© 2017 GE All Rights Reserved
Exploring the benefits of modularizationEMANUELA SILENZI
GE OIL & GAS MODULES PRODUCT MANAGER
© 2017 GE All Rights Reserved
Agenda
GE OIL & GAS HERITAGE & CAPABILITIES
MODULARIZATION EVOLUTION
GOING MODULAR
CASE STUDIES:AdvantEDGE* Power Plant (Atish Roy-Choudhury), Gas Processing (Alicia Trent)
*Trademark of General Electric Company 2
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GE & ModularizationInnovation & Excellence
COST REDUCTION SIMPLER
DESIGN SOLUTION
PROJECT EXECUTION
EXCELLENCE AND RISK
MITIGATION
SMOOTH AND SMART
INSTALLATION
PARTNERING
IN PROJECT
DEVELOPMENT
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Adapting to the new cycle
UPSTREAM MID TERM LOCK-IN
- 2017 MIGHT BE THE TURNING YEAR FOR
INVENTORY REDUCTION
- UP TO 7 MILLION BBL/D OF SUPPLY NEEDED
THROUGH 2021 FROM UNSANCTIONED
PROJECTS
- MODEST SPENDING RECOVERY CONTINUES
BALANCING RISKS AND REWARDS
- DE-RISKING: BUDGET AND TIMING CERTAINTY
- INNOVATE TO BECOME LEANER, MORE ADAPTIVE
TO CHANGE
- NEW TECHNOLOGY AND NEW EXECUTION
MODELS
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Building on 30+ years modularization experience
NORTH SEA
BUCHAN FIELD
Gas lift
BRAZIL
CAMPOS BASIN
Power Gen
& Compression
KAZAKHSTAN
KASHAGAN
H2S Gas injection
System
GORGON
Power gen modules
(130 MW)
FSNL tested
UZ 750
Power gen modules
(43 MW)
FSFL tested
TENGIZ
Power gen modules
(130 MW)
FSFL tested
1980 1990 - 2008 2006 - 2008 2012 2016 2019
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Yard evolution
- 5 PLATFORM
- FULL SPEED NO LOAD (P<16 BARG)
- STRUCTURE SUB-ASSEMBLED AND
ERECTED IN YARD
- LIFTING, STRUCTURE WELDING,
SCAFFOLDING, TOUCH UP
- MECHANICAL COMPLETION AND
COMMISIONING (PAPER BASED)
- COVERED STORAGE: 11.000 M2
- 2D DRAWING
- MODULE LOAD OUT LIMIT: 4000
TONS
- MODULE DIMENSION LIMIT: 21 WX60
L
- 10 PLATFORM
- FULL SPEED FULL LOAD (P<24
BARG AND POWER 130MW...FR9)
- STRUCTURE ALREADY FULLY
ASSEMBLED (NO ERECTION ,
NO WELDING)
- SKIDDING
- COVERED STORAGE: 30.000 M2
- 3D DRAWING
- POSITIONING TRACKING SYSTEM
- ADDITIONAL 4 PLATFORM
- FULL SPEED FULL LOAD
- (P<70 BARG AND POWER
130MW...LMS100)
- HEAT REMOVAL 220 MW
(EVAPORATIVE TOWERS)
- FULLY DIGITIZED DOCUMENT
MANAGEMENT
- FOR MECHANICAL COMPLETION
AND COMMISSIONING (POWERED
BY PREDIX)
- NO LIMITATION IN LOAD OUT &
DIMENSION CAPACITY (SEA
FRONT)
GORGON
PROJECT
ZADCO
& TENGIZ
40.000 M2
UNTIL 2011
240.000 M2
(2012-2019)
200.000 M2
(FROM 2019)
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Module commissioning and testing
PRE COMMISSIONING
AND COMMISSIONING
- MODULE QUALITY CONTROL PANEL
- MECHANICAL COMPLETION
- COMMISIONING PROCEDURE
- CONTROL LOOP CHECKS
- ELECTRIC MOTORS & PANEL
CHECK
- LUBE OIL SYSTEM FLUSHING
- FUNCTIONAL TEST OF ALL
SYSTEMS
- READY FOR FULL POWER AND
SHIPMENT
Enabling real
plug & play
solutions
MODULE STRING TEST
- FULL SPEED FULL LOAD (UP TO 130
MW)
- LOAD SHARING & SHEDDING
CAPABILITIES
- POWER GENERATION (AVENZA)
& COMPRESSOR DRIVE (PIOMBINO)
- FUNCTIONAL TEST & LOOP CHECK
OF ALL SYSTEMS AT FULL LOAD
- PERFORMANCE, VIBRATION, DLN
MAPPING & CONTROL SYSTEM -
ALL TESTED BEFORE SHIPMENT
- NO ADDITIONAL TEST AT SITE
REQUIRED, FULLY PLUG & PLAY
SOLUTION
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Modularization as a product
APPLICABLE
PRODUCT
SPECS
STRUCTURAL
DESIGN
PLANT
LAYOUT
EXECUTION
STRATEGY
EQUIPMENT
DESIGN
LESSON
LEARNED
CUSTOMER
REQUIREMENTS
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Technology enablersPower density and plant simplification
DRIVERS COMPRESSION DIGITAL
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Technology enablersPower density and plant simplification
DRIVERS
10
LM6000PF+
55MW
IN THE SAME PF
LM900065MW HIGHER
POWER AND BEST
MAINTANCE
INTERVAL
FR7EA
2 SHAFTS120 MW HIGHER
POWER AND NO
VSDS
HELPER MOTOR
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Technology enablersPower density and plant simplification
COMPRESSIONHIGH PRESSURE RATIO COMPRESSOR
FROM 2 COMPRESSOR BODIES TO 1
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Technology enablersPower density and plant simplification
COMPRESSION SCRUBBER COMPRESSOR
STRONG FOOTPRINT AND WEIGHT REDUCTION
WET COMPRESSOR
PROCESS BOP OPTIMIZATION
Integrated
Moto Compressor
Suction
Scrubber
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Technology enablersDesign & operations simplification
DIGITAL
DESIGN FOR MODULARIZATION (FOOTPRINT):
PRESSURE SCANNERS
COMPACT AND MINIATURIZED SENSORS
MULTI-TASKING SENSORS
WIRELESS TECHNOLOGY
DESIGN FOR MAINTAINABILITY:
DRONES
CAMERAS
REMOTE OPERATION
LIVE INSTRUMENT HEALTH MANAGEMENT
SYSTEM
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Ingredients for structural Optimization
DESIGN TARGET DESIGN DRIVER
WEIGHT RATIO
WR=(KG STEEL STRUCTURES)/
(KG EQUIPMENT)
OPTIMIZATION TOOL
BENCHMARKING
BOAT: 0.86
COMM. AIRPLANE:<0.30
CAR: 0.43 (STEEL FRAME)
HD GT’S MODULAR
CONSTRUCTION
ONSHORE: >0.8
WEIGHT RATIO TARGET<0.7
- MAINTENANCE
- HUMAN FACTOR
- CUSTOMER SPECS
- CODE & STANDARS
- MAX STATIC DEFLECTIONS
- DYNAMIC STIFFNESS
- NEW CRITERIA FOR MODULE
STATIC DEFLECTION
- INTEGRATED ROTOR-DYNAMIC
MODULE TYPICAL FIGURES:
# PROFILES >20
# LOAD CASES> 100
# DESIGN CHECKS >3000
REDUCE MODULE STEEL
STRUCTURE
WEIGHT THROUGH AN
OPTIMIZATION
WORKFLOW BASED ON
GENETIC ALGORITHMS
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Module as a Product ... visionCost & Delivery time reduction up to 50%
ONGOING NEXT
PASTREFERENCES
DESIGN TOMODULARIZATION
INDUSTRIALIZATION
- 100 REFERENCES
- 30 CONFIGURATIONS
- REFERENCE CONFIGURATION
& VARIANTS
- INTEGRATED ROTORDYNAMIC
TECHNOLOGY
- STRUCTURAL DESIGN
STANDARDIZATION
& OPTIMIZATION
- MODULES PRODUCT SPEC
- EQUIPMENT + MODULE
INTEGRATED DESIGN
- PRODUCTION ENGINEERING
- SUPPLIERS ECOSYSTEM
WEIGHT AND FOOTPRINT OPTIMIZATION STANDARD COST & LEAD TIME
EQUIPMENTDESIGN
MODULEDESIGN
CONSTRUCTION& TESTING
PROCUREMENT
INTEGRATEDMODULE DESIGN
CONSTRUCTION& TESTING
PROCUREMENT
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SMALL SCALE MODULES
DESIGNED FOR REGIONAL ROAD
REQUIREMENTS
FLEXIBLE LAYOUT FOR CUSTOMER
SPECIFICATION
SMALL SCALE TRUCKABLE MODULES
GE MODULES
- PROCESS & 3D DESIGN THROUGH
MANUFACTURING
- PRE-ASSEMBLY AND TESTING DONE IN GE
- HIGH WELDING & CLEANLINESS STANDARDS
REDUCED ERECTION AND SITE ACTIVITIES
- STANDARDIZATION TO REDUCE SITE &
FACTORY REWORK
- POTENTIALLY REDUCE SCHEDULE THROUGH
- CONCURRENT TIMELINE AND/ OR
STANDARDIZATION
Case study – Liquefaction ModuleGE Solutions: from truckable small scale LNG plant to Mega Liquefaction Module
EXPERIENCE
IN LNG
PROCESS PLANT +
MODULES
+ INNOVATION
GE MEGA
LIQUEFACTION
MODULES
=
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CASE STUDY
• Single Liquefaction Process
in one Module
• Ideal For Compact
Or Multi-train Configurations
MODULE COUNT
REDUCTION
TOTAL PACKAGES
FIELD CONNECTIONS
WELDS
TIME TO INSTALL
DIMENSIONS
BENEFITS
80% reduction
50% reduction
70% reduction
30% reduction
50% reduction
148’ x 72’ x 57’
- Fewer connections
- Faster installation
© 2017 GE All Rights Reserved
GE Gas Power Plant SolutionsModular plant outlook
VALUEVAST
EXPERIENCE LIFE CYCLECUSTOMER
TESTIMONIALS
- SCHEDULE & COST
CERTAINTY (RISK
REDUCTION)
- FASTER DELIVERY (NTP
TO COD)
- LOWER TOTAL
INSTALLED COST (TIC)
- FROM 30 MW TM TO 1.5 GW H
CLASS PLANTS, E.G.
- F-CLASS: 8 MODULAR CCPPS
(~60 MODULES)
- H-CLASS: 1.5 GW MODULAR
CCPP IN EXECUTION (100+
SUB-MODULES)
- PROVEN DESIGN
INCORPORATING LESSONS
LEARNT
- PRE ENGINEERED
- MANUFACTURED BY
PROVEN SUPPLIER BASE
- INTEGRATED PLAN: DESIGN-
FABRICATION-LOGISTICS
- LESS LAYDOWN AREA
- LESS NEED FOR QUALIFIED
ERECTION PERSONNEL
- MINIMIZES IMPACT OF SITE
INTERRUPTIONS
- HIGH QUALITY SP. WELDING &
CLEANLINESS
- LESS COMMISSIONING
EFFORT
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GE Gas Power Plant SolutionsModular plant outlook
LIFE CYCLE ENGINEERING ORDER
PLACEMENT
MANUFACTURE,
ASSEMBLY
& TESTING
PACKING
& DELIVERY
INSTALLATION
AT SITE
1 2 3 4 5
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GE Gas Power Plant SolutionsModular plant outlook
Up to 50%site man-hours
Up to 10%faster power
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Modularisation Gas Power Plants Case study
CALCULATION SET UP
9HA.02 SS CC plant (804 MW*)Project site in EU
Module fabrication in Western EU
Data from executed projects
CONCLUSION
Risk reduction during execution
Schedule reduction: 10%
Total installed cost reduction: 6%
* net output as per GE
product catalogue 2017
TAKE AWAYS
- GE Investing substantially in smart
design, cost out, supply chain
optimization of plants & modules
- NPI program on modularization to
develop portfolio of pre-engineered
- modules GPS & GE Oil & Gas
working together on design &
manufacturing to leverage
expertise
- Target
- bring maximum value to the
customer
- by mitigating execution risks.
bring down TIC of modular
solution (up to 10 %)
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Potential modules In critical and high work density areas
POWER TRAIN
(GT GENO + ST)HRSG
POWER
ISLAND
GT PRIME PACKAGING – 6 MODULES
AIR INLET FILTER HOUSE AND SILENCER
FIRE PROTECTION
COMBINED LUBE OIL SYSTEM
FUEL GAS CONDITIONING
GENERATOR STATOR COOLING WATER
GENERATOR GAS SYSTEM
GENERATOR SEAL OIL
MODIFIED C FRAMES (INCL. DOWN COMERS)
IP AND LP DRUMS
STACK (PRE FABRICATED)
HRH AND CRH VERTICAL PIPING CLUSTER
VENTS AND DRAINS
SILENCER AND VENT STACKS
FEEDWATER RECIRCULATION
BYPASS AND STEAM PIPING – 3 MODULES
CLOSED COOLING WATER
EXPANSION TANK MODULE
FEEDWATER PIPING
MAIN PIPE RACK
SMALL PIPE RACK
MAIN COOLING WATER
BUS DUCT
ELECTRICAL MODULES*
SAMPLING*
DOSING*
CEMS*
FEEDWATER PUMP *
CONDENSER*
EMERGENCY DIESEL *
AUX. BOILER *
* Same delivery condition also in stick built (bts)
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© 2017 GE All Rights Reserved
Module designswith Application Range and Options
EXPANSION
VESSEL
CLOSED
COOLING WATER
MAIN
PIPE RACK
COMBINED
LUBE OIL SYSTEM
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© 2017 GE All Rights Reserved
GE & ModularizationInnovation & Excellence
COST REDUCTION SIMPLER
DESIGN SOLUTION
PROJECT EXECUTION
EXCELLENCE AND RISK
MITIGATION
SMOOTH AND SMART
INSTALLATION
PARTNERING
IN PROJECT
DEVELOPMENT
24