Microturbine applications for the oil and gas industry
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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. What is a MicroTurbine?. Power generator driven by a small scale gas turbine

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Microturbine applications for the oil and gas industry

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


What is a microturbine

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


Air bearings

Air Bearings

Spring

Spring

Foil

Shaft

Shaft

Boundary Air

Foil


Inside the capstone microturbine

Cooling fins

Exhaust output

Recuperator

Fuel injector

Air intake

Combustion

chamber

Generator

Compressor

Air bearings

Turbine

Inside the Capstone MicroTurbine

  • No gearbox, pumps, or other mechanical components

  • Recuperated Engine

  • Permanent magnet alternator

  • Lean premix combustion

  • Air Bearings

  • Air Cooled


Power electronics

No moving parts

Variable Voltage 400-480 volts

Variable Frequency 10-60 Hz

Voltage & Current source Inverter

“Electronic” Gearbox

Built in Fault protection

Power Electronics


Inverter based electronics

Inverter Based Electronics


Multipac grid connect

MultiPac & Grid Connect


Capstone products

Capstone Products

Available with gas & liquid fuels

C30 & C65

C200 & C200 CHP

C65 CHP


Capstone products1

Capstone Products

C30 & C65Class I Div 2ATEX Zone 2

C30 & C65 SS


Performance

Performance


Packaged solution

Packaged Solution

  • (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


C1000 iso efficiency

C1000 ISO Efficiency

High Part Load Efficiency


Installation

Installation

20 kw Recip Package

60 kw MicroTurbine


Typical site layout

Typical Site Layout


Oil gas experience

Oil & Gas Experience

  • Mexico

    • 36 Units in Offshore Oil Production

      • Flare Gas Fuel

  • NE United States Pipeline

    • 31 Units in Gas Transmission

      • CHP Applications

  • Russia Pipeline

    • 50 Units in Remote Gas Transmission

  • South America Pipeline

    • 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


Certification

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 state-approved 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


Capstone a big small company

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 14001:2004UL-certified

  • Offices in LA, NYC, Mexico, Milan, Bath, Shanghai and Tokyo

  • Distributors located world wide

Capstone Corporate Headquarters

Chatsworth, California


Preventative maintenance

Preventative Maintenance

  • Typical Maintenance cost of $0.016 kWh

  • Average of 6 Hours of Planned Maintenance per year

  • Capstone will guarantee cost of planned and unplanned maintenance through Factory Protection Plan

Servicing injectors at 20,000 hrs

on an offshore platform


Oil gas specific applications

Oil & Gas Specific Applications


Key o g objective

Primary Uses

Generate Power

Eliminate Flare/Vent

Combine Heat/Power

Use power for applications

Prime site power

Black start power

Back-up power

Peaking

Supplemental power

Reduce utility costs

Generate power from fuel sources such as

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%

Key O&G Objective

3-pack on oil flare gas in New Mexico


Benefits of microturbines in o g

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

  • < 65dBA Acoustic Emissions

  • Ultra-low NOx emissions with nopost-combustion devices or chemicals

  • Accepts 350-2500 Btu w/up to 7% H2S (C30)

Test prior to platform deployment, Netherlands


Microturbine applications for the oil and gas industry

Integrated Heat Exchanger


Exhaust heat utilization chp

Exhaust Heat Utilization - CHP

Traditional Approach

Capstone ICHP

120 kWth

120 kWth

65 kWe

30 kW waste

150 kW fuel

80% av. boiler

efficiency

230 kW

fuel

65 kWe

345 kW

fuel

160 kW

waste

40 kW

waste

33% av. utility

efficiency

130 kW waste

195 kW fuel

  • 54% average total efficiency

  • 3.4 lb/MWhNOx & 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


Exhaust heat utilization chp1

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


Exhaust heat utilization

Microturbines also generate voluminous exhaust heat

C65 Generates 561,000 BTU/hr (591,000 kJ/hr) at 588F (309C)

Exhaust Heat Utilization

Heat from two C30s running on untreated wellhead gas goes to “heater/treater” separator


Example applications

Example Applications


Cathodic protection

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


Cathodic protection1

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


Primary power for remote site

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 inremote 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


Primary power for remote site1

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


Primary power for oil pipeline

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.


Primary power for oil pipeline1

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


Offshore resource recovery

Offshore Resource Recovery

  • The Issues:

    • Provide a reliable power source in a hazardous oil and gas application on an offshore platform in the Gulf of Mexico

    • Recover value from onsite flare gas which is normally lost to the environment

  • The Solution:

    • A Capstone microturbine, UL certified for hazardous oil and gas applications

    • The microturbine runs on onsite unprocessed wellhead gas which is normally flared, providing a power source to the platform

    • The microturbine cut maintenance time by ~95% compared to reciprocating engine generators

    • The microturbine ran almost non-stop for 25,000

    • 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


Offshore installations

Offshore Installations

Deployed in the Gulf of Mexico


Conclusions

Conclusions

  • Ideal power generation for oil & gas installations, onshore and offshore

  • More than 5,000 Capstone MicroTurbines sold and 19+ million operating hours

  • Fuel Gas from 350 BTU – 2500 BTU with up to 7% H2S

  • Low emissions of less than 9 ppm NOx

  • Lowest maintenance cost of 0.016 $/kWh with 6 hours/year of planned maintenance

  • No lubricants or coolants


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