Transcript Microtubines - America Approved

MicroTurbine Applications
for the Oil and Gas Industry
Lee Richards - Director of Sales for Oil & Gas,
Capstone Turbine Corp
Bryan Hensley - VP Sales,
Pumps & Service
15 July 2008
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
What is a MicroTurbine?
Power generator driven by a small scale gas turbine
• Electrical Efficiency of 26-33%
• Combined with CHP can achieve thermal efficiency of 80%+
• Wide range of fuels – 350 btu to 2500 btu
• Up to 7% H2S with C30
• Extremely Low Emissions - <9 ppm NOx
• Air Bearings
• No Oils or Lubricants
• Air Cooled
• No Antifreeze or Coolants
• Variable Speed
• 45,000 to 96,000 RPM
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Air Bearings
Spring
Spring
Foil
Shaft
Shaft
Boundary Air
Foil
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Inside the Capstone MicroTurbine
Cooling fins
Exhaust output
• No gearbox, pumps, or
other mechanical
components
Recuperator
Fuel injector
Air intake
Combustion
chamber
• Recuperated Engine
• Permanent magnet
alternator
• Lean premix combustion
• Air Bearings
Generator
• Air Cooled
Compressor
Air bearings
Turbine
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Power Electronics
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No moving parts
Variable Voltage 400-480 volts
Variable Frequency 10-60 Hz
Voltage & Current source Inverter
“Electronic” Gearbox
Built in Fault protection
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Inverter Based Electronics
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
MultiPac & Grid Connect
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Capstone Products
Available with gas & liquid fuels
C30 & C65
C65 CHP
C200 & C200 CHP
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Capstone Products
C30 & C65
Class I Div 2
ATEX Zone 2
C30 & C65 SS
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Performance
C30
C65
C200
Rated
Power
30 kw
65 kw
200 kw
Full Load
Efficiency
26%
28%
33%
12,200 Btu/kWh
(12,800 kJ)
11,000 Btu/kWh
(11,600 kJ)
10,300 Btu/kWh
(10,900 kJ)
Liquid Fuel
D2, 1-K, Jet A, JP8, JP-5
D2
In Development
Gas Fuel
(HHV)
325-2131 Btu/scf
325-2550 Btu/scf
325-2550 Btu/scf
Output
Current
46 Amps RMS
100 Amps RMS
310 Amps RMS
Nominal
Voltage
400 to 480 VAC
400 to 480 VAC
400 to 480 VAC
Exhaust
Gas Temp
530 F (275 C)
588 F (309 C)
535 F (280 C)
NOx
Emissions
Gas : <9 ppm
Liquid : <35 ppm
Gas: <9 ppm
<5 ppm CARB
Gas: <9 ppm
<5 ppm CARB
Acoustics
65 dBA
65 dBA
65 dBA
Heat Rate
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Packaged Solution
C600
C800
C1000
Rated
Power
600 kw
800 kw
1000 kw
Full Load
Efficiency
33%
33%
33%
Heat Rate
10,300 Btu/kWh
(10,900 kJ/kWh)
10,300 Btu/kWh
(10,900 kJ/kWh)
10,300 Btu/kWh
(10,900 kJ/kWh)
Output
Current
930 Amps RMS
1240 Amps RMS
1550 Amps RMS
Nominal
Voltage
400 to 480 VAC
400 to 480 VAC
400 to 480 VAC
Exhaust
Gas Temp
535 F (280 C)
535 F (280 C)
535 F (280 C)
Exhaust
Energy
4,050,000 BTU/hr
5,400,000 BTU/hr
6,750,000 BTU/hr
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(3), (4), or (5) C200 Units
Stackable Footprint
30’ Enclosure with ISO Footprint
Load control from 100% to idle
Flexible Maintenance
Parts redundancy with C200
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
C1000 ISO Efficiency
35
30
Efficiency (%)
25
20
15
Load Share Efficiency
10
Typical Turbine Efficiency
5
0
0
100
200
300
400
500
600
700
800
Power (kW)
High Part Load Efficiency
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
900
1000
Installation
Height (ft)
Width (ft)
Depth (ft)
Weight (lbs)
C30 Industrial
6.4
2.5
5.0
1271
C30 C1D2
7.7
3.1
7.0
2475
C65 Industrial
6.9
3.1
7.0
2471
C65 C1D2
8.2
3.1
7.0
3600
C200
8.2
5.5
12
7000
C1000
9.6
8.0
28
28,500
20 kw Recip
Package
60 kw MicroTurbine
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Typical Site Layout
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Oil & Gas Experience
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Mexico
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36 Units in Offshore Oil Production
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NE United States Pipeline
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31 Units in Gas Transmission
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50 Units in Remote Gas Transmission
South America Pipeline
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CHP Applications
Russia Pipeline
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Flare Gas Fuel
Units Sold
O&G
Installations
C30
3350
285
C60
1282
122
C65
360
135
C200
45
2
Total
>5037
>544
65 Units in Gas Transmission
More than 60 O&G customers worldwide
More than 70 packages installed offshore
80% of all Microturbines Sold
Worldwide are Capstone
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Certification
• California CARB 2007 Listed
• UL 2200, the latest generator safety
standard, and UL 1741, the national
grid interconnect standard
• MicroTurbines were the first
generators of ANY type stateapproved by New York and by
California (“Rule 21”) for direct-to
-grid interconnection
• Also compliant with NFPA, IEEE519,
CE, NEC, CSA, ATEX and other
internationally recognized safety
standards
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Capstone: A Big Small Company
• Founded 1988
• First to introduce microturbine
energy products ten years later
• 100% microturbine focused
• The world leader in
microturbines
• >5000 production units sold and
shipped
• ISO 9001:2000 and 14001:2004
UL-certified
• Offices in LA, NYC, Mexico,
Milan, Bath, Shanghai and Tokyo
• Distributors located world wide
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Capstone Corporate Headquarters
Chatsworth, California
Preventative Maintenance
8,000
Hours
20,000
Hours
40,000
Hours
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Air Filters
Clean/Replace
Fuel Filter
Replace
Igniter
Replace
Injectors
Replace
Battery Pack
Replace
Thermocouple
Replace
Engine &
Generator
Exchange
Typical Maintenance cost of $0.016 kWh
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Average of 6 Hours of Planned Maintenance
per year
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Capstone will guarantee cost of planned and
unplanned maintenance through Factory
Protection Plan
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Servicing injectors at 20,000 hrs
on an offshore platform
Oil & Gas Specific Applications
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Key O&G Objective
• Primary Uses
• Generate Power
• Eliminate Flare/Vent
• Combine Heat/Power
• Use power for applications
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Prime site power
Black start power
Back-up power
Peaking
Supplemental power
• Reduce utility costs
• Generate power from fuel sources such as
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Casing gas from oil production
Condensate gas from liquid processing
Gas too rich or too lean to meet pipeline standards
Sour gas with H2S – up to 7%
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
3-pack on oil flare gas in
New Mexico
Benefits of MicroTurbines in O&G
• Low Installed Cost
• Short Commissioning Period
• Easy Interconnects to Local Grid
or Bus
• Very Low Maintenance
• Ease of Operations
• No Lubricants or Coolants
• Small Footprint, Light Weight
Test prior to platform deployment,
Netherlands
• < 65dBA Acoustic Emissions
• Ultra-low NOx emissions with no
post-combustion devices or chemicals
• Accepts 350-2500 Btu w/up to
7% H2S (C30)
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Integrated Heat Exchanger
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Exhaust Heat Utilization - CHP
Traditional Approach
Capstone ICHP
120 kWth
65 kWe
150 kW
fuel
345 kW
fuel
80% av. boiler
efficiency
65 kWe
120 kWth
30 kW
waste
230 kW
fuel
160 kW
waste
40 kW
waste
33% av. utility
efficiency
195 kW
fuel
130 kW
waste
• 54% average total efficiency
• 3.4 lb/MWh NOx & 2,320 lb/MWh CO2
• 80% average total efficiency
• 0.15 lb/MWh NOx & 1,540 lb/MWh CO2
Source: EPA and DOE, see notes page for specific references
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Exhaust Heat Utilization - CHP
• Heat to glycol or hot oil systems
• Preheat fuel gas to larger turbines
or engines
• Preheat water to steam boilers
• Direct heat to oil/water separators
• Supplemental heat to regas LNG or
other liquid regas process
• Building or utility heat
• Various gas plant and amine plant
applications
• Refrigerant based systems
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Exhaust Heat Utilization
Heat from two C30s running on untreated wellhead gas goes to “heater/treater” separator
Microturbines also generate voluminous exhaust heat
• C65 Generates 561,000 BTU/hr (591,000 kJ/hr) at 588F (309C)
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Example Applications
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Cathodic Protection
Example Installation by Pumps & Service
• Client – Major US Gas Transmission Company
• Project - Gas Pipeline Cathodic Protection
• Requirements - Customer required extremely reliable
power source at low current in very remote applications.
• Alternative Solutions
• Grid power – would require several miles of power lines
installed
• Recip Generators – would require regular maintenance
intervals
• Thermal Electric Generators (TEG) – unreliable
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Cathodic Protection
• Solution – Single C30 installed along pipeline as required
• Benefits
• Minimal maintenance requiring site visits only once each 6 months
• Remote monitoring and diagnostics to verify operational quality
• Extremely low emissions for installation in national forest
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Primary Power for Remote Site
Example Installation by Pumps & Service
• Client:
Major US Production Company
• Project:
Primary Power for Salt Water Disposal
• Requirements:
Needs reliable, cost-effective power in
remote location
• Alternative Solutions
• Grid Power – Not available
• Re-Power – Eventually same problems with high maintenance
cost, high emissions, and excessive down time.
• Reciprocating generators – Same as re-power
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Primary Power for Remote Site
• Solution - Multi-pac of 3-C30 installed in a control room
fabricated for this site.
• Benefits
• Lowered maintenance cost
• Improved reliability of site
• Improved flexibility to control and maintain pressures and flow
rates
• P&S Later designed New SWD in 2006 with Capstone
because of success
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Primary Power for Oil Pipeline
Example Installation by Pumps & Service
• Client:
Large US Oil Pipeline
• Project:
Transfer pumps for a major Oil Pipeline in
Remote Location
• Requirements:
Reliable Power because of extremely
high cost for down time as well as
being on a very remote location
• Alternative Solutions
• Grid Power – Not available
• Reciprocating Generators – regular maintenance schedules,
unplanned down time (low oil, high engine temp..) and reliability.
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Primary Power for Oil Pipeline
• Solution:
(15) C65 installed as the power supply for location
• Benefits:
• Minimal maintenance requiring planned site visits on
semiannual schedule
• Remote monitoring and diagnostics to verify operation
• Reliability. No unacceptable downtime
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Offshore Resource Recovery
The Issues:
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Provide a reliable power source in a
hazardous oil and gas application on
an offshore platform in the Gulf of
Mexico
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Recover value from onsite flare gas
which is normally lost to the
environment
The Solution:
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A Capstone microturbine, UL certified for hazardous oil and gas applications
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The microturbine runs on onsite unprocessed wellhead
gas which is normally flared, providing a power source to the platform
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The microturbine cut maintenance time by ~95%
compared to reciprocating engine generators
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The microturbine ran almost non-stop for 25,000
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Capstone has microturbines running on other platforms
in the Gulf of Mexico, Gulf of Alaska, Bay of Campeche,
the North Sea, Mediterranean Sea, and South China Sea
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Offshore Installations
Deployed in the Gulf of
Mexico
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
Conclusions
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Ideal power generation for oil & gas
installations, onshore and offshore
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More than 5,000 Capstone MicroTurbines
sold and 19+ million operating hours
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Fuel Gas from 350 BTU – 2500 BTU with
up to 7% H2S
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Low emissions of less than 9 ppm NOx
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Lowest maintenance cost of 0.016 $/kWh
with 6 hours/year of planned maintenance
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No lubricants or coolants
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com
© 2008 Capstone Turbine Corporation • www.capstoneturbine.com