Subsea High Power Long Offset ElectricalHåvard Devold, ABB, 2014 US-Norway Oil & Gas Technology Partnership Conference
Subsea High Power Long Offset Electrical Power Systems
© ABB GroupMarch 5, 2014 | Slide 1
© ABB GroupMarch 5, 2014 | Slide 2© ABB GroupMarch 5, 2014 | Slide 2
ABB Electrical Subsea HistoryDeveloping with the industryDeveloping with the industry
2011-Åsgard
2012-Gullfaks WGC
Long Step-out 2x9MVA,22km,200Hz
2008-2011Åsgard/K-lab
Long Step-out PowerQualification,
15MVA,47km,200Hz2007 2010
ÅsgardLong Step-out
2x15MVA,47km,200Hz
2006-2009Tyrihans
31 km tie-back Subsea
El t i l t
2007-2010Ormen Lange
20MVA SubseaSubsea Transformer
Technology qualification
2000SEPDIS
Subsea Frequency
2000-2003Topacio &Ceiba
First Systems withSubsea Transformers
Electrical system
System knowledge
Industry collaboration
Technology qualification
1980-presentESP
More than 200 electrical systems
delivered
q yConverter
C t
Project execution
System knowledge
© ABB GroupMarch 5, 2014 | Slide 3© ABB GroupMarch 5, 2014 | Slide 3
C o m p e t e n c e
Evolvement of Subsea Power DistributionTowards longer step-outTowards longer step out
Long step-out drive system Single motor drive supply
Curre
Cable transfer ~50km
Control based on onshore meas.
ABB supplying core technology
ent Status
Tyrihans (Reference Project - 2009)
2*Pumps (seawater injection) 4 MVA
Åsgard Gas Compression Project (2011)
2 x Compressors 18 MVA / 11.5 MW
200 H 4 MVA 70 Hz 31 km tie-in
Compressor 15 MVA / 8 MW
200 HV
200 Hz 2 x Pumps 1MW
200 Hz 47 km cable sim.
SD
© ABB GroupMarch 5, 2014 | Slide 4© ABB GroupMarch 5, 2014 | Slide 4
ACS MV converter
Topside VSD Road Map
Compressors10-20MVA
Pumps 3-6MVA
© ABB GroupMarch 5, 2014 | Slide 5
Next GenerationNext GenerationSubsea Power
© ABB GroupMarch 5, 2014 | Slide 6
Longer, Deeper, Colder Subsea Factory 2020Subsea Factory 2020
Key success factorsSubsea gas compression (Åsgard, Gullfaks)• Subsea separation• Long subsea power transmissions
© ABB GroupMarch 5, 2014 | Slide 7© ABB GroupMarch 5, 2014 | Slide 7
Subsea Opportunity (Outlook from 2010)One of fastest growing segments in Oil & Gas
CAGR 2009 15
One of fastest growing segments in Oil & Gas
• Eliminate costly topside solutions
Subsea driversTotal market growing at 18% CAGR –reaching ~$100B by 2020
CAGR 2009-15
1008
100$bn
Service
• Deeper waters, longer distance, marginal fields and arctic developments
• Increased recovery at falling pressureCustomers
18%
60
80
56
32 Equipment• Operators on Norwegian Continental Shelf
(NCS), GoM and Brazil driving next subsea frontier – going deeper and further out
• Operators in emerging markets like China
40
23 11
3519
60SURF(Umbilicals,Risers,
• Operators in emerging markets like China following next
• Break-through contracts for subsea compression in 2011-2012 on NCS, ABB awarded power systems for both Aasgard and Gullfaks
0
20
2011
14
7
2013
21
2015
35
2020
Flowlines)systems for both Aasgard and Gullfaks
• Oil companies prepared to invest in technology programs with ABB to develop and qualify subsea electrical and automation solutions
© ABB GroupMarch 5, 2014 | Slide 8© ABB GroupMarch 5, 2014 | Slide 8
Source: Rystad Energy: INTSOK annual report 2009-2014Subsea services: Flow Assurance Services, IMR (Subsea Inspection, Maintenance, and Repair (ROV + Diving)), Well intervention and light drilling vessels Subsea Eqp: Control Systems, Subsea Processing Equipment, Templates and Manifolds, Trees and Wellheads, Other Subsea Tools
Subsea technology programBusiness opportunity summaryBusiness opportunity summary
Region Expected projects Total MW
Step-out distance
(Km)
Water depth
(meter)
Prototypequalifi-cation**
Type Nos. Power (MW)
G lf f P i (MPP) 2 4 0Gulf of Mexico
Pumping (MPP) 2 4.017.6 50 3,000 2015
Pumping (ESP) 12 0.8
BrazilPumping (MPP) 2 4.0
17.6 100 3,000 2015Pumping (ESP) 12 0.8
NCS – Compression (SGC) 4 1563 2 145 to 330 2017NCS
Barents Gasp ( )
63.2 145 to 175 330 2017
Pumping (SPP) 4 0.8
Arctic – Oil
Pumping (MPP) 8 3.0Pumping (RSWI) 4 5.0Direct Electric Heat 1 0 5Arctic – Oil
to shore 48 250 1,500 2018(IF-DEH) 1 0.5
Pumping (CFP) 2 4.0Direct Electric Heat (CF-DEH) 2 2.0
Pumping (MPP) 2 2 7
Arctic – Oil Barents
Pumping (MPP) 2 2.7
11.9 155 500 2017Pumping (RSWI) 1 2.1Pumping (PWIP) 1 1.4Direct Electric Heat (CF-DEH) 1 3.0
© ABB GroupMarch 5, 2014 | Slide 9© ABB GroupMarch 5, 2014 | Slide 9
SE Asia Gas condensate
Compression (SGC) 4 1570 600 2,000 2020
Pumping (MPP) 4 2.5MPP: Multiphase Pump; ESP: Electrical Submersible Pump, SGC: Subsea Gas Compression, SSP: SubSea Pump, RSWI: Raw SeaWater Injection, CFP: CentriFugal Pump, PWIP: Producing Well Improvement Process** TRL 4
Reliable Subsea PowerABB as a technology supplierABB as a technology supplier
Cable transfer
ABB’s global competencies that can be leveraged for subsea powerABB s global competencies that can be leveraged for subsea power
Project execution Large offshore electrification, automation and
telecom projects
Products Transformers Power Cable
M t
Drives (LV, MV) HVDC
IGBT IGCT Advanced VSD & power electronics systems for subsea
Life cycle services
Motors Switchgear Flow Assurance
IGBTs, IGCTs… Capacitors Process ctrl&Safety Condition Monit.
Domain knowledge Oil and gas process understanding Subsea Safety Marinization
R&D Power Electronics Material science Switching technology Complex systems
Insulation Magnetics Semiconductors Control & sensors
© ABB GroupMarch 5, 2014 | Slide 10© ABB GroupMarch 5, 2014 | Slide 10
Marinization p y Control & sensors
Subsea Power Road MapT d O i F tT d F t
Topside
Today Ongoing FutureToday Future
e/shore
Platform/floaters
O&G processing
Subsea
Subs
based
Power supply
Platform based power generation or power
f h
Long distance power from shore
Subsea
seafrom shore o s o e
ABB investing in subsea electrification & automation solutions to enable future subsea processing
+ Subsea O&G processing+ No platforms/floaters+ One cable over many+ Longer distance
Subsea AC
+ Subsea O&G processing– Platforms/floaters needed– Many cables needed– High OPEX, CAPEX
+ Subsea O&G processing+ No platforms/floaters+ One cable+ Cheaper cable
Topside AC Subsea DC
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– Limited distance– People safety procedures– Environmental impact– Limited step-out distance
+ Longest distance+ Common DC: no rectifiers
Subsea technology programSubsea Power and Automation Schedule
Jan 2013 2014 2015 2016 2017 2018 2019
TRL 1 2 TRL 3 4 TRL5 6
2020
TRL 1-2 TRL 3-4 TRL5-6 TRL 7
Joint Industry ProgramPre-JIP
Technology Development & Qualifications
Materials & Qualifications
Project DeliveriesPriority JIP partners
Prototyping VSDs
Prototyping Distribution
© ABB GroupMarch 5, 2014 | Slide 12© ABB GroupMarch 5, 2014 | Slide 12
System TRL2 Concept design or novel features of design validated by model or small scale testing in laboratory environment.
System TRL4 Full scale prototype built and put through qualification program
System TRL6 Full scale prototype (or production unit) built and tested in intended Environment. The technology has successfully operated <10% of its expected life-cycle
DG: Decision Gate, TRL: Oil companies’ technology readiness level
Subsea Technology ProgramDeliverables from across the groupDeliverables from across the group
Modules
PA
PA: Power conversion module PA: Power distribution module PA: Control module
Products
DM/PP/PS
PP: Vacum breaker PP: Transformer (existing) PS: Power cable(deep water)
DM: PEBB DM: AC800 PEC
Components
DM/PP/PSPS: Hipak IGBT
© ABB GroupMarch 5, 2014 | Slide 13
PP: Metalized film capacitorPS: Press pack IGBTPS: Semiconductor DM: PCBA
Subsea Power JIPKey progress 2013 Organization
Top competence engineering and
Converter and Power Cells Natural cooled, oil
immersed concepts for
Key progress 2013
research resources across the ABB divisions mobilized and a core subsea power and automation organization is in place
immersed concepts for power electronics and complete converters
organization is in place Semiconductors and Capacitors
Material compatibility and pressure tolerant Power
Switchgear Concepts detailed and
first breaker materials pressure testedpressure tolerant Power
Electronics Components understanding developed
Electronics
pressure tested
Subsea Infrastructure Several thousand hour tests
at 300bar completed Lab – Oslo Labs – at our
Corporate Research Centers
© ABB GroupMarch 5, 2014 | Slide 14© ABB GroupMarch 5, 2014 | Slide 14
Centers Test facility West
Coast
Materials TestingAging test of material interaction with insulating oilAging test of material interaction with insulating oil
Aging in heat block at high temperature
Pouring of the oil after aging
Bubbling with N2oil after aging
© ABB GroupMarch 5, 2014 | Slide 15© ABB GroupMarch 5, 2014 | Slide 15
Aging in oven at high temperature
Assembly, Marinization and Full Scale Test FacilityABB OGP Subsea Organization•Sales •Execution
•Project management•Design•Application and Marinization EngineeringS l M t
ABB OGP Subsea Organization Customers
ABB DM (Drive)
ABB suppliers (key building blocks)
•Supply Management•Production/assembly•Testing
Subsea Equipment
ABB PP, Subsea transformers
DocumentationABB PPMV, switch gear parts
Equipment
Third party suppliers•Connectors/penetrators•Mechanical tank productionp•Etc.
© ABB GroupMarch 5, 2014 | Slide 16© ABB GroupMarch 5, 2014 | Slide 16
Longer, Deeper, Colder Artic FieldsArtic Fields
© ABB GroupMarch 5, 2014 | Slide 17© ABB GroupMarch 5, 2014 | Slide 17
© ABB GroupMarch 5, 2014 | Slide 18© ABB GroupMarch 5, 2014 | Slide 18© ABB Group March 5, 2014 | Slide 18
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