Exploring the benefits of modularization EMANUELA SILENZI GE OIL & GAS MODULES PRODUCT MANAGER
Agenda GE OIL & GAS HERITAGE & CAPABILITIES MODULARIZATION EVOLUTION GOING MODULAR CASE STUDIES: AdvantEDGE* Power Plant (Atish Roy-Choudhury), Gas Processing (Alicia Trent) *Trademark of General Electric Company 2
GE & Modularization Innovation & Excellence COST REDUCTION SIMPLER DESIGN SOLUTION PROJECT EXECUTION EXCELLENCE AND RISK MITIGATION SMOOTH AND SMART INSTALLATION PARTNERING IN PROJECT DEVELOPMENT 3
Adapting to the new cycle UPSTREAM MID TERM LOCK-IN - 2017 MIGHT BE THE TURNING YEAR FOR INVENTORY REDUCTION - UP TO 7 MILLION BBL/D OF SUPPLY NEEDED THROUGH 2021 FROM UNSANCTIONED PROJECTS - MODEST SPENDING RECOVERY CONTINUES BALANCING RISKS AND REWARDS - DE-RISKING: BUDGET AND TIMING CERTAINTY - INNOVATE TO BECOME LEANER, MORE ADAPTIVE TO CHANGE - NEW TECHNOLOGY AND NEW EXECUTION MODELS 4
Building on 30+ years modularization experience 1980 1990-2008 2006-2008 2012 2016 2019 NORTH SEA BUCHAN FIELD Gas lift BRAZIL CAMPOS BASIN Power Gen & Compression KAZAKHSTAN KASHAGAN H2S Gas injection System GORGON Power gen modules (130 MW) FSNL tested UZ 750 Power gen modules (43 MW) FSFL tested TENGIZ Power gen modules (130 MW) FSFL tested 5
Yard evolution 40.000 M 2 UNTIL 2011 240.000 M 2 (2012-2019) 200.000 M 2 (FROM 2019) GORGON PROJECT - 5 PLATFORM - FULL SPEED NO LOAD (P<16 BARG) - STRUCTURE SUB-ASSEMBLED AND ERECTED IN YARD - LIFTING, STRUCTURE WELDING, SCAFFOLDING, TOUCH UP - MECHANICAL COMPLETION AND COMMISIONING (PAPER BASED) - COVERED STORAGE: 11.000 M 2-2D DRAWING - MODULE LOAD OUT LIMIT: 4000 TONS - MODULE DIMENSION LIMIT: 21 WX60 L - 10 PLATFORM - FULL SPEED FULL LOAD (P<24 BARG AND POWER 130MW...FR9) - STRUCTURE ALREADY FULLY ASSEMBLED (NO ERECTION, NO WELDING) - SKIDDING - COVERED STORAGE: 30.000 M 2-3D DRAWING - POSITIONING TRACKING SYSTEM ZADCO & TENGIZ - ADDITIONAL 4 PLATFORM - FULL SPEED FULL LOAD - (P<70 BARG AND POWER 130MW...LMS100) - HEAT REMOVAL 220 MW (EVAPORATIVE TOWERS) - FULLY DIGITIZED DOCUMENT MANAGEMENT - FOR MECHANICAL COMPLETION AND COMMISSIONING (POWERED BY PREDIX) - NO LIMITATION IN LOAD OUT & DIMENSION CAPACITY (SEA FRONT) 6
Module commissioning and testing PRE COMMISSIONING AND COMMISSIONING - MODULE QUALITY CONTROL PANEL - MECHANICAL COMPLETION - COMMISIONING PROCEDURE - CONTROL LOOP CHECKS - ELECTRIC MOTORS & PANEL CHECK - LUBE OIL SYSTEM FLUSHING - FUNCTIONAL TEST OF ALL SYSTEMS - READY FOR FULL POWER AND SHIPMENT Enabling real plug & play solutions MODULE STRING TEST - FULL SPEED FULL LOAD (UP TO 130 MW) - LOAD SHARING & SHEDDING CAPABILITIES - POWER GENERATION (AVENZA) & COMPRESSOR DRIVE (PIOMBINO) - FUNCTIONAL TEST & LOOP CHECK OF ALL SYSTEMS AT FULL LOAD - PERFORMANCE, VIBRATION, DLN MAPPING & CONTROL SYSTEM - ALL TESTED BEFORE SHIPMENT - NO ADDITIONAL TEST AT SITE REQUIRED, FULLY PLUG & PLAY SOLUTION 7
Modularization as a product APPLICABLE PRODUCT SPECS LESSON LEARNED EQUIPMENT DESIGN CUSTOMER REQUIREMENTS EXECUTION STRATEGY PLANT LAYOUT STRUCTURAL DESIGN 8
Technology enablers Power density and plant simplification DRIVERS COMPRESSION DIGITAL 9
Technology enablers Power density and plant simplification LM6000PF+ 55MW IN THE SAME PF FR7EA 2 SHAFTS 120 MW HIGHER POWER AND NO VSDS HELPER MOTOR DRIVERS LM9000 65MW HIGHER POWER AND BEST MAINTANCE INTERVAL 10
Technology enablers Power density and plant simplification COMPRESSION HIGH PRESSURE RATIO COMPRESSOR FROM 2 COMPRESSOR BODIES TO 1 11
Technology enablers Power density and plant simplification Integrated Moto Compressor Suction Scrubber COMPRESSION SCRUBBER COMPRESSOR STRONG FOOTPRINT AND WEIGHT REDUCTION WET COMPRESSOR PROCESS BOP OPTIMIZATION 12
Technology enablers Design & operations simplification LIVE INSTRUMENT HEALTH MANAGEMENT SYSTEM DIGITAL DESIGN FOR MODULARIZATION (FOOTPRINT): PRESSURE SCANNERS COMPACT AND MINIATURIZED SENSORS MULTI-TASKING SENSORS WIRELESS TECHNOLOGY DESIGN FOR MAINTAINABILITY: DRONES CAMERAS REMOTE OPERATION 13
Ingredients for structural Optimization DESIGN TARGET DESIGN DRIVER OPTIMIZATION TOOL WEIGHT RATIO WR=(KG STEEL STRUCTURES)/ (KG EQUIPMENT) BENCHMARKING BOAT: 0.86 COMM. AIRPLANE:<0.30 CAR: 0.43 (STEEL FRAME) HD GT S MODULAR CONSTRUCTION ONSHORE: >0.8 - MAINTENANCE - HUMAN FACTOR - CUSTOMER SPECS - CODE & STANDARS - MAX STATIC DEFLECTIONS - DYNAMIC STIFFNESS - NEW CRITERIA FOR MODULE STATIC DEFLECTION - INTEGRATED ROTOR-DYNAMIC MODULE TYPICAL FIGURES: # PROFILES >20 # LOAD CASES> 100 # DESIGN CHECKS >3000 REDUCE MODULE STEEL STRUCTURE WEIGHT THROUGH AN OPTIMIZATION WORKFLOW BASED ON GENETIC ALGORITHMS WEIGHT RATIO TARGET<0.7 14
Module as a Product... vision Cost & Delivery time reduction up to 50% ONGOING NEXT PAST REFERENCES - 100 REFERENCES - 30 CONFIGURATIONS DESIGN TO MODULARIZATION - REFERENCE CONFIGURATION & VARIANTS - INTEGRATED ROTORDYNAMIC TECHNOLOGY - STRUCTURAL DESIGN STANDARDIZATION & OPTIMIZATION INDUSTRIALIZATIO N - MODULES PRODUCT SPEC - EQUIPMENT + MODULE INTEGRATED DESIGN - PRODUCTION ENGINEERING - SUPPLIERS ECOSYSTEM WEIGHT AND FOOTPRINT OPTIMIZATION STANDARD COST & LEAD TIME EQUIPMENT DESIGN MODULE DESIGN CONSTRUCTION & TESTING INTEGRATED MODULE DESIGN CONSTRUCTION & TESTING PROCUREMENT PROCUREMENT 15
Bigger advantages with modularization? 16
Case study Liquefaction Module GE Solutions: from truckable small scale LNG plant to Mega Liquefaction Module SMALL SCALE MODULES DESIGNED FOR REGIONAL ROAD REQUIREMENTS FLEXIBLE LAYOUT FOR CUSTOMER SPECIFICATION SMALL SCALE TRUCKABLE MODULES GE MODULES - PROCESS & 3D DESIGN THROUGH MANUFACTURING - PRE-ASSEMBLY AND TESTING DONE IN GE - HIGH WELDING & CLEANLINESS STANDARDS REDUCED ERECTION AND SITE ACTIVITIES - STANDARDIZATION TO REDUCE SITE & FACTORY REWORK - POTENTIALLY REDUCE SCHEDULE THROUGH - CONCURRENT TIMELINE AND/ OR STANDARDIZATION EXPERIENCE IN LNG PROCESS PLANT + MODULES + INNOVATION = GE MEGA LIQUEFACTION MODULES MODULE COUNT REDUCTION TOTAL PACKAGES FIELD CONNECTIONS WELDS TIME TO INSTALL DIMENSIONS BENEFITS CASE STUDY 80% reduction 50% reduction 70% reduction 30% reduction 50% reduction 148 x 72 x 57 - Fewer connections - Faster installation Single Liquefaction Process in one Module Ideal For Compact Or Multi-train Configurations 17
GE Gas Power Plant Solutions Modular plant outlook VALUE VAST EXPERIENCE LIFE CYCLE CUSTOMER TESTIMONIALS - SCHEDULE & COST CERTAINTY (RISK REDUCTION) - FASTER DELIVERY (NTP TO COD) - LOWER TOTAL INSTALLED COST (TIC) - FROM 30 MW TM TO 1.5 GW H CLASS PLANTS, E.G. - F-CLASS: 8 MODULAR CCPPS (~60 MODULES) - H-CLASS: 1.5 GW MODULAR CCPP IN EXECUTION (100+ SUB-MODULES) - PROVEN DESIGN INCORPORATING LESSONS LEARNT - PRE ENGINEERED - MANUFACTURED BY PROVEN SUPPLIER BASE - INTEGRATED PLAN: DESIGN- FABRICATION-LOGISTICS - LESS LAYDOWN AREA - LESS NEED FOR QUALIFIED ERECTION PERSONNEL - MINIMIZES IMPACT OF SITE INTERRUPTIONS - HIGH QUALITY SP. WELDING & CLEANLINESS - LESS COMMISSIONING EFFORT 18
GE Gas Power Plant Solutions Modular plant outlook LIFE CYCLE ENGINEERING ORDER PLACEMENT MANUFACTURE, ASSEMBLY & TESTING PACKING & DELIVERY INSTALLATION AT SITE 1 2 3 4 5 19
GE Gas Power Plant Solutions Modular plant outlook Up to 50% site man-hours Up to 10% faster power 20
Modularisation Gas Power Plants Case study CALCULATION SET UP 9HA.02 SS CC plant (804 MW*) Project site in EU Module fabrication in Western EU Data from executed projects CONCLUSION Risk reduction during execution Schedule reduction: 10% Total installed cost reduction: 6% * net output as per GE product catalogue 2017 TAKE AWAYS - GE Investing substantially in smart design, cost out, supply chain optimization of plants & modules - NPI program on modularization to develop portfolio of pre-engineered - modules GPS & GE Oil & Gas working together on design & manufacturing to leverage expertise - Target - bring maximum value to the customer - by mitigating execution risks. bring down TIC of modular solution (up to 10 %) 21
Potential modules In critical and high work density areas POWER TRAIN (GT GENO + ST) HRSG POWER ISLAND GT PRIME PACKAGING 6 MODULES AIR INLET FILTER HOUSE AND SILENCER FIRE PROTECTION COMBINED LUBE OIL SYSTEM FUEL GAS CONDITIONING GENERATOR STATOR COOLING WATER GENERATOR GAS SYSTEM GENERATOR SEAL OIL MODIFIED C FRAMES (INCL. DOWN COMERS) IP AND LP DRUMS STACK (PRE FABRICATED) HRH AND CRH VERTICAL PIPING CLUSTER VENTS AND DRAINS SILENCER AND VENT STACKS FEEDWATER RECIRCULATION BYPASS AND STEAM PIPING 3 MODULES CLOSED COOLING WATER EXPANSION TANK MODULE FEEDWATER PIPING MAIN PIPE RACK SMALL PIPE RACK MAIN COOLING WATER BUS DUCT ELECTRICAL MODULES* SAMPLING* DOSING* CEMS* FEEDWATER PUMP * CONDENSER* EMERGENCY DIESEL * AUX. BOILER * * Same delivery condition also in stick built (bts) 22
Module designs with Application Range and Options EXPANSION VESSEL CLOSED COOLING WATER MAIN PIPE RACK COMBINED LUBE OIL SYSTEM 23
GE & Modularization Innovation & Excellence COST REDUCTION SIMPLER DESIGN SOLUTION PROJECT EXECUTION EXCELLENCE AND RISK MITIGATION SMOOTH AND SMART INSTALLATION PARTNERING IN PROJECT DEVELOPMENT 24