MicroTurbine Applications for the Oil and Gas Industryamericaapproved.com/presentation3.pdf ·...
Transcript of MicroTurbine Applications for the Oil and Gas Industryamericaapproved.com/presentation3.pdf ·...
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
MicroTurbine Applications for the Oil and Gas Industry
Lee Richards - Director of Sales for Oil & Gas, Capstone Turbine Corp
Bryan Hensley - VP Sales, Pumps & Service
15 July 2008
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
What is a MicroTurbine?
Power generator driven by a small scale gas turbine
• Electrical Efficiency of 26-33%• Combined with CHP can achieve thermal efficiency of 80%+• Wide range of fuels – 350 btu to 2500 btu
• Up to 7% H2S with C30• Extremely Low Emissions - <9 ppm NOx• Air Bearings
• No Oils or Lubricants• Air Cooled
• No Antifreeze or Coolants• Variable Speed
• 45,000 to 96,000 RPM
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Air Bearings
Spring
Foil
Shaft
Boundary Air
Spring
Foil
Shaft
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Inside the Capstone MicroTurbine
Combustionchamber
Exhaust output
Recuperator
Fuel injector
Air bearings
Compressor
Generator
Air intake
Cooling fins
Turbine
• No gearbox, pumps, or other mechanical components
• Recuperated Engine
• Permanent magnet alternator
• Lean premix combustion
• Air Bearings
• Air Cooled
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
• No moving parts• Variable Voltage 400-480 volts• Variable Frequency 10-60 Hz• Voltage & Current source Inverter• “Electronic” Gearbox• Built in Fault protection
Power Electronics
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Inverter Based Electronics
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MultiPac & Grid Connect
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Capstone Products
C30 & C65
Available with gas & liquid fuels
C200 & C200 CHPC65 CHP
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Capstone Products
C30 & C65Class I Div 2ATEX Zone 2
C30 & C65 SS
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Performance
C30 C65 C200Rated Power 30 kw 65 kw 200 kw
Full Load Efficiency 26% 28% 33%
Heat Rate12,200 Btu/kWh
(12,800 kJ)11,000 Btu/kWh
(11,600 kJ)10,300 Btu/kWh
(10,900 kJ)
Liquid Fuel D2, 1-K, Jet A, JP-8, JP-5 D2 In Development
Gas Fuel (HHV) 325-2131 Btu/scf 325-2550 Btu/scf 325-2550 Btu/scf
Output Current 46 Amps RMS 100 Amps RMS 310 Amps RMS
Nominal Voltage 400 to 480 VAC 400 to 480 VAC 400 to 480 VAC
Exhaust Gas Temp 530 F (275 C) 588 F (309 C) 535 F (280 C)
NOx Emissions
Gas : <9 ppmLiquid : <35 ppm
Gas: <9 ppm<5 ppm CARB
Gas: <9 ppm<5 ppm CARB
Acoustics 65 dBA 65 dBA 65 dBA
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Packaged Solution
C600 C800 C1000Rated Power 600 kw 800 kw 1000 kw
Full Load Efficiency 33% 33% 33%
Heat Rate10,300 Btu/kWh(10,900 kJ/kWh)
10,300 Btu/kWh(10,900 kJ/kWh)
10,300 Btu/kWh(10,900 kJ/kWh)
Output Current 930 Amps RMS 1240 Amps RMS 1550 Amps RMS
Nominal Voltage 400 to 480 VAC 400 to 480 VAC 400 to 480 VAC
Exhaust Gas Temp 535 F (280 C) 535 F (280 C) 535 F (280 C)
Exhaust Energy 4,050,000 BTU/hr 5,400,000 BTU/hr 6,750,000 BTU/hr
• (3), (4), or (5) C200 Units• Stackable Footprint• 30’ Enclosure with ISO Footprint• Load control from 100% to idle• Flexible Maintenance• Parts redundancy with C200
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
C1000 ISO Efficiency
High Part Load Efficiency
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Installation
60 kw MicroTurbine
20 kw Recip Package
Height (ft) Width (ft) Depth (ft) Weight (lbs)
C30 Industrial 6.4 2.5 5.0 1271
C30 C1D2 7.7 3.1 7.0 2475
C65 Industrial 6.9 3.1 7.0 2471
C65 C1D2 8.2 3.1 7.0 3600
C200 8.2 5.5 12 7000
C1000 9.6 8.0 28 28,500
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Typical Site Layout
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Oil & Gas Experience
Units Sold O&G Installations
C30 3350 285
C60 1282 122
C65 360 135
C200 45 2
Total >5037 >544
• Mexico• 36 Units in Offshore Oil Production
• Flare Gas Fuel
• NE United States Pipeline• 31 Units in Gas Transmission
• CHP Applications
• Russia Pipeline• 50 Units in Remote Gas Transmission
• South America Pipeline• 65 Units in Gas Transmission
• More than 60 O&G customers worldwide• More than 70 packages installed offshore
80% of all Microturbines Sold Worldwide are Capstone
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Certification
• California CARB 2007 Listed
• UL 2200, the latest generator safety standard, and UL 1741, the national grid interconnect standard
• MicroTurbines were the first generators of ANY type state-approved by New York and by California (“Rule 21”) for direct-to-grid interconnection
• Also compliant with NFPA, IEEE519, CE, NEC, CSA, ATEX and other internationally recognized safety standards
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Capstone: A Big Small Company• Founded 1988• First to introduce microturbine
energy products ten years later• 100% microturbine focused• The world leader in
microturbines• >5000 production units sold and
shipped
• ISO 9001:2000 and 14001:2004UL-certified
• Offices in LA, NYC, Mexico, Milan, Bath, Shanghai and Tokyo
• Distributors located world wide
Capstone Corporate HeadquartersChatsworth, California
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Preventative Maintenance
Servicing injectors at 20,000 hrs on an offshore platform
8,000 Hours
Air Filters Clean/ReplaceFuel Filter ReplaceIgniter Replace
20,000 Hours
Injectors ReplaceBattery Pack ReplaceThermocouple Replace
40,000 Hours
Engine & Generator
Exchange
• Typical Maintenance cost of $0.016 kWh
• Average of 6 Hours of Planned Maintenance per year
• Capstone will guarantee cost of planned and unplanned maintenance through Factory Protection Plan
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Oil & Gas Specific Applications
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Key O&G Objective• Primary Uses
• Generate Power• Eliminate Flare/Vent• Combine Heat/Power
• Use power for applications• Prime site power• Black start power• Back-up power• Peaking• Supplemental power
• Reduce utility costs
• Generate power from fuel sources such as• Casing gas from oil production• Condensate gas from liquid processing• Gas too rich or too lean to meet pipeline standards• Sour gas with H2S – up to 7%
3-pack on oil flare gas in New Mexico
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
• Low Installed Cost• Short Commissioning Period • Easy Interconnects to Local Grid
or Bus• Very Low Maintenance• Ease of Operations• No Lubricants or Coolants• Small Footprint, Light Weight• < 65dBA Acoustic Emissions• Ultra-low NOx emissions with no
post-combustion devices or chemicals
• Accepts 350-2500 Btu w/up to 7% H2S (C30)
Benefits of MicroTurbines in O&G
Test prior to platform deployment, Netherlands
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Integrated Heat Exchanger
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Exhaust Heat Utilization - CHP
Source: EPA and DOE, see notes page for specific references
33% av. utilityefficiency
80% av. boilerefficiency
120 kWth
65 kWe 160 kWwaste
345 kWfuel
130 kW waste
30 kW waste
195 kW fuel
150 kW fuel
40 kWwaste
230 kWfuel
65 kWe 120 kWth
• 80% average total efficiency• 0.15 lb/MWh NOx & 1,540 lb/MWh CO2
• 54% average total efficiency• 3.4 lb/MWh NOx & 2,320 lb/MWh CO2
Traditional Approach Capstone ICHP
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Exhaust Heat Utilization - CHP
• Heat to glycol or hot oil systems• Preheat fuel gas to larger turbines
or engines• Preheat water to steam boilers• Direct heat to oil/water separators• Supplemental heat to regas LNG or
other liquid regas process• Building or utility heat• Various gas plant and amine plant
applications• Refrigerant based systems
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Exhaust Heat Utilization
Microturbines also generate voluminous exhaust heat• C65 Generates 561,000 BTU/hr (591,000 kJ/hr) at 588F (309C)
Heat from two C30s running on untreated wellhead gas goes to “heater/treater” separator
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Example Applications
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Cathodic ProtectionExample Installation by Pumps & Service• Client – Major US Gas Transmission Company• Project - Gas Pipeline Cathodic Protection• Requirements - Customer required extremely reliable
power source at low current in very remote applications.• Alternative Solutions
• Grid power – would require several miles of power lines installed
• Recip Generators – would require regular maintenance intervals
• Thermal Electric Generators (TEG) – unreliable
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Cathodic Protection• Solution – Single C30 installed along pipeline as required• Benefits
• Minimal maintenance requiring site visits only once each 6 months• Remote monitoring and diagnostics to verify operational quality• Extremely low emissions for installation in national forest
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Primary Power for Remote SiteExample Installation by Pumps & Service• Client: Major US Production Company• Project: Primary Power for Salt Water Disposal• Requirements: Needs reliable, cost-effective power in
remote location• Alternative Solutions
• Grid Power – Not available• Re-Power – Eventually same problems with high maintenance
cost, high emissions, and excessive down time.• Reciprocating generators – Same as re-power
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Primary Power for Remote Site• Solution - Multi-pac of 3-C30 installed in a control room
fabricated for this site.• Benefits
• Lowered maintenance cost• Improved reliability of site• Improved flexibility to control and maintain pressures and flow
rates• P&S Later designed New SWD in 2006 with Capstone
because of success
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Primary Power for Oil PipelineExample Installation by Pumps & Service• Client: Large US Oil Pipeline• Project: Transfer pumps for a major Oil Pipeline in
Remote Location• Requirements: Reliable Power because of extremely
high cost for down time as well as being on a very remote location
• Alternative Solutions • Grid Power – Not available• Reciprocating Generators – regular maintenance schedules,
unplanned down time (low oil, high engine temp..) and reliability.
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Primary Power for Oil Pipeline• Solution: (15) C65 installed as the power supply for location• Benefits:
• Minimal maintenance requiring planned site visits on semiannual schedule
• Remote monitoring and diagnostics to verify operation• Reliability. No unacceptable downtime
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Offshore Resource Recovery
The Solution:• A Capstone microturbine, UL certified for hazardous oil and gas applications• The microturbine runs on onsite unprocessed wellhead
gas which is normally flared, providing a power source to the platform • The microturbine cut maintenance time by ~95%
compared to reciprocating engine generators • The microturbine ran almost non-stop for 25,000 • Capstone has microturbines running on other platforms
in the Gulf of Mexico, Gulf of Alaska, Bay of Campeche, the North Sea, Mediterranean Sea, and South China Sea
The Issues:• Provide a reliable power source in a
hazardous oil and gas application on an offshore platform in the Gulf of Mexico
• Recover value from onsite flare gas which is normally lost to the environment
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Offshore Installations
Deployed in the Gulf of Mexico
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Conclusions
• Ideal power generation for oil & gas installations, onshore and offshore
• More than 5,000 Capstone MicroTurbines sold and 19+ million operating hours
• Fuel Gas from 350 BTU – 2500 BTU with up to 7% H2S
• Low emissions of less than 9 ppm NOx
• Lowest maintenance cost of 0.016 $/kWh with 6 hours/year of planned maintenance
• No lubricants or coolants
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com