GT for Oil&Gas Application

7/30/2019 GT for Oil&Gas Application

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11/15/2001 - #1

Turbo Expo 2003Gas TurbineGas Turbine

Technology CenterTechnology Center

Southwest Research InstituteSouthwest Research Institute

Gas Turbines in Oil and Gas Applications

Dr. Klaus Brun Southwest Research Institute

Dr. Rainer Kurz Solar Turbines

-- Gas Turbine Technology CenterGas Turbine Technology Center --

Southwest Research InstituteSouthwest Research InstituteJune 2003June 2003

11/15/2001 - #2

Outline

Introduction

Function and Features of GT:- Mechanical Drive (Compressors, Pumps, Blowers)- Electricity Generation (Generator)

On-Shore Versus Offshore Requirements

American Petroleum Institute (API) Codes:- Applicable Codes (API 616,617,614)- Critical Technical Requirements

Principal GT Application Areas:- Upstream

a) Oil Field and Offshore Power Generationb) Gas Lift (Enhanced Oil Recovery -EOR)c) Waterflood(EOR)d) Gas Injection (EOR)f) Export Compression

Gas Turbine Technology Center

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Outline Cont.

g) Gas Gatheringh) Gas Plant and Gas Boosti) Gas Storage/Withdrawal

- Midstreama) Pipeline Compressionb) Oil Pipeline Pumpingc) LNG Plant (refrigeration, compression, power)

- Downstreama) Refinery power (Steam and Power Cogeneration)b) Refinery Integrated Gasification Combined Cyclec) Methanol / Fischer-Tropsch / Ethanol Fueled Plants

Summary

Questions

Gas Turbine Technology Center 11/15/2001 - #4

O&G Applications

Why Differentiate O&G Gas Turbines from other Applications?

Oil & Gas Requirements:

- Availability / Reliability- Ruggedness

- High Power/Weight ratio

- Efficiency not Critical

Industrial Power Generation Requirements:

- Cost of Electricity

- Efficiency

- Cost of O&M

Different Gas Turbine Products for O&G Market


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Gas TurbineGas Turbine


Southwest Research InstituteSouthwest Research Institute Single and Two Shaft

Shaft Coupling

Single Shaft Gas Turbine (with Shaft Coupling):- Power Turbine and Gas Generator Turbine on Same Shaft- Fixed Speed Applications (Range: 90%-100% Full Speed)- Mostly used for Electric Power Generation; i.e., Generator Drive via Gearbox

(1500 rpm 50 Hz, 1800 rpm 60 Hz)

Gas Turbine Technology Center 11/15/2001 - #10

Single and Two Shaft

Two-Shaft Gas Turbine (no Shaft Coupling):- Power Turbine Independently Supported on its Own Shaft and Bearings- Variable Speed Applications (Range 25%-100% Full Speed)- Used for Compressor, Pump and Blower Applications

Single and Two-Shaft Gas Turbine Power Range:0-100% Full Load (Low Efficiency and High Emissions at Loads Below 60%)

No Shaft Coupling


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Components & Layout

Inside the Package:- Fuel System

Natural Gas

Liquid (pumped)

- Bearing Lube Oil System Tank

Filter Pumps (main, pre/post, backup)

- Starter (pneumatic, hydraulic, AC motor)- Controls (on-skid, off-skid)

- Seal Gas System (compressors)

Outside the Package:

- Enclosure and Fire Protection- Inlet System

Air-filter (self-cleaning, barrier, inertial)

Silencer

- Exhaust System Silencer

Stack

- Lube Oil Cooler (water, air)

- Motor Control Center

- Switchgear, Neutral Ground Resistor

- Inlet F ogger/Cooler

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Manufacturers & Models

Major Oil and Gas Market Players (Below 30 MW):

Solar Turbines:- Saturn 20 1 MW

- Centaur 40/50 3-4 MW

- Taurus 60/70 5-7 MW- Mars 90/100 8-10 MW- Titan 130 13 MW

General Electric Oil & Gas:- GE 5 5 MW- GE 10 10 MW

- LM 1600 16 MW- LM 2500 25 MW

Rolls-Royce:- Avon 15 MW

- RB211 30 MW

Alstom:

- Typhoon 5 MW- Tornado 8 MW

- Cyclone 13 MW- GT 35 17 MW


2004 Southwest Research Institute. All rights reserved.


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11/15/2001 - #13



Southwest Research InstituteSouthwest Research Institute Offshore Platform (Marine)

Land Based Fixed Leg Jack-Up Semi-Sub FPSO Tension Leg

Features Compact design, reduced lube oil tank, single lift modules

Vibration isolators, special grouting

Stainless steel (enclosure and inlet/exhaust system)

Baffles/Scavenging pump in LO tank, inclinometers

Lloyds, DNV, ABS, Coast Guard Certification

Sub base, three point mount, gimbles, vibration mounts

Technical Requirements Low weight and dimensions

Low Vibrations

Resistance to Saltwater

List, trim, pitch, roll operation

Marine codes

Foundation twisting

Operational RequirementsHighest availability as platform often depends on GT, but

No direct access to technicians and repair facilities Limited spare parts storage capabilities ?

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Offshore Features

Compressor

Gas Turbine

Sub Base

Mount

Lube Oil Tank Baffles Scavenging Pump for

Pressurized Bearings

Inclinometer

Single Lift

ModuleInclinometer - Alarm and Shutdown at High List, Trim, Pitch, Roll Angles

Sub Base - Added Sti ffness for Gas Turbine and Compressor Skids

Baffles - Continued Supply of Lube Oil at Inclined Operation

Scavenging Pump - Forced Supply of Lube Oil at Inclined Operation

Mounts - Isolation from Twisting and Vibration

Single Lift Module - Simplified Installation and Transportation to Platform

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Gas Turbines for Oil & Gas

- Mid Stream -

The Oil & Gas Transportation Process

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Natural Gas Compression

Laying of Underground NG Pipeline

- Major natural gas pipelines operate between 800-1400 psi pressure.

- Re-compression is required every 50-300 miles

to compensate for line (friction) losses.

- Most pipeline compressor stations above 2000 hputilizes gas turbine driven centrifugal compressors.




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LNG Process

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Liquid Natural Gas (LNG):In the LNG Plant Methane cooled to 260 F to be liquid at

atmospheric pressures. In liquid form Methane has a volume600 times smaller than in gaseous form. Thus, it can easily betransported on special tanker-ship with a built-in cr yogenic

cooling system.

The LNG process involves multi-stages of compression, cooling,and expansion of methane.

LNG Plant Concept:

Vapor Pressures



Southwest Research InstituteSouthwest Research Institute

Methane Gas

P=300 psiT=100 F

Liquid Methane

P=14.7 psi

T=-260 F

P=3000 psi

T=100 FP=3000 psi

T=500 F

Compressor Cooler Expander(Gas Turbine Driven)

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LNG Production Plant

Gas Turbines

For Power

Generation

Multi-Stage Cooling to Boil

Off Higher Hydrocarbon Chains

Gas Turbines

For Compression

of Natural Gas

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LNG Gas Turbines

Compression

Typical LNG Compression Requirements:Flows: 5-200 MMSCFDPressure ratios: 14.7-3500 psiGas: Methane

Preferred Equipment:- Gas turbine with multi-body centrifugal compressor- Often gear box required- Each centrifugal compressor has up to 10 stages and intercooling- Single train arrangement (very expensive; i.e, no redundancy)- Gas turbines from 10,000 to 60,000 hp

Power Generation

Typical LNG Power Generation Requirements:Power: 5-50 MWOperation: ContinousGas: Methane

Preferred Equipment:- Gas turbine generator- Gear box required to 1500 rpm ( 50 hz) or 1800 rpm (60 hz)- Simple cycle operation (efficiency not critical)- Multiple unit arrangements with redundancy- Gas turbines from 3 MW to 20 MW

Multi Body Driven Compressor

Gas Turbine Generator

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LNG Receiving Terminal

Processes:

- Receiving of liquid LNG

- Warming of LNG to convert it to

Methane (natural) gas

- Re-compression of Methane into

pipeline ( 0 to 1000-1400 psi)

Gas Turbines are used for LNGPumping and Methane Compression

LNG Tanker with

Cryogenic Cooling




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Southwest Research InstituteSouthwest Research Institute Gas Turbines for Oil & Gas

- Down Stream -

The Refining and Distribution of Oil & Gas

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Refinery

Converts Crude Oil Into Marketable Products

Products:- 43% gasoline - 4% propane

- 22% heating oil & diesel - 3% asphalt- 10% jet fuels - 18% others(lube oil, waxes, plastics, etc.)

Cracking(Breaking of largehydrocarbon chains)

- Thermal

Steam

VisbreakingCoking

- Catalytic

FluidHydrocracking

Fractional Distillation

Alkylation(Altering molecular

structure)

Catalytic Reforming(Combining molecularchains to form longer

chains)

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Refinery Gas Turbines

Steam & Power Gas Turbine Cogeneration- Steam requirements for distillation, coking, steam cracking, and visbreaking- Electric power requirements for pumping of hydrocarbons and water/steam

Heat Recovery Steam GeneratorHeat Recovery Steam GeneratorUse Gas Turbine Exhaust Heat to Generate Steam For Refinery Processes(aka HRSG, Waste Heat Recovery Unit, WHRU, Boiler)

Gas Turbine

Generator Exhaust

Heat

Boiler

Economizer

Supplemental

Duct Firing

By-Pass

StackStack

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Refinery IGCC

Integrated Gasification Combined Cycle

Gasificaton

Gasifier HX

Oxidant

Supply

System

Combined

Cycle

Cleanup

Sulfur

Slag

Syngas

Clean

Fuel

Slag

Hydrogen

Ammonia

Methanol

Chemicals

Electricity

ProductsFuels

z Bituminous Coal

z Sub Bituminous Coal

z Lignite

z Orimulsion

z Residual Oils

z Refinery Bottoms

z Petroleum Cole

z Biomass

z WastesFour (4) Islands:- Gasification- Syngas Clean-Up- Power- Air separation Unit

IGCC Process:

- Converts Waste Products from refinery (pet coke, heavy oils, tars)

into hydrogen and gas turbine fuel (synthesis gas)

- Provides steam and power for refinery needs

- Provides hydrogen for refinery hydro-cracking needs



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Southwest Research InstituteSouthwest Research Institute Refinery Gas Turbines

Sarlux Refinery Sardinia / Italy

Power & Steam Generation

Typical Refinery Requirements:

Power: 20-250 MWSteam: Never Enough!Operation: ContinousFuels: Methane, LPG,

Naphtha, Hydrogen,Synthesis Gas,Refinery Off-Gas,Diesel

Preferred Equipment:- Gas Turbine Generator Train with Waste Heat

Recovery Unit (HRSG)- Frame type gas turbine (no aero-derivatives)- Island mode: Multiple Units for redundancy- Grid Connected: Single Larger Unit

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Alternate Gas Turbines Fuels

Stranded Natural Gas:

- Associated natural gas is by-product of oil production

(up to 70% of volume from well can be associated natural gas)

- Associated natural gas is abundant in many places

of the world but is often not close to a market

- Options for oil producer:

a) Flare the gas too dirtyb) Re-inject the gas expensive

c) Generate power no market for power

d) Transport gas to market via pipeline short distances only, expensive

e) Convert gas to transportable & marketable (liquid) product

Liquid Natural Gas Options

LNG High infrastructure costs (LNG plant , tanker, terminals)

Methanol (MeOH) High conversion costs, market very small, transport risks

Fischer-Tropsch High conversion costs, market not developed

Ethanol - High conversion costs, market not developed

Potential Gas

Turbine Fuels

Methanex MeOH Plant Punta Arenas / Chile

Worlds Main Energy Problem Is Not Availability.

It Is Energy Transportation.

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Oil & Gas Gas Turbines

Questions?


Documents

GT for Oil&Gas Application