energy efficient solutions for fpso applications
DESCRIPTION
Arne Spetalen, Head of Global Sales Topsides Systems, Siemens AG - Oil & Gas Division, Oslo on how FPSO Applications can be energy Efficient SolutionsTRANSCRIPT
Solutions for the Oil & Gas Industry
Energy Efficient Solutions for FPSO Applications
Presentation by Arne SpetalenHead of Global Sales, Topsides Systems
Page 2Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Scope of Presentation
1. Energy Efficient Solutions – What it means to Siemens.
2. Energy Efficient Solution for FPSO’s – Variable Speed Drive (VSD)
3. Mechanical versus Electrical Drive (Case Study)
4. Summary
Page 3Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Energy Efficient Solutions;It all begins with Commitments
Our Vision is to Create Innovative and Reliable Solutions for Cleaner Energy Worldwide
Major R&D investments in Siemens AG
� €3.9 billion in fiscal 2009, or 5.1% of revenue
� 31,800 R&D employees worldwide
� 17,000 software engineers
� 176 R&D locations in over 30 countries around the world
� 7,700 inventions in FY2009
� More than 56,000 active patents
� Our patent position in fiscal 2009: �Germany: No. 2�Europe: No. 2�USA: No. 12
Page 4Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Subsea Power and Processing
Pros / Cons
Significantly lower investment than surface installations
Unmanned facilities – safety for personnel
Reduced environmental impact
Suitable for arctic conditions / hurricane areas
Sound economic arguments
Subsea experience to be built for machinery – reliability subsea to be proven
Selected References
Statoil testing – subsea capable compressor ordered
StatoilHydro – SnoA, COP 8 Control System
Statoil – SnoB, Gas Detection
Norsk Hydro – SnoA, X-tree & Well Control
Saga / Hydro – Snorre B, DIACS
What’s involved?
Production systems moved to sea bed
Now – minimizing topsides
Future – sub sea to beach – no topsides
Operating - subsea transformers, VSD, motor, power distribution
Near future – sub sea compression, process packages
Page 5Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Electric Power on Sea (EPOS)
••EPOS explores the value of stranded gas in areas in areas with nEPOS explores the value of stranded gas in areas in areas with n o or limited gas transport infrastructureo or limited gas transport infrastructure
••EPOS employs commercial plant technologies with ver y low risks rEPOS employs commercial plant technologies with ver y low risks r elated to production and operationelated to production and operation
••It refines It refines ““ lostlost ”” and marginal energy resources and offers a very low environmentand marginal energy resources and offers a very low environment al footprintal footprint
Page 6Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Cable from Shore
Overall Objective Selected References
Removes CO2 obligations from platform operator
Centralised power production reduces overall emissions and increases efficiency
Maintenance costs reduced by removing the GT’s
Increases reliability / availability on platform
Economic case strong for cables to say 100km; study looking at 300km
Statoil FEED - Luva project, North Sea
300km offshore
Involves:
Centralized power plant onshore
Electrical power transmission by HVAC or HVDC technology depending on distance to grid/consumer and power capacity
All electric drives on vessel / platform
Page 7Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Utilization of VSD as an Energy Efficient Solution for FPSO Applications
Variable Speed Drive (VSD) Definition
A VSD regulates the speed and rotational force, or torque output, of an electric motor.
•Significant technology improvement over the last 15 years
•General knowledge about VSD’d have resulted in a larger market share in the offshore market - fixed and floaters
•Wide speed range up to 15.000 rpm
•Currently, VSD’s up to 65 MW are being put in operation
23 MW VSD in Holland23 MW VSD in Holland
Page 8Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Development of Variable Speed Drive Systems
� 4x10 MW starter-helper VSDS
� incl. scheme for export of power
� MV switchgear� Automation� SHELL-
specification
Project TIGA
� 2x65 MW VSDS� 1x32 MW VSDS� as prime movers
of refrigerant � compressors� network analysis� dynamic &
vibration study� full load
performance test
Project Snøhvit/Hammerfest
20022004
order date operational
19992003
20022005
� 4x7,5 MW VSDS
Project OMAN � 2x17 MW starter-helper VSDS
� network analysis� dynamic &
vibration study� full load
performance test
Project SEGAS
19962000
tech
nica
l com
plex
ity &
pow
er r
ange
�
Page 9Innovative and Reliable Solutions for Cleaner Energ y Worldwide
VSD Drive – Key Features
Converter transformer
Adapt the power system voltage to the converter & motor voltageProvide for isolation and the pulse supply systemLimit possible fault current in thyristor circuit
Frequency Converter
Rectify incoming power voltage & frequency to generate a variable output voltage & frequency for the motor
Motor
Induction motor ~2-20MW, to 15,000 rpmSynchronous above ~8MW, to 7000 rpm
.
VSDVSD’’s provides:s provides:••Limited thermal and mechanical stressLimited thermal and mechanical stress
••No measurable tear and weir over timeNo measurable tear and weir over time
••Not sensitive towards frequent starts and loads variationsNot sensitive towards frequent starts and loads variations
••Limited number of moving components Limited number of moving components –– easy to handleeasy to handle
••Suited for 3Suited for 3--5 years continuous operation5 years continuous operation
••Small demand for stocking spare parts (very few required)Small demand for stocking spare parts (very few required)
In Summary:In Summary:
A VSD solution is robust A VSD solution is robust and almost and almost
maintenance freemaintenance free
Page 10Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Mechanical versus Variable Speed Drive; Case Study
Page 11Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Energy Efficient Solutions Specifically for FPSO’s
Selection of drivers for high speed rotating machinery.
Electrical versus mechanical
On what basis is this decision being made?
By the mindset of individuals and/or by what’s regarded as ”company standard”?
Or
By a proper case evaluation where energy efficiency is one of the key criteria for making the
decision?
Page 12Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Commercial Considerations
Gas Turbine Electric VSD
Auxiliary equipment - Air intake, anti-icing and exhaust silencer- Air filtration & Noise enclosure- Fire and gas detection & Fighting- Emission control and regulation- Additional lube oil system- Hydraulic starter- Water-washing system on-/offline- Ventilation for cooling and pressure-preset
- Utility substation- Harmonic Filters- Converter building or module if required
Maintenance Very High Very Low
Scheduled Downtime Approx. 5 days p.a. Approx. 1 day p.a.
Spare Parts High Low
Insurance cost High (Due to fire hazard) Low
Pollution, emissions High “None”
CAPEXCAPEX LowLow HighHigh
Page 13Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Performance Related Considerations
Gas Turbine Electric VSDOutput Power Highly depends on temperature No adjustments for site conditions.
Output power vs speed Almost constant Proportional to speedFull load efficiency < Approx 40 % > 96%
Part load efficiency < low at 70% load Always running at high efficiency
Starting reliability Lower than 100 % Typically 100%Reliability Medium HighAvailability Medium HighRestart after forced shut-down (trip) Typically about 2 hours Immediately
Speed control range Limited speed range Less limitationSpeed control accuracy High HighDesign flexibility Low HighStarting time Medium Short (seconds)Load assumption Approx. 15 min. after successful start Instantaneous after switch-on, but limited
to compressor
Influence on power supply None Depends on char. of grid. Harmonic study required
Dynamic braking Impossible StandardRun out by power failure Short time to stop Longer time (motor inertia), requires
more oil
Page 14Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Summary of Evaluation Criteria
Impact of ambient conditions
Operational flexibility **CAPEX*
Availability / Reliability
Interfaces / hook up
Starting reliability/
# starts allowed
Speed control range / part
load efficiency
*CAPEX – based on multiple GTGs and comps
** When moving from one field to another – ease of a daptation with existing VSD drives
OPEX
Weight / footprint Start up time
Page 15Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Case Study: Mechanical versus Electrical Drives
Traditional concept using gas turbines as compressor drives: In this example your drive configuration on the FPSO appears as follows:
Electrical load, GT rated at 32 degC 19,000 kW (3 x 50%)Compression 2 x 100% LP shaft power 2,200 kW eachCompression 3 x 50% HP shaft power 4,300 kW each
GG
GG
GG
PG: 3 x 13 MW ISO (n+1) LP: 2 x 3.1 MW ISO HP: 3 x 6.0 MW ISO
Total installed gas Total installed gas turbine power:turbine power:
63,2 MW63,2 MW
Page 16Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Case Study: Mechanical versus Electrical Drives
Here, the gas turbine drives are replaced by VSD’s:Power Generation 19,000 kW 19,000Power for LP Compression (2x100%) 2,200 kW each 2,200Power for HP Compression (3x50%) 4,300 kW each 8,600
Σ 29,800 kW
MM
MMGGGGGG GG
MM
MMMM
PG: 4 x 13 MW ISO (n+1)
LP: 2 x 2.4 MW drives HP: 3 x 4.7 MW drive
Total installed gas Total installed gas turbine power:turbine power:
52 MW52 MW
Page 17Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Summary of Example
Initial concept:
Alternative concept:
MMMMMM
GGGGGG GG MMMM
GGGGGG
By introducing VSD’s, your total installed gas turbine
duties drops from 63,2 MW to 52 MW.
More importantly, number of gas turbines is reduced by 50% (from eight to four) and we’re only having one
turbine type
Page 18Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Final Word: Why are VSD systems normally the ”looser” when decisions are made ?
Commercial:Commercial:
No secure source of electrical power available at the facility
Lack of offshore references"Unproven equipment“
Psychological:Psychological:2.2.Electrical equipment, high voltage in particular, represent a safety issue for the workersUncertainty regarding the rotor dynamics from an electrically driven shaft
Technical:Technical:3.3.Outside the comfort zone of mechanical personnel when it comes to vibrations and harmonics as applies to VSD systems.
Need for step-up gear for special applications
1.1.
Outside the comfort zone of ops personnel
Lack of competence and skills to evaluate VSD systems and solutions
The procurement policy is focusing entirely on CAPEX, OPEX is not considered important
Focus is on rotating machinery drives alone and not in combination with the power generation plant
If the reasons are not
psychological, then these are the reasons.
Page 19Innovative and Reliable Solutions for Cleaner Energ y Worldwide
Thank you for listening
Power ManagementSystem
Power DistributionWater treatment
Power Generation
Compressor Systems
Control system & Communication(Offshore – Onshore)
VSD