Floating Production Systems Power Generation and

Transcription

1 Floating Production Systems Power Generation and Compression Solutions

2 Floating Production Solutions Dresser-Rand is a leading supplier of rotating equipment to the global offshore industry with amongst the highest powered gas turbines and steam turbines ever installed on floating production, storage and offloading (FPSO) vessels. EXPERIENCE Dresser-Rand upholds a strong reputation of custom-engineering solutions for offshore production environments, whether they are arctic or tropical, shallow or deepwater, and for fixed or floating facilities. Dresser-Rand has an extensive product portfolio of providing steam turbines, gas turbines, centrifugal compressors, reciprocating compressors, gas engines, control systems, and aftermarket services to this market. Dresser-Rand has worked with many clients worldwide, and has considerable experience in supplying equipment to FPSO vessels, floating storage and re-gasification units (FSRU), and floating storage and offloading (FSO) units. GLOBAL PRESENCE Our global experience map (center pages) shows some of the projects Dresser-Rand has delivered equipment for and this list continues to grow. We have 49 global service and support centers including those located in principal floating production areas such as Brazil, West Africa, the North Sea, Australasia, and South East Asia to serve your needs. Because of the critical role played by the equipment we sell, clients place a great deal of importance on our ability to provide rapid, comprehensive service. With a global network of service centers around the world, we re prepared to deliver service anytime, anywhere and for any brand. PHILOSOPHY All of our manufacturing and service facilities strive to provide equipment that is technologically advanced. We work closely with the client to provide custom solutions that help reduce carbon footprint and provide reliable, energy efficient rotating equipment. quality & certification Dresser-Rand has extensive experience in meeting the full requirements of all relevant marine standards. Certification and classification authorities include: Lloyds Register Bureau Veritas RINA ABS DNV IMO CCNR Germanischer Lloyds Cover image Aker Floating Production SMART FPSO #1. Inset image Three 5 MW steam turbines installed on the SMART FPSO #1. 2

3 TEST FACILITIES All equipment manufactured by Dresser-Rand is subjected to rigorous, in-house testing to industry standards before dispatch. We have some of the most comprehensive test capabilities in the world, including: Dresser-Rand designed, manufactured and installed two 27 MW steam turbine generator sets on board the Knock Allan FPSO vessel for power generation service (owned by Fred Olsen). These machines are the highest powered steam turbines ever installed on an FPSO vessel and are part of our large repertoire of steam turbine gensets on FPSOs. Centrifugal compressors combined testing and full-load testing in Olean, USA, to ASME PTC 10 Type 1, up to 80 MW with gas turbine drives and 50 MW with electric drives and in Le Havre, France, with natural gas up to 150 MW with gas turbine drives or 100 MW with electric drives. Steam turbines we conduct full-speed testing on all machines at our facilities in Wellsville, N.Y. and Burlington, IA, USA and in Peterborough, UK. Reciprocating compressors full-load testing at our facility in Painted Post, N.Y., USA. Gas engines full-load testing is provided at our facility in Bilbao, Spain. Dresser-Rand successfully engineered, manufactured and tested what is believed to be the world's highest gas density, high-pressure centrifugal compressor for re-injection service in early The unit, which compresses a mixture of natural gas and carbon dioxide, is one of two trains supplied to SBM for an FPSO vessel destined for the presalt fields offshore Brazil. 3

4 Power Generation Gas Turbine Generator Sets Our gas turbine packages are built and tested specially for offshore applications and feature: General Electric LM2500 and LM6000 engine 1 families VECTRA power turbine matched to the LM2500 engine range KG2 gas turbine generator set for continuous duty and stand-by applications Common torque-tube base plate, with integrated auxiliary systems Light-weight, modular design Easy access for maintenance, easy changeouts and reduced downtime Single lift Reduced footprint, site work and commissioning time Auxiliary equipment modules accessible and maintainable from underneath the deck at "walk-up" height Complete package; fully commissioned when arrives on-site Ability to handle high specification, highly complex projects Gas Turbine Power Generation Ratings Model Gas Generator Three DR-61G gas turbine generator sets on the Aseng FPSO offshore Equatorial Guinea. ISO Power ISO Heat Rate Shaft Speed MWe BTU/kWeh kj/kweh (RPM) VECTRA 30G LM ,800 9,430 9,940 6,200 DR-61G LM ,400 9,280 9,790 3,600 VECTRA 40G LM ,500 8,780 9,260 6,200 DR-61GP LM ,700 8,820 9,300 3,600 VECTRA 40G4 LM2500+G4 33,200 8,740 9,210 6,200 DR-61G4 LM2500+G4 33,200 8,810 9,290 3,600 DR-63G PC LM6000 PC 43,700 8,170 8,610 3,600 DR-63G PG LM6000 PG 50,400 8,210 8,660 3,930 KG2-3E Cont. Duty 1,900 20,960 22,100 1,500/1,800 1("LM2500" and "LM6000" are registered trademarks of General Electric Company.) KG2-3E Standby 2,200 19,870 20,950 1,500/1,800 KG2-3G Cont. Duty 2,000 13,470 14,200 1,500/1,800 4

5 Steam Turbine Generator Sets With the world s largest fleet of steam turbine generator sets supplied for FPSO vessels, Dresser-Rand is a world leader in steam turbine power generation on FPSOs. Dresser-Rand steam turbine generator sets can be designed to exhaust to the vessels existing condensers or we can supply the condenser. We offer a complete range of turbine generator (TG) sets from 0.5 MW to 100 MW. A variety of direct-drive or geared configurations are available, including: Three 24 MW condensing steam turbine generator sets on board the Peregrino FPSO. Condensing or non-condensing Single- or multi-valve Single- or double-controlled extraction Mixed-pressure designs Deck mounted Engine room mounted Steam Turbine Application Limits Inlet Pressure 140 bar (2,000 psig) Inlet Temperature 540º C (1,000º F) Speed Range Power Range Exhaust Pressure Extraction Pressure 3,000 to 17,000 rpm Up to 100 MW Vacuum to 55 bar (800 psig) Up to 55 bar (800 psig) Gas Turbine Packaging Lightweight, three-point mount, patented torque-tube baseplate designed specifically for offshore use All auxiliary system modules are conveniently located either side below the baseplate and provide easy access for maintenance so it is not necessary to enter the gas turbine acoustic enclosure for preventive maintenance Several standard designs, as well as bespoke design, to address custom needs for non-standard solutions 5

6 North America 11 Gas turbines 10 Compressors Client / Operator Vessel Location Scope of Supply DSME / ChevronTexaco Agbami FPSO Offshore, Nigeria 3 x VECTRA 40G gen sets 3 x VECTRA 40G mechanical drivers 3 x D10R7B & 6 x D06R5S DATUM compressors Latin America 22 Gas turbines 10 Steam turbines 170 Compressors Client / Operator Vessel Location Scope of Supply Maersk Contractors/South Atlantic Holdings B.V. Peregrino FPSO Offshore Brazil 3 x 24 MW condensing steam turbine generator sets Floating Production Experience - Key Gas turbine generator sets Gas turbine mechanical drive Steam turbine generator sets Compressors 76 gas turbines, 47 steam turbines and 244 compressors for floating production applications As of July 2012 Floating Production These are just a few of the power generation and compression solutions Dresser-Rand 6

7 Europe 30 Gas turbines 7 Steam turbines 9 Compressors Client / Operator Vessel Location Scope of Supply SBM Aseng FPSO Equatorial Guinea 3 x DR-61G gas turbine gen sets 2 x D6R7B & 2 x D6R8B DATUM Compressors Middle East / Africa 13 Gas turbines 15 Steam turbines 26 Compressors Asia Pacific 15 Steam turbines 29 Compressors Client / Operator Vessel Location Scope of Supply Fred Olsen Production A.S. / CNR International Knock Allan FPSO Offshore Gabon 2 x 27 MW condensing steam turbine generator sets Project Profiles offers for a wide range of applications in the floating production market. 7

8 Compression Dresser-Rand offers an extensive array of compression solutions to meet a wide range of duties and applications such as gas lift, CO 2 injection, natural gas injection, export gas, CO 2 recycle, and low-pressure / high-pressure separation. Reciprocating Gas Compressors Dresser-Rand has more than 60 years experience supplying reciprocating gas compressors for offshore applications including FPSO, TLP, SPARs, etc. These have primarily been horizontally opposed gas field separable compressors driven by either spark gas engines or electric motors. Eight different frame sizes with crank-throws, allowable rod loads from 68.5 kn to 400 kn and HP up to 8,206 kw Cylinders up to 28" (711 mm) in diameter with pressures up to 10,000 psig D-R can also supply slow-speed, longer stroke process reciprocating compressors with up to 10 crank throws and 33,570 kw D-R engineers and manufacturers its own compressor valves and regulation devices and provides a full suite of capacity control solutions Reciprocating Compressor Ratings Allowable Rod Load Max Nominal Rated Power Frame Crank Stroke Throws RPM in. mm lbs. kn HP kw A-VIP 2/4 3.5/4.5 89/114 1,800/1,500 15, , B-VIP 2/4 5/6 127/152 1,500/1,200 24, ,140 1,600 C-VIP 2/4 4/5/6 102/127/152 1,800/1,500/1,200 33, ,880 2,150 MOS 2/4/6 5/6/7 127/152/177 1,500/1,200/1,000 45, ,400 3,280 HOS 2/4/6 5/6/7 127/152/177 1,500/1,200/1,000 60, ,000 4,480 HOSS 2/4/6 6/7 152/178 1,200/1,000 75, ,800 5,820 BOS 2/4/6 7.25/ /216 1,000/850 90, ,000 8,210 8

9 The first ICS unit shipped in 2010 for installation on Petrobras' existing P-18 production platform off the coast of Brazil. DATUM Centrifugal Compressors Cartridge concept Modular design minimizes downtime onsite to accommodate changing reservoir conditions and field duties Various drive options electric motor, gas turbine and steam turbine drives Driver flexibility available with our own gas and steam turbines as well as other manufacturers' turbines For many applications, the DATUM compressor is able to meet the process requirements in a single back-to-back casing, as opposed to multiple casings, because of its higher pressure ratio capability per case Reduced weight and footprint Inherently stable rotordynamics ensure high availability and reliability D-R Mechanical Drive Gas Turbines Model Gas Generator DATUM ICS (Integrated Compression System) High-efficiency DATUM centrifugal compressor technology (DATUM I compressor) High-speed, close-coupled, gas-cooled motor Magnetic bearing rotor system Dedicated unit controls Process coolers, valves, instrumentation, and interconnecting piping Packaged in a compact, modular design Integral rotary separator separates liquids from process gas and eliminates need for large vessel separator More than 50 percent less space and 35 to 50 percent less weight than typical offshore compression modules Flow rates up to 500,000 acfm Pressure to 10,500 psia Power to 89,483.9 kw (>120,000hp) ISO Power ISO Heat Rate Shaft Speed hp MW BTU/hph kj/kwh (RPM) VECTRA 30G LM ,500 23,500 6,820 9,650 6,200 DR-61G LM ,000 23,900 6,780 9,590 3,600 VECTRA 40G LM ,100 31,400 6,350 8,980 6,200 DR-61GP LM ,100 31,400 6,440 9,110 3,600 VECTRA 40G4 LM2500+G4 45,900 34,200 6,320 8,940 6,200 DR-61G4 LM2500+G4 45,400 33,900 6,430 9,100 3,600 DR-63G PC LM6000 PC 59,400 44,300 6,040 8,550 3,600 DR-63G PG LM6000 PG 66,800 49,800 6,050 8,570 3,740 9

10 Power Generators & Auxiliary Drives DIESEL & GAS ENGINE POWER Dresser-Rand has more than 45 years experience in the marine industry as a provider of Guascor marine engines. These engines are used for continuous power and standby generation and auxiliary drives on ocean going vessels around the world, operating in harsh offshore conditions, where easy maintenance, reliability and minimum fuel consumption are critical. We offer a complete range of engines from 270 to 1,100 kwe. GAS TURBINE POWER With 99.3% start reliability and consistently demonstrating 99% operation reliability, full-load, throw-on capability, minimal maintenance and a compact, lightweight design, the Dresser-Rand KG2 gas turbine generator set is ideal for offshore applications where reliable power is required. The KG2 turbine is available to operate on either gaseous or distillate fuel and the latest rating KG2-3G unit now has a dry low emission combustion system (standard). The Dresser-Rand KG2 gas turbine is a 2 MWe class gas turbine available for base load and standby power generation. Services Safety is always our top priority. That is why Dresser-Rand strives to be incident free. To protect your interests and ours, we are proactive in preventing incidents that can result in injury, property damage or have a negative environmental impact. Comprehensive safety training is used internally by Dresser-Rand, and results in lower OSHA recordable and lost-time rates. These rates are well below the industry average for companies providing similar services. Dresser-Rand Control Systems are used on Dresser-Rand gas turbines, steam turbines, motors, pumps, expanders, generators, centrifugal and reciprocating compressor packages, and are available for use on equipment manufactured by other OEMs. 10

11 Dresser-Rand offers a comprehensive range of services and solutions including: Controls retrofits, commissioning and troubleshooting Customized training Field services Gas generator / turbine storage Long-term service agreements Parts Performance assessment Project services Revamps Reapplications Reliability improvement programs Rerates Repairs (in our service facilities or on-site) Rotor storage Service contracts Technical support services and field crews Upgrades Additionally, we are continually developing new value-added services and solutions for our equipment, as well as equipment supplied by other manufacturers. Control Systems and Envision Condition Monitoring Software The Dresser-Rand Envision suite of machinery software was developed to enhance equipment control systems by providing intelligent condition monitoring, and constantly measure the performance and efficiency of rotating machinery. These attributes help equipment operators make educated, timely decisions regarding the maintenance of their equipment. Designed to support all critical rotating equipment, Envision modules are available for: Gas turbines Steam turbines Turbo compressors Reciprocating compressors The Envision suite combines what are often provided in multiple platforms into a single software program that combines operation, performance data and diagnostic information. It conducts real-time performance calculations and vibration analysis. The software generates reports and can generate automatic notifications to operators when alarms are triggered. Multiple compressor trains can be monitored from a single computer that can be accessed from anywhere in the world through an Internet connection. When accessing Envision tools remotely, users encounter the same experience that they would if they were physically on-site. 11 Dresser-Rand Control Systems provides solutions designed to fit clients needs and uses bestin-class hardware PLC platforms including: Allen Bradley Triconex GE DCS platforms include: Honeywell Yokogawa Emerson

12 For a complete list of products and services, visit us at us at [email protected] or contact us at one of the following locations: CORPORATE Headquarters Dresser-Rand West8 Tower, Suite Westheimer Road Houston, Texas USA Tel: (Int l +1) Fax: (Int l +1) Dresser-Rand 112, Avenue Kleber Cedex 16 Paris France Tel: (Int l +33) Fax: (Int l +33) Regional Headquarters The Americas West8 Tower, Suite Westheimer Road Houston, Texas Tel: (Int'l +1) Fax: (Int'l +1) EMEA (Europe, Middle East & Africa) Dresser-Rand S.A. 31 Boulevard Winston Churchill Cedex 7013 Le Havre 76080, France Tel: (Int'l +33) Fax: (Int'l +33) /5367 Asia-Pacific Dresser-Rand Asia Pacific Sdn Bhd Unit 9-4, 9th Floor Bangunan Malaysian Re 17 Lorong Dungun Damansara Heights Kuala Lumpur, Malaysia Tel: (Int'l +60) Fax: (Int'l +60) Dresser-Rand. DRESSER-RAND is a registered trademark of Dresser-Rand Company. Printed in U.S.A. This brochure comprises a general overview of the Dresser-Rand products described herein. It is solely for informational purposes, does not represent a warranty or guarantee of the information contained herein, and is not to be construed as an offer to sell or solicitation to buy. Contact Dresser-Rand for detailed design and engineering information suitable to your specific applications. Dresser-Rand reserves the right to modify its products and related product information at any time without prior notice. Form 85242