCTION AND PROFIT IMPROVEMENT

RISK EVALUATION AND NEGOCIATION OF O&M CONTRACTS

CRITICAL FAILURE PREVENTION/FORECAST/SOLUTION

CLAIMS AND LITIGATION TECHNICAL SUPPORT

TECHNICAL SCOPE

TRAINING / KNOW HOW TRANSFER

MULTIDISCIPLINED ENGINEERING CAPABILITIES

KNOW HOW AND EXPERTISECODES AND STANDARS

ASME/TEMA/APIADVANCED SIMULATION TOOLS

solution focused, expertise driven

APPROACH

MAIN EQUIPMENT AND PIPING

PROCESS AND POWER PLANTS/UNITS:

STRUCTURES AND DUCTS

EEA – Expert Engineering Assessment

EEA - EXPERT ENGINEERING ASSESMENT

CADE boasts of a very relevant trajectory as provider of advancedengineering services which has allowed the company to position itself as arenowned expert in the evaluation of complex problems in an industrialenvironment that demands great technical expertise.

To that end, CADE integrates expert knowledge in distinct technical areasand disciplines of engineering with the intensive use of advancedsimulation and analysis tools and the collaboration with prestigiouslyrecognized testing and measurement laboratories and entities.

Benefits

Solution to complex problems impossible to solve understandards, rules or design codes Increase of profitability of industrial equipment and facilities Reduction of operating and maintenance costs Reduction of manufacturing costs Reduction of material costs Expert support Know-How Transfer Customized Traning in-house

Typical tasks:

On-service failure root-cause investigation Fitness For Service (API579) Welding Process and secuence simulation Operational limits of critical equipment Performance, operation and maintenance, security and financial balance Mechanical integrity evaluation. Remaining life. Piping Vibration analysis Thermal shock / Fatigue simulation HEX Joints Leakage evaluation Flue gas ducts design and CFD simulation Expert consulting. Litigation support Advanced analysis and simulation

Scope of Work:

Process and heat equipment (pressure vessels, tanks, heat exchangers, reactors, etc.)

Power and Process Plants Piping Special structures and Ducts Complex phenomena (stress corrosion, ratcheting, creep, fatigue, etc.) Materials

Engineering & Consulting Services

CONSULTING:

Process & Mechanical Consulting and Expert advisory

Design and performance of Heat and Process Equipment

Heat Transfer and Process Simulation

High pressure & temperature processes and equipment

Complex Piping simulation

Reliability and Integrity

PROCESS EQUIPMENT AND PIPING ENGINEERING

• Thermal / process design (TEMA, API) – HTRI/ASPEN• Mechanical Design (ASME, AD2000, EN13445) - PVELITE• FEM Mechanical Structural Analysis – ANSYS• Computational Fluid Dynamics (CFD) – CFX –OPEN FOAM• Flexibility and stress piping analysis - CAESAR II• Detail engineering of equipment and structures (3D/2D)• CE Marking

PLANT ENGINEERING

• Technology consulting• Basic/Process Engineering• Detail Engineering• Purchasing Management• Construction Supervision• Start-up• Permitting

• 4MW Cogeneration Plant (Spain) (CUMMINS)• Andorra Power Plant. (Andorra) (ENDESA)• Brazi CCGT Power Plant (Romania) (ENEL)• Escatron Combined Cycle Power Plant (Spain)• Escombreras Combined Cycle Power Plant (Spain)• Gas Turbine Open Cycle Power Plant ( Nigeria)• Kazeroun Combined Cycle Power Plant (Iran)• Kerman Combined Cycle Power Plant (Iran)• LKPL Stage II Power Plant Project (India) (INDIRA INDUSTRIES)• Marcinelle CCGT Power Plant. (Belgium) (METKA)• Neka Combined Cycle Power Plant (Iran) (MAPNA)• Power & Steam Generation Plant (Iran) (ILAM PETROCHEMICAL COMPLEX)• Puente Nuevo Thermal Power Plant (Spain)• S.C. Petromidia Power Plant (Romania) (S.C. PETROMIDIA)• Sodom combined cycle power plant(Israel) (NOOTER ERIKSEN)• UMM AL-NAR Independent Power and Water Project (CCPP) (United Arab Emirates)• Vantaa Incineration Plant (Finland) (LAB)• Vasilikos Combined Cycle Power Plant (Cyprus)• Yazd Combined Cycle Power Plant (Iran)

Relevant References – Some projects in which CADE has taken part

POWER PLANTS• 2 X Biodiesel Production Plant (Spain) (BIONOR)• BP Oil Refinery (Spain) (BP OIL)• C-10 Refinery expansion (Spain) (REPSOL)• Cartagena Refinery Expansion. Delayed Coker Unit (Spain) (FOSTER WHEELER / REPSOL)• Crude Oil Piping Storage Facility (Bélgica) (GELDOF)• Dunkerke LNG Terminal (Francia) (DUNKERQUE LNG GROUP EDF)• G16A-B Well Protector Platform (Dutch Northsea) (FRAMES / GDZ SUEZ)• Hydrogen Production Plant – TUAPSE (Rusia) (TECHNIP / LLC ESCORT)• Izmit Refinery (Turkey) (TUPRAS / TECNICAS REUNIDAS)• Jamnagar Refinery (India) (GE OIL&GAS / RELIANCE)• Jetty Boil-Off Gas Recovery (Qatar) (FLUOR / QATARGAS )• Jubail Expansion Refinery Project ( Saudi Arabia) (ARAMCO)• Margarita Project – CPF Plant (Bolivia) (TECNICAS REUNIDAS / REPSOL)• La Pampilla Refinery (Peru) (SAINCO/FLUOR/REPSOL)• Liquefiable extraction plant - Gran Chaco (Bolivia) (YPFB)• Puertollano Refinery (Spain) (REPSOL/DYNASOL)• Petromidia Refinery (Romanía) (ROMPETROL)• Reconversao da Refineria de Sines (Portugal) (GALP)• Refining Project Evolution-Limbe (Cameroon) (FOSTER WHEELER / SONARA)• Revamp Chloralkali Electrolisis Plant (Romanía) (CHIMCOMPLEX)• South Yoloten Gas Field Development Proj. (Turkmenistan) (PETROFAC / TURKMENGAS)• Sulphur Recovery Unit PJ177 Petrobrazi Refinery (Romanía) (ROMPETROL)• Ticona Kelsterbach Relocation Project (Germany) (TICONA)• Volvograd Refinery Lukoil (Rusia) (LUKOIL)• Wilhelmshavener Raffineriegesellschaft (Germany) (CONOCO PHILLIPS)• YARA Project (Tailandia) (GE OIL&GAS)

REFINERY & PETROCHEMICAL PLANTS

Relevant References – Some projects in which CADE has taken part

• Alexandria East Wastewater Treatment Plant (Egypt) (EWTP)• Arcelor-Asturias Production Plant (Spain) (ARCELOR)• Cepsa Quimica Puente Mayorga. Alquilation Unit (Spain) (INTECSA / CEPSA)• Chemical Plant (The Netherlands) (DEGUSSA)• Food production plant (Spain) (GULLON)• La Caleta Desalination Station (Spain) (EDAM)• Las Cruces Cupper Plant (Spain) (SNC LAVALIN / COBRE LAS CRUCES)• Polymers Plant (Spain) (ELIX POLYMERS)• Pumping Station – Segarra-Garrigues System – Irrigation Distributuion Network (Spain)• TAQSA Industrial Complex (Spain)• Waste Treatment Plant RECIMED (Spain)

MISCELANEOUS PLANTS

• Andasol I (Spain) (SENER&COBRA)• Andasol II (Spain) (SENER&COBRA)• Astexol-2 CSP Plant (Spain) (FLUOR/ELECNOR)• Casablanca CSP Plant (Spain) (COBRA)• CSP Pilot Plant. Based on Molten Salt HTF (Spain) (COBRA)• Extresol-3 CSP Plant (Spain) (SENER/COBRA)• KAXU Solar Plant (South Africa) (ABINSA EPC)• KHI Solar Plant (South Africa) (ABEINSA EPC)• La Africana CSP Plant (Spain) (UTE AFRICASOLAR)• La Dehesa CSP Plant (Spain) (SAMCA)• La Florida CSP Plant (Spain) (SAMCA)• Les Borges Blanques CSP Plant (Spain) (ABANTIA/COMSA/IDOM)• Manchasol CSP Plants (SENER/COBRA)• Mojave CSP plant (USA) (ABENGOA SOLAR)• Puerto Errado CSP Plant (Spain) (ECOLAIRE/TSK/NOVATEC)• Soluz-Guzman CSP Plant (Spain) (ESPELSA/ABANTIA/IDOM)• Lebrija CSP Plant (Spain) (SOLEVAL)• Villena (PLENIUM PARTNERS-FCC)

CSP PLANTS

UPGRADING STUDY IN HEAT EXCHANGERS AND STEAM GENERATOR TRAIN (CSP PLANT)

Goal :

To improve plant performance to improve the exchangers thermal performance by means of modification its operation points (determination of equipment' limits).

Thermal simulation:

Point of design validation

Thermal simulation under different conditions of point of design

Thermal – Mechanical Simulation:

Thermal analysis to obtain metal temperatures

Static analysis to obtain stress results and location of critic points (nozzles, heads, tube-sheet, saddles)

Thermal shocks effect

Fatigue analysis to determine existing damage and remaining life

Fouling effectOversizing level effectStart-upUnbalanced flowsEvaluation of the potential to increase output thermal power delivered

EEA: Study Cases

VALIDATION OF OVALIZED SHELL OUT OF DESIGN CODE TOLERANCE

Goal:

FEA analysis performed on the coker fractionator unit (item 652C-001) because ofthe ovalization showed by some ferrules, out of tolerances.

ASME VIII D.2 ed.2007

Non-lineal static analysis (plasticity).

Elastoplastic analysis

Consideration of tension redistribution as a result of non-linearity

Material non-linearity (elastoplastic material)

Geometric non-linearity (great deformations)Elasto-plastic analysis results

The evolution of displacements is gradual (not abrupt changes inthe slope of the curve) neither local buckling nor generalizeferrules.

Conclusions

Out-of-tolerances' validation of the ovalized ferrule isjustified by means of elasto-plastic analysis convergence.

The analysis means a big save for the client since justifiesthat there is no need to replace the ferrules.

EEA: Study Cases

VIBRATION ANALYSIS ON DISTILLATION UNITGoal:

To evaluate the influence of installing a new structure to support the new equipment upon an existent structure on a glycerin distillation process building by means of a dynamic analysis.

Modal analysis. Frequencies. Resonance.

Modal analysis to get the own-frequencies range of the structure in orderto compare them with the excitation frequency of any equipmentinstalled in the process building.

Goal: to avoid that structure frequencies concur with equipmentoperating frequencies, and prevent this way a resonance phenomenonoccurs.

Results: coincidence between natural frequencies and excitationfrequencies.

Conclusion: to evaluate the resonance phenomenon harmonicanalysis

Harmonic Analysis:harmonic analysis of the structure are conducted considering two operating scenario:

- filled equipment- empty equipment

Harmonic loads are considered as isolatedThe aim is to determine the stress and deformation states of the structure within thefrequency range of operation

Limitation of maximum displacements (CTE DB SE-A Acero)

EEA: Study Cases

UPGRADING STUDY OF AN AIRCOOLER DESIGNGoal:

To analyze by CFD an air cooler' start-up cycle.• Obtaining heat transfer coefficients + radiation on the side tubes versus time.• Obtaining bulb temperatures on the side tubes versus time.• Obtaining fluid velocities in the side tubes versus time.• Obtaining pressure distributions in the tube side versus time

These data were applied as load conditions (inputs) in a subsequent thermal analysis performed guided to obtain metal temperatures

Results:

Conclusion:

Detection of supersonic fluid areas on the inlet.Detection of higher pressure loss than allowed.Proposal of alternative operational strategies

EEA: Study Cases

STRUCTURAL AND FATIGUE ANALYSIS OF AIR COOLER HEAT EXCHANGER

Goal:

To determine the air cooler acceptability based on “ASME VIII Div 2 ed. 2007./2008 Add Code” specification,particularly “Part 5: Design by analysis requirements”.

Thermal transient analysis and static analysis were performed, according to the thermal land pressure loads of theexchanger start-up cycle.

Thermal transient analysis

A thermal transient analysis was performed in order to determine distribution of metal temperatures along thestart-up cycle. This temperature distribution was later considered on the static analysis to evaluate the effect of thedilations.

Steady-state static analysis

A steady-state static analysis was performed on every point of the start-up cycle in order to obtain the stress statesand deformation of the equipment, considered the thermal and pressures loads (cyclical). The stress valuesobtained were later compared to the allowable limits established by code ASME VIII Div. 2, ed.2007. Part 5 “Designby analysis requirements”.

Fatigue analysis

A fatigue analysis according to the code ASME VIII Div. 2 , ed.2007. Part 5 “Design by analysis requirements” wasconducted with the goal of determining the maximum number of allowable cycles, starting from the alternatingstress results calculated on the previous static analysis.

EEA: Study Cases

Goal:

To determine the behavior of the gaskets and evaluate the occurrence of leaks.

To determine the torque of the screws and the assembled sequence.

Thermal Analysis:

To evaluating the influence of the thermal dilations due to the different materials.

Static Analysis:

Modeling of gaskets as non linear material. Non lineal modeling of gaskets-metals' contacts.

Consideration of load and unload state on the gaskets.

Pressure evaluation on the gasket under assembled and operation conditions to predicting leaks

Results:

Detection of the areas with very low pressure or even separated gaskets possible tightness problems

(coincidence with the real fact happened).

Conclusion:

The chosen gaskets were the right ones. Other gaskets were suggested based on the load and unload cycles.

Leaking problem was detected because of the non-linearity consideration of the gasket and its contacts; by

means of realization of a formula-traditional analysis this problem would not have been detected.

BREECHLOCK CLOSURE LEAKAGE ANALYSIS

EEA: Study Cases

BREECHLOCK CLOSURE LEAKAGE ANALYSIS

EEA: Study Cases

MISCELANEOUS

Flue Gas Ducts: Flow simulation, Thermal and Structural analysis

EEA: Study Cases

MISCELANEOUS

By Pass Systems: Flow simulation, Thermal and Structural analysis

EEA: Study Cases

Relevant Clients

Relevant Clients

Rodesol

TÉCNICOS CALDEREROS

C A D E s o l u c i o n e s d e I n g e n i e r í a , S . L . P a s e o d e l a I n n o v a c i ó n , 3 - 0 2 0 0 6 A l b a c e t e – E S P A Ñ A