Electrification, Energy Efficiency and Power from ShoreEnergy+Efficiency+and+Power.pdf ·...
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© ABB GroupJune 28, 2012 | Slide 1
ElectrificationElectrification, Energy Efficiency and Power from Shore
Håvard Devold, Tor-Eivind Moen, ABB Oil and Gas, Esbjerg 31 05 2012
© ABB GroupJune 28, 2012 | Slide 2© ABB Inc. June 28, 2012 | Slide 2
Electrification Energy Efficiency and Power From Shore
Why Electrification and Energy Efficiency
How to Electrify?
Power from Shore
References
Summary
Contents
© ABB GroupJune 28, 2012 | Slide 3
Electrification:
Is there an alternative fuel that can deliver a fast solution while at the same time being economically viable?Yes, and it is not about the environment:It’s about
• Using less energy for the same tasks• Reduced Product Losses• Higher Stability better Safety• Reduced Maintenance• AND Lower emissions
Good for your wallet, good for the environment
© ABB GroupJune 28, 2012 | Slide 4
Reducing losses along the energy chainLosses
Primary energy Transport Generation T&DIndustrial processes
Industrial production
80% of energyis lost
Avai
labl
e en
ergy
12% In the industry
© ABB GroupJune 28, 2012 | Slide 5
Primary energy Transport Generation T&DIndustrial processes
Industrial production
Avai
labl
e en
ergy
ABB technology can reduce losses by 20-30%
More efficient fuel combustion
Higher pipeline flows
Improved well efficiency
Power generationTransportAll electric
Lower line losses, higher substation
efficiencyImproved
productivity
More efficient motors & drives
Drives &motors
ProcessAutomation
Marine & pipelines
Power plantautomation
Gridoperation
Processautomation
Reducing losses along the energy chainPotential increases in efficiency
© ABB GroupJune 28, 2012 | Slide 6
Nowhere is this more visible in ME vs Europe
Source: Jim Crane, Cambridge University
© ABB GroupJune 28, 2012 | Slide 9© ABB Group June 28, 2012 | Slide 9
Classical Powering ChallengesTypical power consumption
10-100 MW for new production field>100 MW for oil sand/shales250 MW new 7.5 MTPA LNG Plant300 MW for large compressor stations
(6->25 MPa, 150 Mscm/d)Typical power source
Local generation – EmissionsPower from grid – AvailabilityPower from shore - Cost
© ABB GroupJune 28, 2012 | Slide 10
Energy Efficiency:Finding the toasters in your process
“The Toaster”Runs continuously 06:00-10:00, 2 kWAir conditioned area, so 3 kW to cool down again50% efficiency => (2+3)/0,5 * 4 h = 40 kWh thermalConventional: Two loafs/2 min each 5 min @1kW gives (1+1,5)*(2/5)/0,5 *4 = 4 kWh thermal
So what are the “toasters” in your process ?PumpsCompressorsProcess Instabilities (all variations drain energy)Heat lossMaintenances issues (wear, friction, scaling…)
© ABB GroupJune 28, 2012 | Slide 11
Asset management and Energy efficiency
Electrical: Drive power, speed, torque, stallProcess: Flow, Temperature, Pressure, VibrationDiagnostics:
Wheel wear, Scaling, Motor electrical faults, EfficiencyWhy ?
Eliminate in operation failures (3-10 additional uptime days per year)Reduce periodic maintenance costs by 15-30%Extend equipment lifetime by 10-30%
“The worlds of automation and electrification are becoming increasingly entwined due to the substantial potential for energy savings, increased reliability and uptime, and reduced maintenance costs. ABB’s ability to integrate the process control, process electrification, and power distribution and management portions of a plant with System 800xA , leveraging the IEC61850 standard, offers end users significant operational benefits,” said Larry O'Brien, Research Director for Process Industries, ARC. “Typical savings can result in a 20 percent reduction in CAPEX (capital expenditures) and OPEX (operating expenditures).” (ARC 02 nov 2010)
© ABB Group June 28, 2012 | Slide 11
© ABB GroupJune 28, 2012 | Slide 12
Improved Control
Compressor anti-surge control tuning - 20% reduced fuel gas consumption (North Sea Field) – realized due to very tight client/ABB integration
Reduced Fuel Gas Consumption by Controller Tuning
Before After
© ABB GroupJune 28, 2012 | Slide 14
HS(E)Reduced local pollution (NOX)Impoved Safety for personell
Less heavymanintanenceLess heavy liftsReduced ingnitionsourcesStability
Reduced offshore personellLess helicopter traffic
Reduced vibration and audiblenoice
Question Who carries the cost of HSE, in particular long term effects on people
TechnologyReduced delivery timeEasier, simpler installationReduced size and weight ofoffshore installationStability and Uptime
EconomyReduced maintainance and operating costs -OPEXHigher availability (uptime)More gas left to sell
© ABB Group June 28, 2012 | Slide 14
Electrification by Power From ShoreWhy Electrification?
© ABB GroupJune 28, 2012 | Slide 15
(HS)EReduced climate pollution (CO2)Improved Energy efficiency
Question Who’s responsibility is this.Cost benefit analysis
TechnologyOffshore Gas Turbine Power Plant
25-30% turbine efficiency35-40% with waste heat recovery
Onshore Gas Turbine Turbine Power Plant40% turbine efficiency60% with combined cycle80%+ with waste heat recovery
Net ResultUtilization of the gas resource can be twice as good with Power from Shore (including transmission losses) as with offshore power plants.
Key questions Infra structure offshore versus infrastructure onshoreSingle project versus area wide electrification
© ABB Group June 28, 2012 | Slide 15
Electrification by Power From ShoreWhy Electrification?
© ABB GroupJune 28, 2012 | Slide 16
ABB-Technology for Power from Shore projects are already saving more than 1 Million tonn CO2 per year!
Field CO2 NOX
Troll 230 000 230
Valhall 400 000 250
Gjøa 250 000 200
Goliat 90 000 88
Troll 2 250 000 200
SUM: 1 220 000 ton 969 ton
Northstream (lost) 1800 000 ton C 1500 ton
© ABB Group June 28, 2012 | Slide 16
Electrification by Power From ShoreWhy Electrification?
© ABB GroupJune 28, 2012 | Slide 18
Application Areas for Electrification
ACHVDC
HVDC
ACHVDC
AC
Power from shore
Offshore Power Distribution
FPSO e-house solutions
Subsea drives solutions
Large Drives solutions
Packaged Drilling Drives
Onshore Power Distribution
© ABB GroupJune 28, 2012 | Slide 19
Electrification
Statoil: Troll A, phase 1 (HVDC/70 km/2x41 MW/60 kV) Statoil: Troll A, phase 2 (HVDC/70 km/2x50MW/60 kV)
Worlds largest gas production platform, was also the first to be powered with HVDC power from shore. Production capacity maintained with gas compressors, which are compensating for the reduced resorvoir pressure to ensure pressure and flow in pipeline back to onshore facility at Kolsnes, Norway. ABB-delivery:
HVDC converter stations on- and off-shore. AC and DC cables. High voltage motors for the compressors allowing direct operation by HVDC converter.
ABBs “world’s first” electrification references
© ABB Group June 28, 2012 | Slide 19
© ABB GroupJune 28, 2012 | Slide 20
BP Norway: Valhall (HVDC/292 km/78 MW/150 kV)HVDC converter stations on- og offshore, sea cable by NexansAll electrification of the fieldA world’s first offshore brown field conversion to electrification.
GDF Suez: Gjøa (HVAC/98 km/40 MW/90 kV)Transformerstation, static and dynamic sea cable, all HV and MV electrical equipment on-board.
”Partial electrification”First floating vessel/platform with power cable from shore.
ENI: Goliat (HVAC100 km/75 MW/123 kV)Sea cable (static and dynamic), electrical system onboard, land station by SiemensHVAC, 100 km from Hammerfest, ”Partial electrification”Not enough electrical power in Hammerfest for full electrification - -yet.
© ABB Group June 28, 2012 | Slide 20
ElectrificationABBs “world’s first” electrification references
© ABB GroupJune 28, 2012 | Slide 21© ABB Group June 28, 2012 | Slide 21
“Classic” (Radial Feed) Power from (to) Shore
onshore
OnshoreSub Station
Oil PlatformHVDC
OnshoreConverter
Wind farm
offshore
HVAC<150MW<150km
Oil PlatformHVAC
HVDC>50MW>150km
HVDCStation
OnshoreConverter
HVDC>200MW>100km
Gjøa, Goliat, Halul, + +
Troll, Valhall, Luva, + +
E-On
© ABB GroupJune 28, 2012 | Slide 22© ABB Group June 28, 2012 | Slide 22
Offshore Grid Multi-terminal HVDC Light solution (Ring Net)
onshore
PlatformDC
OnshoreConverter
PlatformDC
OnshoreConverter
PlatformDC
PlatformAC Platform
AC
Hosted on platform or buoy
Wind farm
Wind farmWave farm
© ABB GroupJune 28, 2012 | Slide 23© ABB Group June 28, 2012 | Slide 23
Power From Shore
DeliveredStatoil Troll, HVDC-Light 1&2 Compressor drives, 2x40MW, ca. 80kmStatoil, Troll, 20MW AC Cable, 80kmStatoil Gjøa, AC Power, 40MW, 100km, 90kV, dynamic 400m depthE.On Windpower hub, HVDC, 350MW, ca 200km incl onshore (power to shore!)
Under DeliveryENI-Goliat, 60, 90km, HVAC, dynamic 400m depthBP-Vallhall redevelopment, HVDC, 78MW, 292km (Revamp)Troll, HVDC-Light 3&4 Compressor drives, 2x45MW, ca. 80kmStatoil, Troll, 20MW AC Cable, 80km
In FEED, or later stagesTotal Hild, 55MW, 170kmStatoil Utsira High, 300MW, 220km HVDC + AC distribution to five platformsConoco phillips, Ekofisk, retrofit (xxMW, xxkm, )
© ABB GroupJune 28, 2012 | Slide 24© ABB Group June 28, 2012 | Slide 24
Technology Selection: GT vs. AC vs. DC
Power(MW)
Distance(miles)
AC
Tra
nsm
issi
on
DC Transmission
Gas Turbines
An Example ofEconomical Window ofOpportunity for Power From / To Shore
© ABB GroupJune 28, 2012 | Slide 25© ABB Group June 28, 2012 | Slide 25
GT vs. AC vs. DC
”Old Decision Rule”:xMW+ (1.4)ykm<350
AC
xMW+ (1.4)ykm<450 HVDC
Onsite Generation most likely. except where government demands
electrification or field wide electrification
HVDC Solution Chosen
AC Solution Chosen
Halul
Goliat
Dagny
Mariner option
Total Hild 55MW, 170km
Utsira (Statoil, Lundin) 300MW, 220km, HVDC
© ABB GroupJune 28, 2012 | Slide 26© ABB Group June 28, 2012 | Slide 26
Dynamic Cable Technology – GeneralExample from PFS
Long static cable (qualified to 1000m)Short dynamic cable (qualified to 700m)Transition jointDynamic cable in a configuration
Transition joint
© ABB GroupJune 28, 2012 | Slide 27© ABB Group June 28, 2012 | Slide 27
Future development
HVDC ClassicImpregn paper cable system
HVAC SeaExtruded AC cables
HVDC LightExtruded DC cables
HVAC land
Sea Land
Driving forces for increased development efforts are higher voltage and deeper water depths
Development in steps (Voltage, depth, dynamic forces, turret/swivel development, etc.)Test and qualify each step of the developmentDevelop together with clients to find solutions to their specific applicationsStarting 900-1000m deep application development in 2011 for Shell’s Ormen Lange project. Static cable with subsea terminations.Next step would be to qualify a dynamic part for Ormen Lange
© ABB GroupJune 28, 2012 | Slide 29
Business Process – Early Involvement / Studies
Product suppliers responds to RFQ here
System approachearly start
FeasibilityConcept
Market Shift to system approach
Pre Feed FeedBasic/
Detailed Design/FAT
Installation/Commissioning
Start-up Operation
All Electricdecision
Products and services
Procurement Philosophy
The most critical decisions are made early
Secure best information for optimal decisions
© ABB GroupJune 28, 2012 | Slide 30
Recent Power From Shore Studies
2006: Shell Draugen redevelopment, HVDC or AC, 60MW, 60km2007: Statoil -Halten Banken electrification, HVDC and HVAC2008: Statoil Mariner & Bressney, HVDC and HVAC2010: Statoil, Gudrun (Platform to Platform, i.e. Sleipner to Gudrun) –ABB Inputs to EPC2010: Statoil, Sleipner (50/60Hz converter –Platform to platform) ––ABB Inputs to EPC2008: ENI-Goliat, 60-120MW, 90km, HVAC2008-2009: Qatar Petroleum, Halul Oil Terminal, 100-130MW, AC –ABB Inputs to EPC 2008-2010: QP-NFA, 36MW, 80km, 66kV (AC) –Feasibility and FEED electrical studies –inputs to EPC2010-2011: ADMA OPCO/ Tebodin, Assess Study - Electrification infrastructure for all ADMA offshore installations in Abu Dhabi 2014-20302011: Statoil Lundin/DNO Dagny –Luno/Draupne 150MW, 220km HVDC + 2x30km HVAC Feasibility/Pre-FEED2011: Statoil+ + Utsira High –Pre-FEED/Feasibility2012 Petronas – Offshore electrification, multiple platforms
© ABB Group June 28, 2012 | Slide 30
© ABB GroupJune 28, 2012 | Slide 31© ABB Group June 28, 2012 | Slide 31
Agree on Base Parameters
Characteristic Gas Turbines Electric Drive
Weight and space Light unit but space and weight consumingauxiliaries
Similar to that for gas turbines
Minor maintenance cycle 2,500 - 4,000 hours (flashing) 25,000 hours (cleaning)
Major maintenance cycle 20,000 hrs 100,000 hrs
Minor maintenance duration^) 6-10 days 1-2 days
In operation system MTBF 4,000 hours > 25,000 hours
Control Response Slow Medium to quick
Efficiency Narrow peak range High over wide range
Logistics Delivery time 3-4 years Delivery 1-2 years
Average operational efficiency of system 25-38% 97% Drive ++ 95% HVDC Transmission typ+ 60-80% generation
© ABB GroupJune 28, 2012 | Slide 32© ABB Inc. June 28, 2012 | Slide 32
© ABB Group June 28, 2012 | Slide 32
Gas Turbine Characteristics
Typ 37 % at “ISO conditions”More like 25% at off peak
© ABB GroupJune 28, 2012 | Slide 34© ABB Group June 28, 2012 | Slide 34
Reference Case – Gas compression, HVDC
CharacteristicDrive and compressor
A.Electric Drive (actual)
B.Gas Turbines (theoretical)
Difference (Column B –Column A)
Dimensioning capacityDaily full capacity volumeNormalized full capacity days/yearRequired compression powerInstalled capacity
Inlet 65 bar, out 250 bar 150 Mscm/day
250 days287 000 MW
6 x 50 MW
Inlet 65 bar, out 250 bar 150 Mscm/day
250 days287 000 MW
7 x 50 MW
Energy cost energyCO2 quota credit (Emerging Economy)
18.6 €/MWh24.0 €/Ton
0,0667 €/scm24,0 €/Ton
Capex costsInterrest rate calculatoricAnnual interrest and write down
260 700 000 €11%
40 years 35.200.000 €
122.500.000 €11%
20 years 19.600.000 €
- 138.200.000 €
-15.600.000 €
Average annual OPEX costs:Cost of energy/fuel gasLost capacity valueMaintancance costs
34.951.000 €15 000 €
1.066 000 €SUM: 36 033 000 €
27.232.000 €19.159.000 €
8.155.000 €SUM: 54.546.000 € 18 513 000 €
Total cost of ownership/year
Additional export gas (if available) Income from CO2 quota sales
71.200.000 €
-75 606 000 €14 700 000 €
74.146.000 € 2 946 000 €
Balanced cost -19.080 000 € 74.146.000 € 93 226 000 €
Fuel gas consumption - 408 mmSCM 408 mmSCM
CO2 emissions - 612 000 tons 612 000 tons
© ABB GroupJune 28, 2012 | Slide 36
SFNY GOSP-1
TP-20
TP-18TP-18
230 kV
115kV
69 kV69 kV
15 kV
Offshore
Onshore
940930 348 470
656
910
Aux
243
275
TP-19TP-17GOSP 4
Submarine Cables
36
TY
© ABB GroupJune 28, 2012 | Slide 37© ABB Group December 08 | Slide 37
Cable Projects in Qatar
Halul IslandRas Lafan
NFA(QP)36MW
50/60 HZ
66kV
100 MWHVAC132 kV
80-90 km100 km
Al-Morjan(Qxy)Existing Cable
PS 2QP
PS 3QP
Al-KhalijTotal
FutureCables
Handled by ABB NOO&G as a system delivery
© ABB GroupJune 28, 2012 | Slide 40
ReferenceTroll A – powering the compressors
Month DD, Year | Slide 40© ABB Group
FIELD100 km NW of Bergen, Norway and onshore
gas plantWater depth 400 meters, power and pipeline
to shoreOne Gravity base plus subsea tie insRecompression & HVDC Light offshore Upgraded to 146,5 mill Sm3/Day 2006
Benefit by using HVDC 200.000 ton CO2
OPEX reduced by 19 mill USDAdditional saving of fuel gas
© ABB GroupJune 28, 2012 | Slide 41
Off shore power supply .. Troll
Troll, HVDC-Light Pre-Compressors 1 & 2:
2x40MW, ca. 80kmIn operation 2005
Pre Compressors 3 & 42x50MW, ca 80kmSold 2011(Operation 2013)
© ABB GroupJune 28, 2012 | Slide 42
DescriptionOne HVDC light station off-shore and one on-shore292 km HVDC Cable
Main dataP = 78 MWUDC = 150 kV
StatusOnshore station in operationOffshore module being installed Commercial operation 2010
Valhall
Lista
Valhall
© ABB GroupJune 28, 2012 | Slide 43
ReferenceValhall
Month DD, Year | Slide 43© ABB Group
Valhall
Lista
FIELD300 km south of Stavanger, NorwayWater depth 70-75 meters128.000 barrels oe per day, Gas to Ekofisk, Oil to
Teeside (UK).
BP Field of the future concept: Onshore Control Room
First time HVDC is used to supply an entire platform
HVDC Light 292 km 78 MWAC Voltage: 300 kV / 11 kV DC Voltage: 150 kVAdvantages
High availability 98.5-99 %Increased life length 40 yearsIncreased efficiencyReduced maintenance and Shorter maintenance shutdownsFibre optical communication in cableEnvironment – savings:
300.000 ton CO2250 ton NOx
© ABB GroupJune 28, 2012 | Slide 44
TransformerTransformer ValvesValves
Phase ReactorsPhase Reactors
Valhall – PFS – Technical solution
© ABB GroupJune 28, 2012 | Slide 46
Field98 km PEX SeaCable1,5 km is Dynamic CableUse of AC
BenefitsEmissions: 250.000 tons CO2 Reduction (100.000 cars), (NOX) and volatile organic compounds (VOC). Power to satellites fieldsPower from shore from day 1
ChallengeThe seabed is uneven and steep and part of the cable need to be flexible due to the floaterThe flexibility is made by corrugated copper. This makes the cable look and function like a vacuum pipe.
ReferenceGjøa - floater
Month DD, Year | Slide 46© ABB Group
© ABB GroupJune 28, 2012 | Slide 47
ABB EICT scope for the Goliat FPSO:
Power from shore Electrical equipment and power system
Instruments & valves
Safety & Control equipment, system applications and interfaces
40 mechanical packages
Telecommunication systems
Remote collaboration facilities
Facilities for condition based maintenance
Industrial networks & Information security infrastructure
Goliat FloaterElectrical, Instrumentation, Control and Telecommunication
© ABB GroupJune 28, 2012 | Slide 48
Power from shore to Utsira High -Concept
~=
DCland cable
DC subsea cable200 km
Hub platform Inverter
Draupne Luno
Aldous / Avaldsnes Field center
A
Aldous / AvaldsnesB
Dagny
AC subsea cables0 - 60 km
Aldous / AvaldsnesC
Future
SubstationRectifier
Futurewindfarm
Onshore grid300 kV incomers
Kårstø
Power from shore to Utsira High – rating 250 MW +
= ~
Power Hub PWH
Utsira High – Power from shore ProjectA strategic step towards electrification of the NCS
Opportunity: • Statoil will select an
Electrical EPC, ABB competing with Siemens only
• Contract > $500 M, 70-80% ABB content
NCS: Norwegian Continental Shelf
© ABB GroupJune 28, 2012 | Slide 50
EON 2 off shore cluster
75 km land cable
128 km sea cable
400 MW off shoreconvertor
400 MW convertor
© ABB GroupJune 28, 2012 | Slide 51
Supergrid concept (Vision)Main concept, combine:
Integration of renewable energyInterconnections for tradingSecurity of supply
BenefitsReduced investmentIncreased trading capacityBack-up power, e.g. hydro power can support wind powerLarge geographic area gives more stable production
© ABB GroupJune 28, 2012 | Slide 52
Wind Generation - Offshore gridVision 2020 – an offshore grid enabling
Offshore wind parksPower supply to oil fieldsEnergy exchange between marketsAncillary services (freq control ++)
TaskDescribe technology statusDescribe ambitions towards an off shore gridDescribe R&D challenges
© ABB GroupJune 28, 2012 | Slide 53
Electrification
Oil and Gas exploration can be executed with substatntially lower CO2 and NOx emmissionsElectrification gives value creation and competencies which are useful for other areas such as subsea systems and offshore renewablesIncreased power needs offshore can in many regions be covered by renewable energy
Summary
© ABB Group June 28, 2012 | Slide 53
Electrification requires:Political will and supportProgressive approach to new
technologies and system solutions