Gas Turbine Technology Center

Southwest Research Institute

Turbo Expo 2003

Introduction

Outline
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 Generation b) Gas Lift (Enhanced Oil Recovery -EOR) c) Waterflood (EOR) d) Gas Injection (EOR) f) Export Compression

Gas Turbines in Oil and Gas Applications

Dr. Klaus Brun Southwest Research Institute Dr. Rainer Kurz Solar Turbines

- Gas Turbine Technology Center Southwest Research Institute June 2003

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11/15/2001 - #2 Gas Turbine Technology Center

Outline Cont.
g) Gas Gathering h) Gas Plant and Gas Boost i) Gas Storage/Withdrawal - Midstream a) Pipeline Compression b) Oil Pipeline Pumping c) LNG Plant (refrigeration, compression, power) - Downstream a) Refinery power (Steam and Power Cogeneration) b) Refinery Integrated Gasification Combined Cycle c) Methanol / Fischer-Tropsch / Ethanol Fueled Plants Summary Questions

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

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Different Gas Turbine Products for O&G Market

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O&G Definitions
- Unprocessed oil from well - Natural gas that is a recovered from well with the crude oil (also, gas-to-oil ratio) - Power generation to meet needs of oil field or platform - Advanced technologies to improve oil recovery

O&G Definitions
Midstream The Oil & Gas Transportation Process
Pipeline Compression Oil Pipeline Pumping - Compression stations on pipeline to pump natural gas; typically 800-1200 psi compression - Pumping of crude or refined oil. - Liquid natural gas plant. NG is cooled and compressed for transportation in liquid form. - Loading and unloading of liquid natural gas onto LNG tanker (vessel)

Upstream The Oil & Gas Production and Gathering Process

Crude Oil Associated Gas Self-Generation Enhanced Oil Recovery (EOR) Gas Lift Waterflood Gas Re-injection Export Compression Gas Gathering Gas Plant and Gas Boost Gas Storage/Withdrawal
Red Processes that involve gas turbines

- Injecting gas into the production well to help lift the oil LNG Plant - Injection of water into the reservoir to increase reservoir pressure and improve production LNG Terminal - Re-injection of natural gas into the reservoir to increase the reservoir pressure - Initial boosting of natural gas pressure from field into pipeline (a.k.a. header compression) - Collecting natural gas from multiple wells - Processing of gas to pipeline quality; i.e., removal of sulfur, water and CO2 components - Injecting of gas into underground structure for later use: summer storage, winter withdrawal
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Red Processes that involve gas turbines

O&G Definitions
Downstream The Refining and Distribution of Oil & Gas
Refinery Integrated Gasification Combined Cycle Methanol Plant Fischer-Tropsch Liquid Fractional Distillation Column Cracking Blending LPG NGL Distribution
Red Processes that involve gas turbines
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Gas Turbine Function

- Processing of crude oil into its various sellable components - Advanced process to convert heavy oils and pet-coke into synthesis gas and hydrogen - Plant that produces methyl alcohol from Methane (natural gas) - Artificial gasoline produced from coal and/or other lower cost hydrocarbons - Distillation tower to separate crude oil into its gasoline, diesel, heating oil, naphtha, etc. - Breaking large hydrocarbon chains to smaller chains (cocker, visbreaking, thermal, catalytic) - Mixing of hydrocarbons to obtain sellable refinery products - Liquid Petroleum Gas (Propane, Butane, Pentane) - Natural Gas Liquids: Liquids that drop out during gas processing - Delivery of oil & gas products to end-users

A Gas Turbine Converts Fuel Into Mechanical Output Power to Drive Pumps, Compressors, Generators, Blowers, Fans, etc.
Available Output Power Range: Typical Gas Turbine Simple Cycle Efficiency: Output Speed Range: Fuels: 20 kW-250MW (25 hp 350,000 hp) 25-35% 3000 - 25000 rpm Natural Gas and Liquid Fuels

Gas Turbine Driving Generator

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Single and Two Shaft

Single and Two Shaft

Shaft Coupling

No 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)

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%)

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Components & Layout

Outside the Package: Enclosure and Fire Protection
Inlet System
Air-filter (self-cleaning, barrier, inertial) Silencer

Manufacturers & Models

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

Solar Turbines:
- Saturn 20 - Centaur 40/50 - Taurus 60/70 - Mars 90/100 - Titan 130 1 MW 3-4 MW 5-7 MW 8-10 MW 13 MW

Exhaust System
Silencer Stack

Inside the Package:

Fuel System
Natural Gas Liquid (pumped)

Lube Oil Cooler (water, air) Motor Control Center Switchgear, Neutral Ground Resistor Inlet Fogger/Cooler

General Electric Oil & Gas:

- GE 5 - GE 10 - LM 1600 - LM 2500 5 MW 10 MW 16 MW 25 MW

Rolls-Royce:
- Avon - RB211 15 MW 30 MW

Bearing Lube Oil System

Tank Filter Pumps (main, pre/post, backup)

Alstom:
- Typhoon - Tornado - Cyclone - GT 35 5 MW 8 MW 13 MW 17 MW

Starter (pneumatic, hydraulic, AC motor) Controls (on-skid, off-skid) Seal Gas System (compressors)
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Offshore Platform (Marine)

Jack-Up Semi-Sub FPSO Tension Leg

Offshore Features
Gas Turbine Compressor

Land Based

Fixed Leg

Inclinometer

Mount Sub Base Lube Oil Tank Baffles Scavenging Pump for Pressurized Bearings

Technical Requirements
Low weight and dimensions Low Vibrations Resistance to Saltwater List, trim, pitch, roll operation Marine codes Foundation twisting

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

Operational Requirements
Highest availability as platform often depends on GT, but No direct access to technicians and repair facilities Limited spare parts storage capabilities

Inclinometer Sub Base Baffles Scavenging Pump Mounts Single Lift Module

- Alarm and Shutdown at High List, Trim, Pitch, Roll Angles - Added Stiffness for Gas Turbine and Compressor Skids - Continued Supply of Lube Oil at Inclined Operation - Forced Supply of Lube Oil at Inclined Operation - Isolation from Twisting and Vibration - Simplified Installation and Transportation to Platform

Single Lift Module

?
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Gas Turbines for Oil & Gas - Mid Stream -

Natural Gas Compression

Laying of Underground NG Pipeline

The Oil & Gas Transportation Process

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- 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 hp utilizes gas turbine driven centrifugal compressors.
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Pipeline Compression
- Main line to transport NG over large distances - Secondary line (parallel to main line) to increase total capacity - First station on the pipeline, also called zero station - Receiving station, a measuring and pressure throttling point - Switch and valves to by-pass a compressor station

Compressor Station Layout

Major Equipment:
- Turbo-Compressors and Ancillaries/Auxiliaries Gas Turbine - Gas Coolers (Intermediate, Discharge) - Station Isolation Valves - Station Control Center, SCADA System - Emergency Power Supply (Diesel Generators, Tanks) - Surge Control Valves Pipe Valve Skid - Slug catcher, Scrubbers, Filters - Flare - Pig Launcher - Gas Treatment Plant (De-Hydration, Sour Gas Treatment)
TURBINE COMPRESSOR S D

Definitions: Trunk Line Loop Header Station City Gate Station Isolation

Compressor

FLOW ORIFICE SURGE CONTROLLER GAS COOLER DP LOADING SWITCH

DISCHARGE VALVE LOADING VALVE SUCTION VALVE SURGECONTROL VALVE

Typical compression Requirements: Flows: 5-1000 MMSCFD Pressure ratios: 600-1200 psi Line sizes: 5-50 inches Gas: Natural Gas (>90% Methane)

Isolation Valves

CHECK VALVE

Pipeline

Preferred Equipment: Gas turbine with single body centrifugal compressor No gear box between gas turbine and compressor (direct drive) Centrifugal compressor with one or two flow stages, efficiency >80% 3*50% or 4 * 33% capacity arrangements preferred Gas turbines from 1000 to 30,000 hp

Station By-Pass Valve Turbo-Compressor In Buildings

Single Body Direct Driven Compressor

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Discharge Coolers

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Oil Pumping
Definitions Crude Oil
Trans-Alaska Pipeline -12 Pumping Stations - 800 miles - 48 inch diameter - US$ 8 billion to build - 15% of US Crude Oil Production

Crude Oil Pumping

- un-refined liquid hydrocarbon consisting of Paraffins, Olefins, Diolefins, Aromatics, Naphthenes, and acids/bases/salts. - density of fluid. Low API = Heavy Oil High API = Light Oil - < API 20 - API 20 API 30 - > API 30

API Gravity Heavy Crude Medium Crude Light Crude

Note: Lighter crude oils require less refining; the price is, thus, typically higher for lighter oil. Lighter crude oils are also easier to pump and cause less pipe deposits. Blending of lighter oils with heavy crude is often required to make the trude oil transportable.

Crude Oil Pipeline Pumping

- Similar to natural gas pipeline compression, however: a) oil is liquid (incompressible) b) pumping to overcome gravity and pipe friction losses c) less complex and safer process - Natural gas is not available to fuel gas turbine (topped crude is often used). - Most crude oil pumping stations use reciprocating engines or electric motors.
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Typical pumping Requirements: Flows: 100-350,000 cu. ft/hr Pressure Increase: 100-3000 psi Line sizes: 5-50 inches Oil: Crude oil of densities ranging from API 10 API 50

Crude Oil Pump

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Preferred Equipment: - Gas turbine with single body pump - Step-down gear box between gas turbine and pump required to match lower speed pump (2000-4000 rpm) - Multi-stage centrifugal pump, efficiency >60% - 3*50% or 4 * 33% capacity arrangements 11/15/2001 - #20 Gas Turbine Technology Center - Gas turbines from 1000 to 30,000 hp

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LNG Process
Vapor Pressures Gas Turbines For Power Generation

LNG Production Plant

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 volume 600 times smaller than in gaseous form. Thus, it can easily be transported on special tanker-ship with a built-in cryogenic cooling system. The LNG process involves multi-stages of compression, cooling, and expansion of methane.

LNG Plant Concept:

Multi-Stage Cooling to Boil Off Higher Hydrocarbon Chains

Methane Gas P=300 psi T=100 F P=3000 psi T=500 F P=3000 psi T=100 F

Liquid Methane P=14.7 psi T=-260 F

Gas Turbines For Compression of Natural Gas

Compressor
(Gas Turbine Driven)

Cooler

Expander
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LNG Gas Turbines

Compression
Typical LNG Compression Requirements: Flows: 5-200 MMSCFD Pressure ratios: 14.7-3500 psi Gas: 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
-

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)
-

Multi Body Driven Compressor

Gas Turbine Generator

Gas Turbines are used for LNG Pumping and Methane Compression

Power Generation
Typical LNG Power Generation Requirements: Power: 5-50 MW Operation: Continous Gas: 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
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LNG Tanker with Cryogenic Cooling

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Gas Turbines for Oil & Gas - Down Stream Cracking

(Breaking of large hydrocarbon chains) - Thermal Steam Visbreaking Coking - Catalytic Fluid Hydrocracking
Fractional Distillation

Refinery
Converts Crude Oil Into Marketable Products

Alkylation
(Altering molecular structure)

Catalytic Reforming
(Combining molecular chains to form longer chains)

The Refining and Distribution of Oil & Gas

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Products:
- 43% gasoline - 22% heating oil & diesel - 10% jet fuels - 4% propane - 3% asphalt - 18% others
(lube oil, waxes, plastics, etc.)
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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
Fuels Bituminous Coal Sub Bituminous Coal Lignite

Refinery IGCC
Integrated Gasification Combined Cycle
Products Gasificaton Syngas Gasifier HX Cleanup Slag Hydrogen Ammonia Methanol Chemicals Sulfur

Heat Recovery Steam Generator

Use Gas Turbine Exhaust Heat to Generate Steam For Refinery Processes
(aka HRSG, Waste Heat Recovery Unit, WHRU, Boiler) By-Pass Stack

Stack

Orimulsion Residual Oils Refinery Bottoms Petroleum Cole Biomass Wastes

Slag Oxidant Supply System

Clean Fuel Combined Cycle

Gas Turbine Generator

Electricity

Exhaust Heat Supplemental Duct Firing

Economizer

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

Boiler

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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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Refinery Gas Turbines

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)

Power & Steam Generation

Typical Refinery Requirements: Power: 20-250 MW Steam: Never Enough! Operation: Continous Fuels: Methane, LPG, Naphtha, Hydrogen, Synthesis Gas, Refinery Off-Gas, Diesel

- 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 dirty b) Re-inject the gas expensive Methanex MeOH Plant Punta Arenas / Chile 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

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
Sarlux Refinery Sardinia / Italy

Potential Gas Turbine Fuels

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Worlds Main Energy Problem Is Not Availability. It Is Energy Transportation.

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Oil & Gas Gas Turbines

Questions?

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