sanjay verma, wärtsilä: efficient power solution for floating lng
DESCRIPTION
Sanjay Verma, Area Sales Director ME-SEA, Wärtsilä delivered this presentation at the 2013 FLNG Forum in Perth. The two day conference brings attendees key insights into the technology and concepts that will unlock Australia’s stranded gas reserves. This event brings together case studies, keynote and technical presentations from the experts at the forefront of the Floating LNG projects. For more information about the forum, please visit the event website: http://www.informa.com.au/flngforum2013TRANSCRIPT
Efficient Power Solution For Floating LNG
The FLNG Forum
Sanjay Verma - Area Sales Director
3rd- 4th Dec 2013
December 4, 2013 Efficient energy for Offshore Production units 1 © Wärtsilä
Agenda
• Introduction to Wartsila
• Setting the Scene – Why Change?
• Efficient Energy
• References
• Operation & Management
• Condition based maintenance
• Comparison
• Conclusion
December 4, 2013 Efficient energy for Offshore Production units 2 © Wärtsilä
Financial Highlights
4.12.2013 Efficient energy for Offshore Production units 3 © Wärtsilä
MEUR 2012 2011 2010 2009
Order intake 4 940 4 516 4 005 3 291
Order book at the end of the period 4 492 4 007 3 795 4 491
Net sales 4 725 4 209 4 553 5 260
Operating result1 515 469 487 638
% of net sales1 10.9 11.1 10.7 12.1
Earnings/share, EUR 1.72 1.44 1.96 1.97
Wärtsilä – Overview
22,000 professionals
Marine/
offshore Energy
Solutions for
• Listed in Helsinki
4 December 2013 4 © Wärtsilä Efficient energy for Offshore Production units
• Listed in Helsinki
Ship Power
26% (34) Power Plants
34% (31)
Services
40% (35)
5 © Wärtsilä
Exploration &
development
Production
FPSO
Flare recovery
Oil separation
LNG carrier
LNG liquefaction
& terminal
LNG terminal & Regasification
(FSRU/JRU) Distribution & transport
Power generation
LNG bunkering
& barges
LPG/LEG/LNG tanker
LNG fuelled vessels
Small-scale
LNG plants
LNG fuelled
vessels
Oil tanker
with VOC
Wartsila expertise in the Oil & Gas value chain
Exploration &
Drilling
Production &
liquefaction
Transport &
storage
Receiving
terminals &
regasification
Distribution &
transport to the
users
• LNG fuel gas
systems for OSVs
• LNG fuel gas systems
• LPG, LEG & LNG
cargo handling
• On- & Offshore small
scale liquefaction
• Antiflaring/VOC
• Oil separation
• Gas FPSO
• Jetty & Floating
regasification
• Bunkering & barges
• Receiving terminals
• Gas/LNG
distribution/logistics
• Feed gas to Power
plants
LNG receiving
terminal
Liquefaction
Liquids extraction
LNG reliq
Pre-treatment LPG reliq
Wärtsilä Pumps for FLNGs
Wärtsilä can supply a wide range of pump solutions for FLNGs, such as:
• Electric driven deepwell condensate oil pumps (API 610 VS1 or VS4)
• Electric driven deepwell process pumps (API 610 VS1 or VS4)
• Ballast Pumps (submerged or pump room)
• Sea water lift pumps (VS1 or in-line)
• Diesel driven fire water pump packages
04 December 2013 WÄRTSILÄ Hamworthy 7 © Wärtsilä
Products and Solutions for Offshore Production
May 24, 2012 8 © Wärtsilä Efficient energy for Offshore Production units
• Engines – propulsion and gensets
• Thrusters and propulsors
• Power distribution
• Automation
• Engine room pumps
• Pump room systems
• Seawater lift pumps
• Deepwell cargo / offloading pumps
• Firewater pumps
• Inert gas and nitrogen systems
• Hydrocarbon blanketing systems
• Oil separation
• Flare gas recovery
• Waste treatment systems
• Sea water valves
• Wartsila Gas Reformer
Wartsila provides Life Cycle Support
to all its Customers through our
service centers around the globe
04 December 2013 Presentation name / Author, Document ID: 9 © Wärtsilä
OFFSHORE Flow Solutions Oil and Gas Solutions
Type DWP FWPP ERP PRS LNG LPG Drives Electrical GR DF DG IGG Thrusters
FLNG √ √ √ √ √ √
√
√
√
√
√
√
FPSO
√ √ √ √ √ √ √
√
√ √
√
√
WÄRTSILÄ OFFSHORE – FPSO & FLNG
Setting the Scene
Why Change?
Fuel/Energy Efficiency is an important aspect to utilize our resources
in the best possible manner with minimum impact on our environment
•Do we have an alternative?
•CapEx ?
•OpEx ?
•Reliability?
•Maintainability?
•Ease of Operation?
4 December 2013 Efficient energy for Offshore Production units 10 © Wärtsilä
Setting the Scene
Why has fuel flexibility, efficiency and emission level requirement has little
impact on power solutions in the offshore industry ?
•Gas was previously not seen as an asset due to the significant
infrastructure required to utilize it
•Dual fuel alternatives was in the early days not an alternative
•References are seen as a key “must have” when going into the oil & gas
market
•The oil & gas offshore market is conservative and introduction of new
solutions takes many years
•Environmental requirements were not so stringent
4 December 2013 Efficient energy for Offshore Production units 11 © Wärtsilä
Setting the Scene
• Today there exist an alternative solution
with the required reliability and it is
“Reciprocating Dual Fuel Engines” which
provide fuel flexibility, better efficiency and
reduced emissions level
• Has predictive maintenance Op-Ex
• The solution is especially attractive for
reservoir with little gas or where the gas has
a sales value
• Meets or surpasses the Environmental
requirements
• Can run on Multi Fuel
– Gas, Crude, Heavy Fuel, Diesel
04 December 2013 Efficient energy for Offshore Production units 12 © Wärtsilä
Dual Fuel/Gas & Crude Oil Engine Technologies
Gas-diesel (GD) engines:
• Runs on various gas / diesel
mixtures or alternatively on diesel.
• Combustion of gas, diesel and air
mixture in Diesel cycle.
• High-pressure gas injection.
Dual-fuel (DF) engines:
• Runs on gas with 1% diesel (gas
mode) or alternatively on diesel
(diesel mode).
• Combustion of gas and air mixture in
Otto cycle, triggered by pilot diesel
injection (gas mode), or alternatively
combustion of diesel and air mixture
in Diesel cycle (diesel mode).
• Low-pressure gas admission.
Spark-ignition gas (SG) engines:
• Runs only on gas.
• Combustion of gas and air mixture in
Otto cycle, triggered by spark plug
ignition.
• Low-pressure gas admission.
‘87 … ‘92 ‘93 ‘94 ‘95 ‘96 ‘97 ‘98 ‘99 ‘00 ‘01 ‘02 ‘03 ‘04 ‘05 ‘06 ‘07 ‘08 ‘09 ‘10 ‘11 ‘12
Dual-fuel (DF) engines – Multiple fuel engines
Spark-ignition gas (SG) engines
Gas-diesel (GD) engines
34DF
50DF
20DF
0 5 10 15
20V34DF
12V34DF
9L34DF
6L34DF
16V34DF
18V50DF 17.55 MW
16V50DF
12V50DF
9L50DF
8L50DF
6L50DF
9L20DF
8L20DF
6L20DF 1.0 MW
Dual-Fuel Engine Portfolio
Duel fuel Engines Efficiency
• The available power for a
duel fuel reciprocating
engine is constant for an
ambient temperature of less
than approximately 45
degrees
• The available power for a
gas turbo generator is highly
depended on the ambient
temperature
16
©
Wärtsilä
6000
8000
10000
12000
14000
16000
18000
20 30 40 50 60 70 80 90 100
Load [%]
Heat
rate
[kJ/k
Wh
]
Typical gas turbine efficiency versus Wärtsilä 50DF
Wärtsilä 50DF versus Gas Turbine at 35ºC
Wärtsilä DF engine do not face the same challenges in tropical
environment !
Gas Turbine
Wärtsilä 50DF
High efficiency
Low efficiency
Gas turbine and Wärtsilä DF gensets
Specific fuel consumption
Temperature
[ºC] Output (% of the MCR output
in 15ºC, i.e. ISO conditions)
SFOC
[g/kWhr]
SFOC
[g/kWeh]
Max.
power limit
Wärtsilä DF genset
Gas turbine genset
Note: large difference
in low load operation
For example:
At 25°C -60%MCR:
DF: abt 225 g/kWeh
GT: abt 310 g/kWeh
04 December 2013
W12V34DF vs. 7 MW Gas Turbine
Operating Modes for DF Technology
• Gas mode
– Natural gas + MDO pilot
– Automatic and instant trip to diesel operation in alarm/emergency situation
– Transfer to diesel operation at any load on request
• Diesel mode
– MDO/HFO/crude + MDO pilot
– Operated as an ordinary diesel engine
– Transfer to gas operation at any load below 80%
– Pilot fuel injection in operation also during diesel mode operation
• Transfer between modes without power interruption
Gas mode Diesel mode
80%
100%
Engine
Load
0%
Typical plant efficiency at full output
Small
Size Gas
Turbine
Big Size
Gas Turbine
Big Size DF
Engine
30%
37 %
48%
Typical shaft efficiencies - simple cycle prime movers –
No de-rating due to ambient temperature
35 % Power
available in exhaust
gas that can be
recovered as steam
or hot Water/Oil
© Wärtsilä
Dual-Fuel applications - References
Power
Plants
DF Power Plant
64 installations
331 engines
Output 4040 MW
Online since1997
Merchant
LNGC
• 129 vessels
• 519 engines
Multigas Carrier
• 5 vessels
• 20 engines
Conversion
• 1 Chem. Tanker
Offshore
OSV’s
• 20 vessels
• 66 engines
Production
• 1 platform
• 8 FPSO’s
• 1 FSO
• 33 engines
New orders:
• Harvey Gulf;
6 LNG-PSV in
Gulf of Mexico
Cruise
and Ferry
LNG Cruise ferry
• 1 vessels
• 4 engines
• Complete gas
train
LNG ferries
• 2 ferries
• 8 engines
• Complete gas
train
Navy
Coastal Patrol
• DF-propulsion
• DF main and
auxiliary
engines
Others
TUG
• 2 vessel
• 2 engines each
• Mechanical
drive
Guide Ship
• 1 vessel /engine
IWW
• 2 vessel
• 3 engines
6 segments >230 installations > 7’000’000 running hours
35 MW x 3 Modules for P-63 FPSO
04 December 2013 Efficient energy for Offshore Production units 21 © Wärtsilä
6 x Wartsila 18V50DF
COSCO Shipyard Dalian
3 Modules of 35 MW each (2 x 18V50 DF DG Sets)
Initial operation on gas and subsequently on crude
Order by Quip for Petrobras Papa Terra 63 field for Brazil.
04 December 2013 Corporate Presentation 22 © Wärtsilä
Duel Fuel Engines installed in Hull
• Power plant can be housed below decks –
frees up large topside space
• Conventional “engine room design”
• No need for large suction air ducts or
discharge
• Low radiated heat in engine room
• Noise level according to IMO
• No requirement for essentials (also valid for
topside installed engines)
4 December 2013 Efficient energy for Offshore Production units 23 © Wärtsilä
Operational Experience with Dual Fuel Engines
• The Wärtsilä DF engines have now been in commercial operation since
1997. Experience from > 7,000,000 engine running hours have been
collected
• The DF engines has met or exceeded the requirements in terms of:
Reliability, Functionality and Engine performance
– Efficiency > 48% in gas mode
– Fuel back up operation instantly
– Low emissions
– Meet predicted overhaul intervals
• Because of the excellent operational experience Wartsila is willing to
sign long term service & operational contracts preferable based on our
Conditioning based monitoring concept
– The client will have a low and predictable OPEX for the engines
December 4, 2013 Efficient energy for Offshore Production units 24 © Wärtsilä
No essential generators needed
25 © Wärtsilä
ABS: It is assumed you are referring to essential generators and not emergency generators.
Provided the main generators meet the following requirements essential generators may be omitted
provided Flag and Coastal State permission is granted.
i) There must be a minimum of two separate spaces separated by at least a fire rated boundary.
ii) These two spaces must each be capable of delivering 100% of the required essential service.
iii) Each space must be provided with separate and distinct services - no commonality will be
permitted e.g. fuel supply, cooling water, fire protection, switch boards, power distribution.
iv) The generators are to be designed such that they will continue to operate at the worst damage
inclination.
Regards,
Mark Tipping
London Engineering Department
ABS Europe Ltd
DNV:
Dear Sir
We do agree. There is no need for an "essential" generator as long as the dual feed generator will do a
start up on its diesel fuel after a blackout.
Best regard
for Det Norske Veritas AS
Inboard demountable thruster
Patent pending
INTERNAL USE ONLY / CONFIDENTIAL
History
History Lips Modular Thruster:
● 1967: first Lips Modular Thrusters (900 kW)
● 1972: first containerised thrusters (1470 kW)
● 1976: first retractable thrusters (2230 kW)
● 1977: first thrusters with controllable pitch propellers
● 1981: first underwater de-mountable thrusters (3000 kW)
● 1998: first delivery of the largest retractable thrusters in the world (5550 kW)
2001: first delivery of new LIPS Compact Thruster design, max 3.000 kW
● 2004: first order thrusters with pulling propellers (5100 kW)
● 2008 introduction of inboard (submerged) demountable thruster design
LMT designs are based on continuous operation at full load
28 © Wärtsilä 04
December 2013
O&M Agreements
29 © Wärtsilä 04 December 2013
• Over 1800 employees
• 228 installations
• 160 O&M agreements
• in 30 different countries
• (updated 19.11.2009)
North
America
259 MW
Europe
122 MW Middle East
1189 MW
India
879 MW Africa
805 MW South America
1239 MW
Asia
319 MW
Total of 4 812 MW under contract
Marine 112 ships under agreements
Wärtsilä O&M references (11/2009) 4 812 MW under contract
WÄRTSILÄ 50DF REFERENCES
Till today 36 x LNGC have been
delivered with Wärtsilä 50DF.
Total of 62 LNGC on order
Total of 8 LNGC customer not
known bought on speculation
from yard
Service agreements Signed is 22
LNGC ready for signature today
is 15 LNGC legal negotiations
Success rate is 60% of service
agreements signature 2010 to
2011 for LNG section
Wärtsilä’s Service Agreement types
Supply
Agreements
Technical
Management
Maintenance
Agreements
Asset
Management
• Manpower & Parts
• Performance
Guarantee
• Global Coordination
& Supply
• Manpower
• Spare Parts
• Workshops
• Online Solutions
• Dynamic Maintce
Planning
• Risk Evaluation
• Inspection
• Training and
competences
• Planning support
• Operations &
Maintenance
• Part Crew
• Equipment
• Installation
32 © Wärtsilä
Asset crew Concept
Maintenance
Crew Centralised
Management
Onboard
Crew
Spare
parts
Condition Based Maintenance Concept
Dynamic Maintenance Planning Wärtsilä 24/7 Concept
04 December 2013 Efficient energy for Offshore Production units 33 © Wärtsilä
CASE STUDY Power Generator Selection 70 MW - 1/3
Model
EQP
No.
Budget Price
(MMUS$)per
Unit(Total)
Heat Rate@
Normal Load
(kJ/kWh)
FG Cost
(MM US$/y) (*2)
20 years
FG Cost
(MM US$) (*2)
Total CAPEX &
OPEX
(MMUS$)
GE
PGT 25+G4 4+1
(5)
13.0
(65.0)
11,752 27.2 544 609.0
RR
RB211GT61 4+1
(5)
12.7
(63.5)
11,269 26.1 522 585.5
Wartsila
18V50DF 5+1
(6)
9.3
(55.8)
7,751 (*1)
17.9 358 414.1
1) FG cost: 4.8 US$/MMBTU
2) The above costs and foot print of Gas Turbines are market estimates
3) Foot print area does not cover the foot print required for additional skids (Superheat module, gas
pressure module & also gas accumulators)
Model
Driver
Type
ISO
Rated
(kW)
Site
Rated
(kW)
Number
Required
Foot Print
per Unit
Total
Foot Print
(m2)
Experience
GE
PGT 25+G4
Gas
Turbine
33,057 24,800 4+1
(5)
22mLx5mW
x5
550 Onshore / Offshore
RR
RB211GT61
Gas
Turbine
32,135 25,400 4+1
(5)
NA NA
Onshore / Offshore
Wartsila
18V50DF
Gas
Engine
16,500 16,500 5+1
(6)
19mLx5mW
x6
570 Onshore /
Offshore
CASE STUDY Power Generator Selection 70 MW - 2/3
Gas Turbine Gas Engine
(Dual Fuel)
Installation Top Side Hull
Fuel Gas Pressure High Pressure
45 barg
Low Pressure
6 barg
Fuel Gas dryness +28 oC Superheated No requirement
Switching fuel from gas
to diesel
Gradual controlled change
(30 – 60 seconds)
Instant change
Pilot oil Not required Required
(1% of energy consumption)
CASE STUDY Power Generator Selection 70 MW - 2/3
PGT25+G4
Reliability and Availability
CASE STUDY Power Generator Selection 70 MW - 3/3
Generator
Number
Maintenance
Cost (US$/Fired
hr/unit) (*1)
Maintenance Cost
(MMUS$/20years
/unit)
Total Maintenance
Cost
(MMUS$/20years)
PGT25+G4 4+1 215 37.7 150.7
18V50DF 5+1 107 18.8 112.8
COMPARISON OF MAINTENANCE
*1) Spare parts & Labor Costs (not including transportation)
2) Market estimates used for Gas Turbine
•Total Saving for 20 years Cap Ex + Op Ex = 208.3 MUSD
• Added saving of about 10 - 15 MUSD on Essential DG Sets Cap Ex & Op Ex
• Freeing up of approx 550 Sq Met due to installation of power plant in the Hull.
The above figures of Gas Turbines are based on Market Estimates
We request you to make your own comparison, when making a selection.
38 © Wärtsilä 04 December 2013 Presentation name / Author Sanjay Verma
Wouldn’t you
like this as a
free area for
easier topside
layout?
Dual Fuel Versus Gas Turbine
• With DF engine based power solution:
– No derating due to Ambient temperature
– No derating due to Turbine blade fouling (up to 5%)
– No derating or Gear Losses (Approx 2 %)
– No Exhaust system losses (2-3% depending on back pressure)
– No inlet air system losses (2-3%)and costly air filtration system
– No Fuel Gas superheat module required
– Startup load and time much lower for DF Engines
– In addition Wartsila solution do not require costly fuel system and can
run on lower grade of Diesel for liquid fuel.
– Wartsila DF engines are less sensitive to H2S in fuel gas.
– Possibility of having WHRU (approx 35% of generated power is
available as heat power)
– Crude Oil Operation is possible with DF Engines
04 December 2013
Summary
For the New Build FPSO & FLNG we propose:
– Wartsila DF in engine room maximum space utilization. Shipyard fully familiar
with this installation (LNG Carriers)
– Do you still need the Essential DG sets?
– This frees up large space on deck for process modules.
– Much easier to design the E/R and optimize it at an early stage of design.
– Korean Yards very familiar with LNG carriers and have used DF engines for
the construction of over 250 ships.
– CAPEX & OPEX saving
– All maintenance in situ by operation team.
04 December 2013
04 December 2013 Corporate Presentation 41 © Wärtsilä
42 © Wärtsilä
Conclusion
04 December 2013 Efficient energy for Offshore Production units 42 © Wärtsilä
Dual Fuel Reciprocating Engines Offer:
- Lower overall Cap Ex & Op Ex
- Reduced emission
- High efficiency
- Excellent Reliability & Maintainability
- Reduced topside foot print
- Multi Fuel Operation
Thank you for your attention