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Engineering Course
12. Power Generation and
Distribution Systems
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 1
Contents
• Power Generation • Emergency Power Generation
• Gas Turbines • Emergency Diesel Generator
• Gas Turbine Control • Internal Combustion Engines
• Gas Turbine Emissions • Gas Diesel Engines
• Noise Control • Electrical Heat Tracing
• Gaseous Fuel Specification • Electrical Distribution Systems
• Liquid Fuel Specification • Load List
• Gaseous Fuel Consumption • Hazardous Area Classification
• Gas Turbine Ancillaries • Hazardous Gases
• Gas Turbine Data • Temperature Classification
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 2
Power Generation
• The main power generation system on most installations comprises of gas or gas/diesel
(dual fuel) turbines as the normal source of power and diesel engines for emergency
power generation. Large individual consumers such as compressors often have their own
power supply
• Gas turbines are normally fired by fuel gas taken from the production train, when this is
not available, during start-up for example, the turbine can operate on diesel fuel
• The gas turbines are virtually self contained units, complete with their own controls,
switchgear, lubricating and hydraulic oil system, compressed air system, air filters, inlet
and exhaust silencers
• A gas turbine compressor
module being installed onto
BP’s Cleeton platform (left)
• Power generation units
located onshore, Saudi
Arabia
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 3
Gas Turbines
Three-Stage High Pressure Turbine
Exhaust
Combustor
Air Inlet
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 4
Gas Turbines
• Gas turbines can be either aero-derivative type, industrial or hybrid, which combine the best elements of
both models
• Aero-derivative models were originally developed for aircraft service and have been adapted for industrial
applications, they are light and compact and employ modular construction. Fuel specifications are more
strictly controlled than for other turbines
• Industrial machines employ heavy, horizontal split casings, are very durable, have larger combustion
chambers and can tolerate a wider range of fuels
• Aero-derivative machines are more maintenance intensive, with approximately 8000 operating hours
between overhauls with a low down-time. In comparison, industrial models can run for around 16000
hours between overhauls, however the down-time is longer by several days. Also required (outside TAR):
– Washing - 0.75 days every 60 days
– Boroscope - 2 days every 180 days
• Gas turbines consist of a compressor section, combustor and turbine section (the Gas Generator) which
supplies high pressure gas to the power turbine section. When the power turbine section is integral to the
gas generator, the machine is called a Single Shaft machine
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 6
Gas Turbines
High pressure air Hot gases expand through the turbine
Combustion System
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 7
Gas Turbines
• The operating principles of a gas turbine are as follows:
– Air is drawn through inlet filters and silencers and adiabatically
compressed in stages of axial compression, the air then passes to the
combustion chamber
– Some of the air is fed directly to the fuel burners, the majority being
used to cool the outer surfaces of the combustion chamber
– At higher combustion temperatures, the efficiency of the turbine
increases however the the turbine blades would have a reduced
operating life, therefore an economic compromise is required
– The hot gases then expand adiabatically through the power turbine
section which drives the alternator
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 8
Gas Turbine Control
• The control system is capable of starting up the turbine bringing
it up to normal running speed automatically and safely in
response to one single start initiation signal
• Condition monitoring is provided locally and life prediction
software calculates the time between maintenance based to the
load delivered, number of start-ups, etc.
• The primary controls required are the speed governor (electrical
frequency), voltage, shaft speed and turbine temperature which
is measured at the inlet to the power turbine
• If extra load is demanded, the gas turbine frequency falls and
eventually it will trip
• If more than one GT is being operated, the other(s) will attempt
to take on the additional load Gas turbine control panel
• Automatic load shedding will take place if the frequency
continues to fall, that is users will be tripped in a pre-
determined sequence until the load has stabilised
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 9
Gas Turbine Emissions
Low emission • The exhaust gas produced by gas
burner from an turbines generally contains low levels of
GEC Alstom pollutants as the fuel is mixed with large
Tornado gas
turbine
quantities of excess air
• The most significant exhaust gas
pollutant are oxides of nitrogen, NOx
• Liquid fuels produce more exhaust gas
• Historically, water or steam injection has
pollutants than gaseous fuels, such as
reduced the amount of NOx emissions
CO, unburned hydrocarbons (UBH) and
by reducing the flame temperature,
SOx
however more modern gas turbines use
• The target concentrations of exhaust dry, low NOx ‘lean burn’ combustors
gas pollutants for gaseous fuels are as
• Another method of NOx reduction is
follows:
Selective Catalytic Reduction (SCR) in
– NOx: less than 25 ppmv @ 15% O2
which anhydrous or aqueous ammonia is
– CO: less than 20 ppmv @ 15% O2 injected into the flue gas upstream of a
– UHC: less than 20 ppmv @ 15% O2 catalyst bed, which decomposes the
– Smoke: non visible NOx to elemental nitrogen and water
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 10
DLE Gas Turbines - 1
The implementation of dry low emissions technology to gas turbines differs with manufacturer
but broadly the approach is to achieve a lower and more uniform combustion temperature in
the turbine by controlling the fuel:air mixture more tightly than in conventional gas turbines.
This is difficult to do over a wide range of turbine loads and leads to the need for variable
geometry in fuel nozzles, individual control of groups of fuel nozzles, bleed-off of compressor
air at part loads or a combination of some or all of these. This leads to more complex fuel and
engine control systems than non-DLE gas turbines which has implications both for operation
and commissioning.
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 11
DLE Gas Turbines - 2
• DTI consider DLE standard practice and justification required for non
compliance. Not all manufacturers & types available in DLE version e.g. Duel
fuel machine.
• Downside
– Higher spec fuel gas required at higher pressure and dewpoint. Less variation in FG
supply.
– DLE run time and operating experience offshore is in its infancy and industry
experience not be widely circulated at this stage. Onshore DLE operation well
established. Need to focus on obtaining design, commissioning and operating
experience direct from operating companies employing DLE engines as part of the
engine manufacturer selection process.
– Slight performance penalty but disputed by manufacturers.
– Lower availability of spare engines.
– CAPEX differences: about 5 - 10% of the engine cost.
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 12
Noise Control
• The noise created by a gas turbine is considerable and
must be reduced to protect plant personnel and minimise
environmental impact
• The noise associated with the air intake and noise radiated
from the casing is high frequency and in the range most
damaging to the ear, exhaust noise contains more energy
which results in a detectable pressure change, but the
frequency is lower and less damaging Rolls-Royce/Allison
• Inlet noise is reduced by acoustic baffles installed just electrical power package.
before an elbow in the inlet air ducting Acoustic insulation is
• Casing noise is reduced by an acoustic enclosure over the normally part of the
turbine, with integral fire and gas detection and fire equipment manufacturers
scope of supply for the
extinguishing equipment
power generation package.
• On the outlet, acoustic baffles are required and the exhaust
ducting should be sound insulated
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 13
Gaseous Fuel Specifications
• At the system inlet, the gas must not contain any liquid hydrocarbons or water in either
liquid or solid phase, no components in the gas should condense at the prevailing
pressure within the system
• To achieve this specification, fuel gas is normally superheated by 20 ºC.
• Specification for fuel gas (typical, may vary depending on machine)
– Lower calorific value (range) 30 - 100 MJ/m3
– Pressure,min 24.5 0.5 bara (40+ bara for DLE units)
– Temperature, max 120 ºC
– Wobbe Index, variation 5% (min. acceptable change is 0.5% per second)
– Solids, max 5 ppmw (of solid particles should have a
diameter less than 20m)
– Density, dew point, composition and sulphur content to be reported to the manufacturer
– Certain components within the machine are custom built to each individual specifications,
therefore the gas specifications must not vary above the limits agreed by the manufacturer
– Density should be quoted for a dry gas For a low emission burner, it should be of the range 0.7 -
1.2 kg/Nm3 (0.044 - 0.075 lb./scf)
– Typically, the water content should be 1 lb/MMSCF
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 14
Liquid Fuel Specification
• A variety of liquid fuels can be used to power gas turbines, however diesel is the most
commonly used
• Specification for liquid fuel (typical, may vary depending on machine)
– Viscosity depends on temperature and pressure, typical values are 5 - 7 cSt
– Free water 500 ppm max
– Sediment 100 mg/litre max
– Carbon residue 0.25 % max
– Ash content 300 ppm max
– Ca 10
– Pb 1
– Density, flash point, sulphur content cloud point and pour point are to be reported to the
manufacturer
– Fuels with a flash point lower than 30ºC require special safety regulations
– The cloud point or pour point should be at least 10 ºC below the lowest temperature the fuel
system may experience
– The fuel must be protected against contamination by water and sediment during transportation
and storage
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 15
Gaseous Fuel Consumption
• The ISO rating of the turbine is the output power at 15 ºC, 1.013 bar and 60% relative
humidity, with zero inlet and exhaust pressure losses
• The gas turbine will be site-rated according to the installed conditions:
Psite = Piso (1/1.02) 1/[1+0.008(t-15)] 1/(1+0.01H)
Where t = ambient temperature (ºC) and H = height above sea level/100 (m)
• The site-rated efficiency of the gas turbine can be estimated from the ISO power:
– ISO Power Thermal Efficiency (Conservative)
– 0 to 3500 kW 20%
– 3500 to 15000 kW 23%
– above 15000 kW 26%
• A preliminary estimate of fuel consumption can be calculated as follows:
– If the lower heating value and density of fuel gas is unknown, assume a value of 45 MJ/sm 3 and
a standard density of 0.9549 kg/m3
– For example, a 15MW gas turbine will require a fuel gas flowrate of:
– [(15 MJ/s / 45 MJ/sm3)] 100/23 = 1.45 m3/s (4.4 MMSCFD)
– A contingency of 10% should be added to the flowrate to allow for site rating of the turbine
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 16
Gas Turbine Ancillaries
• The gas turbine power generation package comes complete with the following
ancillary systems:
– Compressed Air System
• A dedicated compressed air system is provided for the various pneumatic actuators to enable
the turbine to be started
– Ventilation
• A forced draft system maintains a positive pressure within the gas turbine package
– Lubricating Oil
• A 100% spared system supplies the whole unit with an emergency back-up to ensure the unit
runs down safely
– Cleaning System
• Fouling of the turbine and compressor blades by dust, oil, ash etc. can result in a loss of
performance, therefore online or offline cleaning systems using a wet or dry agent are
installed
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 17
Inlet Air Filtration
• AIR CONTAINS MANY SORTS OF POLLUTANTS:
– DUST
– SALT SPRAY
– SAND
– DRILLING CEMENT
– RAIN
– SNOW
– INSECTS
– SEA WATER
– LEAVES AND OTHER VEGETABLE MATTER
– SOOT AND OTHER ENGINE EXHAUST
MATERIALS
– INDUSTRIAL POLLUTANTS
• EVEN WITH SMALL POLLUTANT
CONCENTRATION HIGH AIR MASS FLOW =
LARGE AMOUNTS OF POLLUTANTS
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 18
Gas Turbine Data
DIMENSIONS L:W:H WEIGHT
MANUFACTURER MODEL TYPE ISO RATING (MW) EFFICIENCY (%) (m) (tonnes)
Solar Centaur 40 A/D 2.9 - 3.5 28 9.0:2.4:2.6 25
Centaur 50 A/D 4.24 28 9.0:2.5:2.8 30
Taurus 60 A/D 5.2 30 12.3:2.4:3.1 45
Taurus 70 A/D 6.6 30 12.3:2.4:3.1 60
Mars 90 A/D 7.9 - 9.6 33 16:2.4:3.0 80
Alstom -formerly European Gas Turbines Hurricane A/D 1.65 26 5.75:2.0:3.2 13.5
(Lincoln Design and Manufacture) TA2500 A/D 3.5 - 9.5:2.4:2.8 25
TB5000 A/D 3.92 - 9.7:2.4:2.4 34
Typhoon A/D 4.35 - 5.25 30.5 8.0:2.4:3.2 * 38.1
Tornado A/D 6.45 - 6.75 31.5 11.5:2.4:3.2 ** 55
Tempest A/D 7.7 - 9.8:2.4:3.5 55
Cyclone A/D 12.9 35 5.75:2.0:3.2 60
GEC Alstom (GE Gas Generator) RLM2500 H 22.5 37 16.5:3.4:3.9 115
Kværner Energy MS5001E (Frame 5)† HDI 26.3 28.5 21.5:3.28:4.0 288
MS6001E (Frame 6) HDI 39.6 31.8 22.6:3.28:3.8 276
MS9001E (Frame 9) HDI 123.4 33.8 30.61:5.10:6.35 475
ABB Stal GT35 H 15 - 20 32 - -
GT10 H 25 34 - -
GTX100 H 43 37 - -
Rolls-Royce/Allison RB211 A/D 23.0 - 30.8 40 25:3.5:3.0 185
501-K A/D 2.5 - 5.0 30 - -
601-K A/D 5.0 - 9.0 30 - -
• HDI = Heavy Duty Industrial * Dimensions and weight shown for 5.25 MW model
• A/D = Aeroderivative ** Dimensions and weight shown for 6.75 MW model
• H = Hybrid (mixture of industrial and aeroderivative) † Frame 5 is a relatively old design which accounts for the lower power/weight
ratio than the Frame 6
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 19
Gas Turbine Data ISO RATING EFFICIENCY DIMENSIONS WEIGHT
MANUFACTURER MODEL TYPE (MW) (%) L:W:H (m) (tonnes)
Solar Centaur 40 H 3.5 28.5 9.8:2.5:2.6 30
Centaur 50 H 4.6 29.4 9.0:2.5:2.8 32
Taurus 60 H 5.5 30.5 11:2.5:3.1 32
Taurus 70 H 7.5 33 12:2.8:3.1 55
Mars 90/100 H 9.4 - 10.7 31.5 15:2.8:3.8 70
Titan 130 H 14 33.5 14:3.1:3.8 75
Alstom Power - (formerly Ruston and EGT) TA1750 HDI 1.3 18 9.0:2.6:3.1 23
Lincoln Design and Manufacture TA2500 HDI 1.9 20 9.5:2.4:2.8 25
TB5000 HDI 4.0 25 9.7:2.4:2.4 34
Typhoon LWI 4.35 - 5.25 30.5 8.0:2.4:3.2 36
Tornado LWI 6.75 31.5 11.0:2.4:3.3 56
Tempest LWI 7.9 31.2 10.75:2.4:3.6 57
Cyclone LWI 12.9 35 13.5:2.7:3.9 75
Alstom Power - (formerly ABB Stal) GT35 H 15 - 20 32 25.0:4.0:4.2 160
Finspong Design and Manufacture GT10B LWI 24.8 34 20.5:4.5:5.3 185
GT10C LWI 29.1 36 20.5:4.5:5.3 185
GTX100 LWI 43 37 22.0:4.5:6.0 275
Rolls-Royce/Allison Avon A/D 14.58 27 - 165
RB211 A/D 23.0 - 30.8 36 - 185
501-K A/D 3.95 - 5.27 29.5 - 27
601-K A/D 6.5 - 7.92 31 - 63
GE LM1600 A/D 13.74 35 - -
LM2500 A/D 22-30 38 - -
LM6000 A/D 42 41.5 - -
MS5001E (Frame 5)† HDI 26.3 28.5 21.5:3.28:4.0 288
MS6001B (Frame 6) HDI 42.1 32.5 22.6:3.28:3.8 276
• H = Hybrid (mixture of industrial and aeroderivative) † Frame 5 is a relatively old design which accounts for the lower
power/weight ratio than the Frame 6
Emergency Power Generation
• In the event of an interruption of the normal power supply, caused by a total
main generation or distribution system failure, power to the emergency
switchboard is provided by automatic start-up of the emergency power
supply
• Emergency power generation can be either an Uninterruptible Power Supply
(UPS) type, a standby diesel generator or both
• The emergency system supplies power via the emergency switchboard to the Emergency Diesel Generator Set
following consumers only,
– communications: emergency radio and public address system
– emergency lighting
– emergency shutdown system (ESD)
– emergency depressurisation system
– fire and gas system
– diesel fire pump control and starting systems
– switchgear tripping facilities
• The Emergency Power Supply is designed to supply power to these loads
continuously for 24 hours
• A UPS system consists of a rectifier/battery charger, DC to AC converter and
transfer or bypass switch Emergency Battery Power Supply
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 21
Emergency Diesel Generator
• The diesel engine drivers are independent of other utilities and have their own
cooling systems, starting mechanism and fuel supply
• Battery supplies are often provided to maintain power for essential equipment if
the power supply from the diesel generator is lost
• Individual generator sets are supplied with diesel day tanks which are sized to
hold enough fuel for 24 hours continuous operation
• A compressed air starting system consists of an electric motor driven
compressor which maintains a pressure of 30 barg in the accumulator vessel
• The engine design includes some limited protection against operation in
potentially explosive gas mixture atmospheres by reduced engine surface
temperatures, exhaust gas coolers and an inlet air shut off valve
• The emergency generator is situated in an enclosure protected by fire walls, and
has a dedicated CO2 fire protection system.
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 22
Internal Combustion Engines
• There are three commonly available types of engines in use both offshore and onshore:
– Spark ignition engines which operate using either LPG or gasoline and are usually referred to as
gas engines
– Compression ignition engines which only operate using diesel fuel which must be of a
consistently high specification
– Dual fuel (gas/diesel) engines operate in either liquid (diesel) only mode or gas mode with a
constant pilot injection of diesel
• Most spark ignition engines use a four stroke cycle however a two stroke cycle gives a
higher output from the same engine size
• Two stroke engines are applicable to both spark ignition and compression ignition
engines
• Supercharged engines use a compressor to increase the density of the combustion air
before it is inducted into the cylinder
• Two types of supercharger are commonly used, a mechanical compressor driven by a
separate prime mover or an exhaust gas recycle
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 23
Gas/Diesel Engines
• Gas/diesel engines use direct injection of fuel into
the combustion space, only air is present in the Air intake
cylinder during the compression stroke
• Pilot fuel is required to stabilise combustion
• Fuel can be natural gas, crude oil, LPG or diesel Air compression
• Engines are commonly used for start-up purposes
where an independent, reliable power source is
required
Fuel injection
• Fire water and seawater lift pumps are often
supplied complete with diesel engines for start-up
and safety purposes
• Gas diesel engines are considerably heavier than
gas turbines but have a lower initial cost
• Levels of availability, reliability and efficiency are
comparable to gas turbines
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 24
Electrical Distribution Systems
• Electrical switchgear is a form of • Power from the main generators is
switchboard in which all the distributed via high or low voltage
equipment required to control an switchboards to each individual
individual circuit including bus, load
circuit breaker, disconnecting • The purpose of switchgear is to
devices, current and potential minimise the risk of short circuits
transformers, controls, instruments and to ensure personnel and
and relays, is assembled in one operational safety during all
metal cubicle and the circuit operating conditions, inspections
breaker is provided with means for and maintenance
ready removal from the cubicle
• Circuit breakers can be of the oil or
air type, although the air type is
more popular
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 25
Load List
• It is important to identify the utilisation voltage of each piece of equipment in
order to properly design the electrical system
• An electrical load list is the best way to determine the overall system
requirements in terms of the operating load
• The load list should include the power rating of each individual consumer and
whether it is run continuously, intermittently or as standby for another
consumer
• Once this has been accomplished, local loads may be grouped to be served
from switchgear which in turn are served from transformers
• When generating power, the starting loads need to be considered in addition to
the total steady state load
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 26
Load List
Power (kW)
Description Continuous Intermittent
MOL pumps 1800 -
Crude export pumps - 3200
Drilling - 3160
Separation 382 -
Compression 5000 600
Gas dehydration 350 -
Water injection 2500 -
Seawater lift pumps 380 190
Seawater treatment 50 50
Fresh water - 80
Electrochlorinator 250 -
Fuel gas 150 -
Cooling medium 160 -
Heating medium 150 -
Relief system 25 25
Closed drains 20 -
Instrument air 360 180
Fuel oil 50 -
Chemical injection 100 150
Miscellaneous 2000 1000
Total (MW) 13.727 8.635
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 29
Electrical Heat Tracing
• The most common type of electrical heat tracing is the resistance type heat
cable
• The resistive material is generally nichrome wire which comes into contact
with the bus wires (one hot, one neutral) at predetermined intervals along the
length of cable
• The nichrome wire creates heat (I2R) as current passes through it
• A temperature switch is used to turn the heat trace on and off when required
• Another type of heat trace cable is the current limiting type cable which is
similar to the resistive cable except that a special property or alloy is contained
within the cable such that the current is limited in proportion to the change in
temperature
Upstream Process Engineering Course Prepared by Genesis Oil and Gas Consultants Ltd Power Generation and Distribution 30