GAS TURBINE SOLUTIONS

Transcription

1 GAS TURBINE SOLUTIONS

2 Commitment to value Dresser-Rand s gas turbine designs exemplify client value: their modular concept allows short change-out times and reduced life cycle costs. Dresser-Rand is committed to bringing you the most value through its unique business processes, advanced technology and installed base support. Dresser-Rand business processes enable faster cycle times for all project phases. When it comes to the total cost of ownership, you can count on Dresser-Rand technology to deliver optimum performance, as well as product upgrades and services that extend the life of your equipment. Combine our innovation, technology and business processes with our total life cycle support, and it s easy to see why Dresser-Rand provides the value you need for that competitive edge. COMPRESSION Dresser-Rand has been designing gas turbine-driven centrifugal compressors and mechanical drive gas turbine packages for more than half a century. Our DATUM centrifugal compressors are used in critical services throughout the world for applications in the oil, gas, petrochemical, and process industries where high reliability and availability are mandatory. We built our first compressor more than a century ago, and have more than 94,000 rotating equipment units installed in more than 140 countries. POWER GENERATION Dresser-Rand specializes in gas turbine generator sets up to 50 MW (ISO rated). A variety of standard designs is available to meet individual applications within the oil and gas, cogeneration and standby markets. During the past 40 years, gas turbine units have played an increasingly important role in the generation of electrical power. They are dominant in the offshore industry and are used extensively throughout the world in general power applications and the rapidly expanding cogeneration market. Dresser-Rand is recognized internationally with generator sets operating in more than 60 countries. VECTRA 40G power turbine during installation. 2

3 CASE STUDY: North Sea: Sleipner a major success. Dresser-Rand completed two of the largest orders ever placed for gas turbine-powered equipment in the North Sea. Statoil awarded the contracts to Dresser-Rand on the basis of a very competitive solution. Critical technical features included: low weight, minimum dimensions and superior arrangements for inspection and maintenance. The first contract placed by Statoil for the A platform covered two 21 MW D-R gas turbine generator sets and five D-R gas turbine/compressor units for recompression, pipeline and reinjection duties. Based on Dresser-Rand s satisfactory performance on this first contract, the award for the equipment on the T platform was negotiated with Statoil. This included one D-R gas turbine generator set, two VFD motor-driven recompression trains and three D-R gas turbine-driven compressor sets for pipeline and CO 2 gas stripping and reinjection in the North Sea. The equipment was delivered on schedule and to the satisfaction of the client. 3 Photo courtesy of Statoil

4 21 MW generator set for cogeneration installation. Experience in mechanical drive Assembly of VECTRA 40G power turbines at Drammen, Norway facility. MECHANICAL DRIVE APPLICATIONS OFFSHORE/ONSHORE For more than 50 years, Dresser-Rand has been a world leader in rotating equipment solutions, designing, manufacturing and servicing a wide range of field-proven centrifugal compressors. Since the mid-1950s, we have built and in many cases installed more than 6,500 centrifugal compressors for applications as diverse and challenging as LNG, ethylene, refining, fertilizers, natural gas production, gas transmission, gas storage, gas reinjection, and gas lift for enhanced oil production. Decades of experience in supplying hundreds of gas turbine-powered compression systems to the oil and gas industry have given us special insight into our clients priorities. Long-term relationships with oil and gas companies around the world have given us extensive experience in complying with the industry s specifications in health, safety, and environment (HSE), QA/QC requirements, rules and regulations, and classification requirements. In addition to gas turbine-driven power generation and compression, including floating as well as fixed-foundation production facilities, Dresser-Rand provides a full range of solutions that may be required within a project, including: Motor-driven compression packages (both centrifugal and reciprocating) Waste heat recovery (steam, thermal fluid, water/glycol) Drilling power Emergency power Essential services Capabilities for difficult and unusual fuels (sour gas, low-caloric-value gas) Operation and maintenance services GENERATOR SETS AND AUXILIARY EQUIPMENT Dresser-Rand generator packages are designed to fulfill the needs of clients in many markets; these include oil and gas, industrial, continuous-duty systems, and standby plant applications. Dresser-Rand s breadth of expertise includes systems incorporating our proprietary heavy-duty turbines as well as General Electric higher-powered aeroderivative engines. Generators are selected to match clients electrical system characteristics and any special requirements such as motor-starting capability, voltage dip limitations, etc. The smaller turbines have integral speed reduction gearboxes. Where necessary, a freestanding gear is included in the higherpowered packages. Turbine, gearbox and generator are normally aligned on a fabricated steel base, together with auxiliary equipment, to provide a well-integrated unit. Auxiliary systems are designed to comply with site environmental conditions and any specific limitations on noise level, exhaust emissions, space, and weight. Optional equipment includes: Intake and exhaust systems to suit the application/specifications PLC-based unit control systems Acoustic enclosures Fire protection Gas detection Generator controls Auxiliary motor control centers UPC batteries and chargers Unit switch gear Modularized control and electrical systems Air start systems Waste heat recovery systems Steam turbine-driven generator packages for combined cycle/ cogeneration applications 4

5 VECTRA 40G power turbine. CASE STUDY: Nigerian FPSO: D-R takes position in expanding market. Dresser-Rand has completed one of the largest orders ever placed for its gas turbines, as six VECTRA 40G power turbines (plus one spare) will supply power and compression to a Nigerian FPSO (floating production, storage and offloading) vessel. Located offshore Nigeria, it is the largest FPSO project in the world, giving D-R a unique position in this expanding market. Each of the power turbines was packaged at Dresser-Rand s plant in Drammen, Norway. Three of the gas turbine packages drive 25 MW electrical generators, and were load tested in Norway. The other three gas turbines drive triple casing gas re-injection compressor trains with a discharge pressure of 7,200 PSI (490 bars), and one of these trains was tested at full load and full pressure on D-R s test stand in Le Havre, France. 5

6 The right driver for each application As one of the world s leading providers of compression solutions, we have the experience, global resources and commitment to do whatever it takes to meet your needs. Dresser-Rand will analyze all of the parameters of your particular application, then use a creative, flexible approach to develop a solution that is superior in value and gives you the lowest total life cycle cost by minimizing operating expenses and maximizing reliability. Our gas turbine-driven compressor sets can be integrated into compact, self-contained single-lift packages incorporating all essential on-skid auxiliaries. We also provide installation and commissioning services, as well as on-site training and ongoing support. The extensive range of prime movers includes industrial and aeroderivative designs across a power spectrum of 1.5 MW to 50 MW. This broad product range includes features offering specific advantages for most applications: Turbine thermal efficiencies up to 43 percent Simplicity and robustness High reliability and availability Modular designs Ultracompact, low-weight units Easy operation and maintenance Emission control (DLE systems, etc.) PLC-based control systems Liquid, gas, dual-fuel, and bi-fuel systems Experience with a wide range of fuels including very low calorific value gas KG MW VECTRA 30G FOR LM2500 (23.5 MW) VECTRA 40G4 FOR LM2500+G4 (34.3 MW) VECTRA 40G POWER TURBINE (LM2500+) 31.4 MW Model Gas Generator ISO Power (SAC) ISO Heat Rate (SAC) BHP kw BTU/HP-HR kcal/kw-hr Speed KG2-3E* --- 2,592 1,934 15,191 5,134 1,500/1,800 VECTRA 30G LM ,540 23,519 6,720 2,271 6,200 VECTRA 40G LM ,066 31,369 6,276 2,121 6,200 VECTRA 40G4 LM 2500+G4 46,004 34,306 6,302 2,130 6,200 DR-63G PC LM 6000 PC 59,436 44,322 6,042 2,042 3,600 DR-63G PG LM 6000 PG 66,822 49,830 6,054 2,046 3,743 *Base load rating 6

7 STANDBY POWER SYSTEMS For many telecommunication centers, airports and hospitals, standby power is mandatory. For banks, computer centers, oil platforms, and many others, protection against blackouts is also necessary. These types of clients require maximum reliability with the absolute minimum of disturbance to their normal businesses. and steam injection. For example, our DLE solutions for the VECTRA 40G can reduce NO X emissions by approximately 80 percent. Effective noise abatement systems are also a priority. Most environmental regulations require that all continuous-duty units be low-no X installations, of which the preferred method is DLE. Even when we produce non-dle packages, we build with DLE retrofit in mind kw KG2 generator set package for a North Sea production platform. North Sea: Two KG2-3E generator sets provide emergency power onboard the Troll oil platform. Four 21 MW D-R gas turbines provide base load power and compression. With 99.3 percent start reliability*, full-load throw-on capacity and minimal maintenance requirements, Dresser-Rand s KG2 gas turbine is ideal for stand-by and continuous power supply onshore and offshore. The KG2 generator set has been specifically designed to meet requirements for power from 1 MW to 10 MW (single and multiple units). More than 900 units have been delivered for standby, industrial, and oil and gas applications worldwide. In addition to the KG2, we can offer any other gas turbines in D-R s product range for standby and peaking duty up to 50 MW. MAINTAINING LOW LIFE CYCLE COST At Dresser-Rand, our concept of service goes far beyond supplying spare parts and providing on-site assistance. D-R aims to be our clients partner for gas turbine solutions, starting with assistance at the conceptual design stage and providing support throughout the life of the equipment. D-R packages are carefully designed to save time and money, and to maximize availability. For example, consider our lightweight, three-point mount, patented torque-tube baseplate design specifically for offshore use. All auxiliary system modules are conveniently located below the main deck on either side of the torque tube, where they are readily available to the operator. This means it is not necessary to enter the gas turbine acoustic enclosure for preventive maintenance. Dresser-Rand s emphasis is on user-friendly solutions to help clients achieve maximum availability and minimum life cycle cost for their rotating equipment. A borescope inspection rapidly determines the condition of critical turbine internal components. System modules located beneath a torque tube skid for easy maintenance. ENVIRONMENTAL FOCUS D-R is committed to addressing critical environmental concerns while continuing to improve operational efficiencies. Dresser-Rand s emission control system for NO X and CO includes DLE, water injection Dresser-Rand s patented torque tube baseplate allows auxiliary modules to be conveniently located below the main deck, permitting unrestricted access. *Based on D-R s field data across the entire installed fleet from our first installation in 1968 to date. 7

8 Dresser-Rand completed construction of its large compressor full-load test facility in Le Havre, increasing its worldwide testing capacity with natural gas up to 150 MW (gas turbine drive) or 100 MW (electrical drive). This facility includes a high capacity quay with direct sea access that facilitates compressor train delivery and shipment from and to any location in the world. Worldwide presence The indoor test stand in Drammen, Norway, can accommodate parallel operation of two large generator sets. Access to deep sea quay facilities allows for easy shipment of large equipment for full-load testing of water injection pump sets. D-R equipment is found worldwide and so is our support. Dresser-Rand employees use their OEM expertise to provide unmatched dedication and reliable technical support, 24 hours a day. Our manufacturing and repair capabilities are also drawing on local resources as well as D-R s worldwide presence and experience. D-R s ISO-certified, state-of-the-art manufacturing facility in Kongsberg, Norway, is equipped to build in the performance and reliability you expect from every D-R product. D-R has been supplying gas turbine packages worldwide using industrial and aero-derivative designs since the mid-1950s and is well prepared to meet your expectations. We have invested heavily in test facilities for gas turbines, compressors and generator sets. In Drammen, Norway, all the generator sets in our product range can be individually tested at full load. At the Dresser-Rand facility in Le Havre, France, we have seven compressor test stands for mechanical and performance testing and two full-load testing stands, including hydrocarbon testing. In Olean, NY, USA, the Dresser-Rand facility has several test stands capable of testing gas turbine-driven compression trains to more than 100 MW, including full hydrocarbon capability. Test capabilities include: String testing Generator set full-load testing Package testing with contract equipment Generator set load-response testing Parallel testing of generator sets Compressor full-load/full-pressure hydrocarbon testing Gas turbine dynamometer load testing (proprietary units only) Noise and vibration testing Acoustic enclosure integrity testing Fire-extinguishing testing Auxiliary system module testing Control panel testing 8

9 VECTRA 40G power turbine. Kongsberg, Norway, 5,700 m 2. Gas turbine driver and complete generator set packaging. The Huldra Platform Train is the first LM2500 gas turbine-driven combined compressor (DATUM D08R6S) and generator train. A special four-shaft gearbox with two output shafts was designed to accommodate a compressor and generator operating at different speeds. A full-load test was conducted at the Dresser-Rand Le Havre facility to test this special shaft line. The test proved the train could operate successfully over the full range of combined compressor and generator loads (max load compressor = 10.6 MW and max load generator = 9 MW). In addition to this unique arrangement, the Huldra platform may be unmanned. The client wanted to test as much of the contract equipment as possible in the Dresser-Rand factory. Therefore, over a period of three months the following equipment was assembled and tested: LM2500 DLE package, including DLE mapping, contract gas turbine enclosure, air inlet, and exhaust systems Driven skid including four-shaft gearbox, D-R compressor and ABB generator Lube oil console and rundown tank Unit control panel including the Woodward Atlas fuel controller, ABB generator excitation cabinet, and the D-R RECON remote condition monitoring system Le Havre, France, 40,000 m 2. Compressor design, manufacture, testing, and packaging. Olean, New York, USA, 82,000 m 2. Compressor and power turbine design, manufacture, testing, and packaging. Drammen, Norway, 4,900 m 2. Compressor and gas turbine packaging plus generator set testing and Client Satisfaction Center. 9

10 Product services to help you get the most from your equipment Dresser-Rand has many ways to help you get the most from your equipment investment by increasing its longevity, availability, safety, reliability, efficiency, and performance. D-R offers a comprehensive range of services and solutions including parts, upgrades, revamps, reapplications, rerates, repairs, field services, controls and condition monitoring, and customized training. Our dedicated teams of professionals have the experience and vision to help you select the approach that provides maximum benefit to your specific equipment, facility and operating requirements. In addition, as an OEM we have complete access to the original design specifications of our equipment and understand the full implications of any changes, so your system s integrity is maintained. D-R s state-of-the-art technology and total solutions capabilities can be applied to all makes and models of rotating equipment. Your assurance of quality parts. OEM REPLACEMENT PARTS Dresser-Rand is a technology leader, committed to R&D. Our replacement and upgraded parts are designed for the application to maximize the reliability and availability of your rotating equipment. To minimize downtime associated with overhauls and turnarounds, packages and kits of consumable parts are readily available for use in standard maintenance procedures and repairs. In addition to custom stocking and recommended spares programs, we maintain a large inventory of replacement parts ready to ship upon order. COMPONENT UPGRADES D-R offers an extensive range of valueadded, state-of-the-art upgrades and modernizations for most brands of rotating equipment. Our latest design, material and manufacturing improvements, our extensive engineering knowledge, testing capabilities and field operating experience provide you with improved components that maximize safety, reduce maintenance, increase reliability/availability, improve performance, extend equipment life, and reduce life cycle costs. OPERATIONS & MAINTENANCE SERVICES Dresser-Rand s pay us for our performance Availability PLUS contracts maximize your profitability by providing increased reliability, availability and efficiency. The Availability PLUS program bundles all the resources within D-R into a comprehensive, value-added package with a single point of responsibility, regardless of nameplate. With D-R taking care of your equipment, you ll be better able to focus on your core business. ENGINEERING ANALYSIS D-R s experienced engineers and technicians are available to visit your site to determine the physical condition and operating performance of your equipment, and recommend the best ways to improve its reliability, efficiency and operation. Our field service personnel have access to information that is simply not available to other field service providers; this includes original designs, historical data and other Dresser-Rand proprietary information that help us to recommend the most effective solutions. SERVICE CENTERS Our dedicated staff is strategically located throughout the world for responsive, reliable support. Our network of nearly 40 service centers feature the latest technology and manufacturing skills to repair and rebuild your steam, reciprocating and centrifugal units including complex equipment such as axial compressors and hot gas expanders. 10

11 FIELD SOLUTIONS Dresser-Rand provides complete field installation, commissioning, maintenance, client training, and repair services for all rotating equipment and control systems. These services can extend to non-dresser-rand nameplate equipment as well. Our dedicated teams around the world can help you develop cost-effective, field-proven solutions for repairs, overhauls, upgrades, rerates, and virtually any other challenge. D-R s on-site, on-time pledge means we ll be there when you need us, 24 hours a day, 365 days a year. TRAINING Formal classroom instruction Hands-on, skills-based labs Video training programs Web-based training PROJECT SERVICES Installation, commissioning and startup Overhauls, refurbishment and revamp projects Emergency repairs LONG-TERM SERVICE AGREEMENTS Long-term maintenance crews Comprehensive maintenance agreements Contract operations and maintenance REMANUFACTURED EQUIPMENT Refurbishment, upgrades and reapplication of client-owned or surplus equipment TECHNICAL CONSULTING AND FIELD CREWS Field consulting OEM-trained field service representatives Trained craft labor RELIABILITY AND MAINTENANCE IMPROVEMENT Condition-based maintenance programs Reliability engineering services Field engineering services Site audits TURNKEY PROJECTS Engineering Procurement Construction Installation Commissioning, startup and acceptance DRESSER-RAND CONTROL SYSTEMS AND REMOTE CONDITION MONITORING Dresser-Rand provides custom-engineered control systems to meet clients specific needs and specifications. Drawing from our unmatched rotating equipment experience, Dresser-Rand provides technologically advanced control systems that achieve new levels of reliability and operational efficiency. Moreover, the D-R standard systems are client-maintainable without significant investment. Our state-of-the-art PLC-based DI-Tronics control system can be configured to monitor and protect an entire turbine-compressor system. Manual and automatic start, unit warm-up and cooldown, local and remote control, gas turbine fuel control, compressor surge control, vibration and temperature monitoring, train sequencing, and machinery protection are all integrated in the DI-Tronics system. Solutions can be configured with single, duplex, or triple redundant PLC controllers based on service criticality. All critical parameters are continuously monitored for signal failure or alarm and shutdown conditions. A fail-safe approach is utilized to provide maximum protection for personnel and machinery in the event of machinery, control system, field device, or electrical failures. The user-friendly operator interface features full-color, graph- and text-based screens, real-time and historical trending, report generation, alarm, shutdown and event logging, and web-based global access connectivity. Many operations have substantially reduced their maintenance budgets and personnel, leaving a shortage of in-plant knowledge. Dresser-Rand provides comprehensive, remote condition monitoring solutions that provide you with the information you need to ensure your equipment operates reliably and cost effectively. 11

12 For a complete list of products and services, visit or contact the following: GAS TURBINE PACKAGING OPERATIONS Dresser-Rand AS Kirkegaardsveien 45 P.O. Box 1010 N-3601 Kongsberg, Norway Tel: (Int l +47) Fax: (Int l +47) CORPORATE HEADQUARTERS Dresser-Rand West8 Tower Suite Westheimer Rd Houston, TX 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) info@dresser-rand.com 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 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