exploring the benefits of modularization - ge oil & gas · pdf fileexploring the benefits...

© 2017 GE All Rights Reserved

Exploring the benefits of modularizationEMANUELA SILENZI

GE OIL & GAS MODULES PRODUCT MANAGER


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


GE & ModularizationInnovation & Excellence

COST REDUCTION SIMPLER

DESIGN SOLUTION

PROJECT EXECUTION

EXCELLENCE AND RISK

MITIGATION

SMOOTH AND SMART

INSTALLATION

PARTNERING

IN PROJECT

DEVELOPMENT

3


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

4


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

5


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)

6


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

7


Modularization as a product

APPLICABLE

PRODUCT

SPECS

STRUCTURAL

DESIGN

PLANT

LAYOUT

EXECUTION

STRATEGY

EQUIPMENT

DESIGN

LESSON

LEARNED

CUSTOMER

REQUIREMENTS

8


Technology enablersPower density and plant simplification

DRIVERS COMPRESSION DIGITAL

9



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



COMPRESSIONHIGH PRESSURE RATIO COMPRESSOR

FROM 2 COMPRESSOR BODIES TO 1

11



COMPRESSION SCRUBBER COMPRESSOR

STRONG FOOTPRINT AND WEIGHT REDUCTION

WET COMPRESSOR

PROCESS BOP OPTIMIZATION

Integrated

Moto Compressor

Suction

Scrubber

12


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

13


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

14


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

15


Bigger advantages

with modularization?

16


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

=

17

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


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

18



LIFE CYCLE ENGINEERING ORDER

PLACEMENT

MANUFACTURE,

ASSEMBLY

& TESTING

PACKING

& DELIVERY

INSTALLATION

AT SITE

1 2 3 4 5

19



Up to 50%site man-hours

Up to 10%faster power

20


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 %)

21


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)

22© 2017 GE All Rights Reserved


Module designswith Application Range and Options

EXPANSION

VESSEL

CLOSED

COOLING WATER

MAIN

PIPE RACK

COMBINED

LUBE OIL SYSTEM

23


GE & ModularizationInnovation & Excellence

COST REDUCTION SIMPLER

DESIGN SOLUTION

PROJECT EXECUTION

EXCELLENCE AND RISK

MITIGATION

SMOOTH AND SMART

INSTALLATION

PARTNERING

IN PROJECT

DEVELOPMENT

24

exploring the benefits of modularization - ge oil & gas · pdf fileexploring the benefits...

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